Prior to unpacking the battery, make sure to use the designated lifting points only and do not use a forklift to handle the battery. The battery enclosure is not a structural component, so no external load should be placed on it or the battery disconnect unit (BDU). Also, it is only designed for environmental protection, meaning it must be protected from crushing, penetrative or ballistic forces.
Ensure the battery is installed in an indoor setting, or shielded from the elements as much as possible in order to not expose the battery’s components to dirt, dust or moisture. When installing the battery into the application it will be powering, we recommend doing so in a location that allows easy removal for serviceability purposes.
For battery pack details such as certification, and assembly ratings, head to the dedicated Battery Pack Details Page. Below is a guide on how to identify your battery pack identification number.
By using the above guide to identify the battery ID number, you can now use the below table to identify the required thread size.
|Module Length||≤13 Modules||14+ Modules|
|12 & 18 ML||4 x mounts|
M16 x 2mm thread
|4 x mounts|
M16 x 2mm thread
|24, 30, 36, 42 ML||4 x mounts|
M20 x 2.5mm thread
|6 x mounts|
M16 x 2.5mm thread
Make sure not to deviate from the thread engagements or tightening torque listed below, as this will damage the pack’s mounting threads.
- 32mm minimum thread engagement
- 35mm maximum thread engagement
- Maximum tightening torque 140M/m
- 40mm minimum thread engagement
- 44mm maximum thread engagement
- Maximum tightening torque 210M/m
1. Unpack & install the battery into the plant #
- When removing the crate and unpacking the battery, make sure not to discard the crate or other shipping parts, as these are essential to ensure safe storing and shipping of battery packs when not installed in the plant.
- Remove the M12 locknuts and washers from the shipping feet to release the pack and free it from the pallet.
- Install the lifting eyes as indicated below, keeping in mind that batteries with six mounting points on the cover can be lifted using only four mounts, ensuring all the corner mounts are used. Please note that lifting eyes are not included with the battery pack.
- Install lifting chains or straps and ensure there’s a minimum 45° angle between the chain or strap and the top surface before lifting the battery with the shipping feet still attached.
- Remove the mounting bolts and washers to detach the shipping feet from the battery, and keep these safely stored somewhere.
Once these steps are complete, your Hibernium® pack is ready for installation. It’s recommended that batteries are primed and commissioned in a horizontal position, and once all those steps are complete, then the battery can be placed into the application horizontally or vertically.
If placed horizontally, the battery pack can be hung from the top or bottom mounts, though all mounting points provided on the same face (top or bottom) need to be used to secure the pack. For a vertically placed battery packs, all mounting points on both sides need to be used.
It’s important to avoid any installation where the BDU is facing down, as this could result in condensation pooling into the BDU electronics, causing damage.
If the pack is installed with cooling ports facing down, the pack must be fully primed with coolant before orientating into position. Coolant should not be permitted to leak from the pack during installation as this could result in airlocks within the thermal management system.
The battery pack enclosure also needs to be grounded using an M8 fastener in the grounding location highlighted, at a maximum thread depth of 21mm.
- Current handling: 500 A
- Maximum Resistance: < 0,1 Ω
Remove any paint and ensure the contact surfaces are cleaned, and anti-corrosion and conductive compound (i.e., copper grease) is applied between the grounding strap lug and this mounting location.
2. Connect the communication connector with the power supply to the battery management system (BMS) and telematics. #
Communication between the battery management system (BMS) and vehicle control unit (VCU) is achieved through the low voltage communication connector located on the battery disconnect unit (BDU) of the Hibernium® battery.
Ensure that the low voltage signal wire is supported for 200mm after the plug.
For this you will need a TE 776163-5 receptacle to pair with a TE 776164-5 mating connector.
Communication connector layout
The pinouts of the connector are shown the table below. Controller Area Network (CAN) nodes 1-3 are not terminated inside the BMS. CAN wire pairs should be either Shielded (STP) or Unshielded (UTP) Twisted Pair, with 1 twist per inch of wire.
The CAN bus termination of 120 Ohm must be present at the two physical end points of the CAN, and the CAN stub length cannot exceed 30cm.
For CAN cabling, follow SAE J1939 standard, for which Xerotech recommends using Deutsch DT or Amphenol AT series or equivalent series connections.
|1||Not connected||Do not connect|
|2||Not connected||Do not connect|
|3||Not connected||Do not connect|
|4||CAN_3_N||CAN 3 Low – VCU Connection ODOS Connection (Multi Pack)|
|5||CAN_3_P||CAN 3 High – VCU Connection ODOS Connection (Multi Pack)|
|6||Not connected||Do not connect|
|7||HVIL_EXT_OUT_FILT_N||External HVIL return|
|8||Not connected||Do not connect|
|9||Not connected||Do not connect|
|10||Not connected||Do not connect|
|11||12V / 24V||UBAT in from 12/24V Battery (KL30)|
|12||12V / 24V||UBAT in from 12/24V Battery (KL30)|
|13||CAN_2_H||CAN 2 High – NC|
|14||Not connected||Do not connect|
|15||Not connected||Do not connect|
|16||Not connected||Do not connect|
|17||CAN_1_N||CAN 1 Low – ODOS Connection (Single Pack)|
|18||HVIL_EXT_OUT_FILT_P||External HVIL out|
|19||Not connected||Do not connect|
|20||Not connected||Do not connect|
|21||Not connected||Do not connect|
|23||12V / 24V||UBAT in from 12/24V Battery (KL30)|
|24||CAN_2_N||CAN 2 Low – NC|
|25||Not connected||Do not connect|
|26||Not connected||Do not connect|
|27||Not connected||Do not connect|
|28||Not connected||Do not connect|
|29||CAN_1_P||CAN 1 High – ODOS Connection|
|30||Not connected||Do not connect|
|31||Not connected||Do not connect|
|32||Not connected||Do not connect|
If the particular BMS CAN node is at the end of the CAN network, a 120 Ohm CAN termination should be fitted within 15cm of the connector on that CAN network.
CAN network “CAN1” is used for connection to the external ‘ODOS’ device. An external 120 Ohm CAN termination should be fitted within 15cm of the communication connector on that CAN network (CAN_1_P [pin 29]/CAN_1_N [pin 17]).
Please note that even if the ODOS device is NOT connected, this termination should be present. A single 15 Amp fuse should be used in line with 12V/24V (pins 11, 12 and 23).
As for electromagnetic compatibility (EMC), the communication harness should incorporate a ferrite [Wurth 74271151 (2 turns)] around the power conductors ONLY ( i.e. Pinout 11, 12, 23 & 33, 34, 35), and should be located <100mm from the communication connector.
For BMS communication and power supply in parallel packs, connect each battery communication connector with the VCU CAN and power supply.
Hibernium® batteries are equipped with a high voltage interlock loop (HVIL) generator that can be used to control HVIL function of the system architecture. You can use the HVIL pins mentioned in the communication connector table above to include other high voltage system components in the loop.
HVIL Pin are sensitive Analog I/O pins. Disconnect the low voltage (LV) communication connector harness from the battery pack receptacle when making electrical connections to the LV Harness.
Pin 18 (HVIL output) and Pin 7 (HVIL return) are sensitive Analog I/O pins and are NOT to be connected to any external power source.
When using an external HVIL monitoring device, short the HVIL pins in the Communication Connector to prevent the BMS detecting a fault.
The maximum allowable external HVIL loop resistance is 250 Ω
In parallel packs, since each pack has an independent HVIL monitoring function, only one pack’s HVIL pins on the communication connector must be routed to HVIL pins on the HV connectors of all batteries. The remaining packs’ HVIL pins on the communication connector must be shorted to avoid BMS error messages.
The BMS logs all CAN data on the cloud via an ODOS cloud device which allows Xerotech to provide the necessary remote support during and after commissioning, as well as for any warranty purposes.
This device needs to be placed in the vehicle cabin or where there is good 4G signal reception.
Connect the ODOS device to the battery system’s CAN referring to the communication connector for the correct pin reference. Please note that the telematics connection depends whether the system is a single or parallel pack.
Single Pack System
|OBD Pin||Signal Required||Function|
|6||CAN_1_P||CAN-1 High connection (pin 29 of Communication Connector)|
|14||CAN_1_N||CAN-1 Low connection (pin 17 of Communication Connector)|
|16||12V/24V||UBAT in from 12/24V Battery|
You will need mating connector Molex 0511151611 and crimp terminal Molex 504208000 to establish the connection.
A 120 Ohm CAN termination should be fitted within 15cm of BMS LV connector on BMS CAN 1 network. A 120 Ohm CAN termination should be fitted within 15cm of the Cloud device (ODOS) on BMS CAN 1 network.
Even if the ODOS device is NOT connected, this termination should be present.
The table below explains the two LED color codes that will help you understand the ODOS connection to the cloud.
|Fixed red LED with orange blinking||Run Mode|
|Red LED blinking every 2 seconds||Idle Mode|
|Orange LED 2000ms ON then 2000ms OFF||Cloud Connection OK/Fix GPS|
|Orange LED 50ms ON then 3950ms OFF||Cloud Connection OK/No GPS|
|Orange LED 50ms ON/100ms OFF 2 times then 3700ms OFF||No Cloud Connection/Fix GPS|
|Orange LED 50ms ON/100ms OFF 3 times then 3550ms OFF||No Cloud Connection/No GPS|
For parallel pack high voltage harnessing, follow these steps:
- Route high voltage (HV) harnesses (Positive/Negative) side-by-side, avoiding large loops.
- Use shielded HV cables, with HV harness shields bonded to vehicle chassis.
- Route low voltage (LV) harnesses away from HV harnesses.
- Position loads (e.g., Power Distribution Unit (PDU)/inverters/motor etc.) away from battery pack battery disconnect unit (BDU).
- Allow provision to add external DC link capacitance pre-charge at the load input if Hibernium® battery pre-charge is not sufficient.
- Ensure HV harness assemblies are constructed identically (equal length, cable type, resistance, connectors) to maintain system balance loading and avoid current hotspots.
- Ensure HV connector polarity is correct for parallel configuration (i.e., positive to positive and negative to negative).
Should one pack be more than 5V out of balance with another, the unbalanced pack should firstly be isolated from the multipack configuration. The unbalanced pack shall be charged/discharged until the pack open circuit voltage (OCV) is within 5V of the other pack(s) in the parallel system.
Only balanced packs (i.e. packs with OCV within 5V of other packs) should be switched into a parallel configuration.
3. Perform the power up and power down procedures #
The BMS sends and receives CAN messages to and from the VCU using J1939 protocol, with a default Baud rate of 500kbps or an optional rate of 250kbps . The list of messages and signals for single and multipacks can be found below, in either PDF or DBC format:
For more information about the BMS functions, click here.
For the Wakeup procedure, follow these steps:
- Set KL15 (ignition) to high
- Send VCU_SleepCmd = 0
- Observe BMS_Mode = INITIALIZATION during self-check sequences
- Observe BMS_Mode = READY when system completes self-check sequences successfully
- Observe BMS_Mode = ERROR or EMERGENCY POWER DOWN if there are faults detected
To go back to INITIALIZATION:
- Send VCU_NormalPowerDownCmd = 1
- Wait a few seconds, then send VCU_SleepCmd = 1
- Wait a few seconds, then send VCU_SleepCmd = 0
Ensure the Link voltage (load side of the pack) is discharged below safety limits (<60V) before wakeup, or else the BMS may forbid closure of the contactors and move to Error mode. Sleep and wakeup cycle may clear this error if the link voltage is below 60V during the self-check sequence.
Should there be a need to disable the isolation, only send the disable command after BMS_mode is in READY MODE, otherwise the BMS won’t be able to finish the self-check sequence.
For BMS configuration, follow the below steps. Essentially, they are needed once, as they are saved in Non-Volatile Memory.
To change or disable the LED lights:
- Choose the option CAN signal VCU_Cmd.VCU_DisableLED_Cmd: 0(Enable-Default), 1(Disable)
- Confirm the selection(in step1) CAN signal VCU_Cmd.VCU_SetDisableLED_Cmd: 0(Default),1(Set/confirm)
- Enter the configuration key CAN signal VCU_Cmd.VCU_ConfigKey. If the configuration key is wrong, the settings will not be applied
- Confirm the configuration by reading the CAN signal BMS_Sts.BMS_LEDActiveSts: 0(Enabled),1(Disabled)
- Clear the VCU_Cmd.VCU_SetDisableLED_Cmd flag
To change the pack ID, you can follow the below steps, although by default, single packs are configured as “Pack ID 0”, while multipacks are configured as “Pack ID 1”.
- Connect only the desired pack(disconnect other packs) in CAN network for easy configuration
- If the current pack ID is X, the BMS messages IDs will be 0x18FF41DX, 0x18FF42DX, 0x18FF43DX, 0x18FF44DX, 0x18FF45DX, 0x18FF46DX, 0x18FF47DX, 0x18FF48DX, 0x18FF49DX, 0x18FF4ADX, the corresponding VCU CAN message will be 0x18FFDX5A
- Choose the pack ID as Y by the CAN signal VCU_Cmd_PackX.VCU_SelectPackID_PackX
- Confirm the selection in Step 3 by CAN signal VCU_Cmd_PackX.VCU_SelectPackID_PackX: 1(Set/confirm), 0(Clear flag)
- Enter the configuration key usingCAN signal VCU_Cmd_packX.VCU_ConfigKey_PackX. If the configuration key is wrong, the settings will not be applied
- Confirm the Pack ID by CAN signal BMS_Sts_PackY.BMS_MyPackID_PackY is Y
- Clear the VCU_Cmd_PackX.VCU_SelectPackID_PackX flag
It is recommended to have Pack ID=0 for single pack and (0 < Unique Pack ID <=14) in one Multipack CAN network. To connect more than 14 packs, use another CAN network with (0 < Unique Pack ID <=14).
Once this is done and the BMS_mode reads “READY”, then the battery pack is ready for power up and the contactors can be closed.
Requesting an unbalanced pack to power up will lead to pre-charge sequence failure and risks damaging components.
If PDU contactors are not closed prior to the BMS Power Up sequence, closing them at a later stage will lead to high in-rush current into the load capacitance. This can cause damage and voids the warranty.
Before powering up parallel packs, ensure that:
- All packs are in READY mode and there are no ERRORS.
- The biggest pack voltage difference for cells of an 8S configuration should not exceed 5V, and should not exceed 10V for cells of a 16S configuration.
- If the power distribution unit (PDU) is equipped with contactors, command the VCU to close them, (connecting loads) before initiating the power-up sequence.
- Power-up sequence for all the balanced packs must be initiated at the same time to reduce pre-charge time.
To initiate the power up sequence, send VCU_NormalPowerUpCmd = 1, and observe that BMS_Mode reads as “OPERATIONAL”. Below you can find a single pack’s power up handshake sequence diagram.
To start charging the battery pack while the BMS is in operational mode, send the VCU_PlugInChrgCmd = 1 and VCU_EndOfChargeCmd = 0, then check that BMS_Mode reads as “CHARGING”.
Charging current in this mode is limited by the BMS_MaxChrgCurrChrgr sent by the BMS on the CAN.
To stop charging, send VCU_EnfOfChargingCmd = 1 and VCU_ PlugInChrgCmd = 0, and check that BMS_Mode reads “OPERATIONAL”.
If the actual effective current is more than current limits from the BMS, the battery may malfunction and enter unrecoverable CAT7 system faults. Enable the charger to source current only after all the balanced packs are in charging mode, otherwise, it may lead to uncontrollable power error, especially at the higher and lower SOC ranges.
Below is the Start and Stop Charging Handshake Sequence Diagram:
Before commencing the power down sequence, ensure that the current load is removed.
Power-Down operation performed under load reduces the contactors’ life, can cause damage to contactors, and causes high back electromotive force.
To commence the power down sequence, send VCU_NormalPowerDownCmd = 1 and observe BMS_Mode reads “POWER DOWN”.
Below is the power-down Handshake Sequence Diagram:
In parallel architecture, initiate the Power-Down sequence of all the packs simultaneously to significantly reduce the power-down procedure time.
For the sleep procedure, send VCU_SleepCmd = 1, and check that BMS_Mode reads “SLEEP”.
The BMS will keep receiving the VCU CAN messages until CAN traffic is live and KL15 line is off. When the CAN traffic is off and KL15 is off, the BMS will go to Low Power mode and stop receiving VCU commands.
4. Connect the thermal management system #
Xerotech recommends a 50-50 water-glycol mixture as the recommended TMS medium for Hibernium® battery platforms. It’s also important to ensure there are no foreign and abrasive particles when introducing coolant to the system, as these may cause reduced TMS performance or damage to the pack.
The recommended inlet pressure should not exceed 1.0 bar, and users should keep in mind that ambient pressure will vary according to sea level elevation. Therefore, the coolant expansion tank shall be vented to ambient to help ensure that the gauge pressure never exceeds 1.0 bar.
Below is a table with the VDA connector information required for this step. These connectors are push to fit.
|Article Number: 07026009012 |
|Article Number: 07027004020 |
Ensure pressure relief valve is fitted before the inlet as specified above.
Make sure to follow the coolant flow directions indicated in the below images, as this is critical for optimal TMS performance. For the ML12 packs, the coolant barbs sit on the opposite end of the BDU, while for ML18 and over packs, these barbs are on the same side as the BDU.
Module Length 12
Module Length 18 & Over
To disconnect the VDA connectors, pull up on the spring clip and pull
For the coolant fill, Xerotech recommends that the system is vacuum filled in two stages to ensure the pack is completely purged of air prior to filling with coolant.
Do not proceed if the battery pack is not powered up. Do not allow the coolant to flow into the battery pack until the wakeup procedure has been completed.
The recommended hardware for this procedure is as follows:
- 20mm hoses
- Typical automotive vacuum fill kit
- Pressure gauges
- 50/50 water OAT glycol ready mixed
- 1.0bar pressure relief valve
The first phase of the procedure is to check for potential damage during transit.
- Power up the battery and complete the wake up procedure.
- Connect the inlet and outlet of the battery together with a Y-piece connector and 20mm hose.
- Connect the vacuum hose to the Y-piece connector.
- Connect the airline to the vacuum kit
- Close valve B and open valve A.
- Turn on airline and pull a vacuum of -0.5bar (Do not exceed -0.5bar), and once -0.5 bar is achieved, close valve A, and wait 15 minutes.
- If the pressure gauge reads -0.5bar, you may proceed with the actual coolant fill procedure. If the vacuum has not been maintained, do not proceed and contact your Xerotech representative.
For coolant fill, power up the battery first and complete the wakeup procedure before allowing coolant to flow into the battery.
Make sure the coolant reservoir is attached to the system and there’s enough pre-mixed 50-50 water-glycol volume to fill the complete system. Use a suitable degas header tank with sufficient expansion volume. If you’re unable to perform a full fill in one session, repeat process steps 7-12 from the below procedure, taking extra care to ensure no air is introduced to this system.
- Connect the coolant system to the battery pack.
- Ensure the header tank position is the highest point in the circuit.
- Attach the vacuum kit to the header tank and fill port as per the manufacturers’ instructions.
- Connect the coolant fill hose to the vacuum kit inlet and ensure that it is fed to the bottom of the coolant drum through a sealed grommet.
- Close valve B and open valve A.
- Attach the airline to the vacuum kit and pull a vacuum of -0.5bar (Do not exceed -0.5bar).
- Once you achieve -0.5bar close valve B and wait 5 minutes. The pressure gauge should read -0.5bar.
If the vacuum has not been maintained, do not fill the battery and contact your Xerotech representative for further instructions.
- Close valve A and open valve B. The coolant should now flow into the system. To completely fill the system, it is recommended that the coolant drum is pressurized to 0.5bar.
- Once the coolant reaches the recommended levels on the degas tank, close valve B and keep valve A closed.
- Remove the vac pump kit and replace the degas bottle cap.
- To check the system is completely full, run the waterpump for 10 minutes with an outlet pressure of circa 0.5bar. Observe the sight glass in the degas line for any evidence of air bubbles.
- Turn off the water pump and check the volume of the coolant. If the volume of the coolant is less than expected, top up as normal.
You can see the schematic examples here.
5. Connect the high voltage connectors. #
Hibernium® battery systems feature two high-voltage connectors, one for each polarity. Depending on the performance specification, the battery pack is equipped with two- or three-pole connectors.
Please consult your specific battery datasheet for information about the type of connectors used. Find the corresponding receptacle and suitable mating connector part number from the table below.
Systems with 2-pole connectors use A/B coding; do not attempt to install A-coded connectors to B-coded receptacles, as this will result in damage to both components.
|Receptacle||Part Number||Mating Part Number|
|HV +||HVSL1000022B150||Straight – HVSL1000062B150|
90° – HVSL1000082B150
|HV –||HVSL1000022A150||Straight – HVSL1000062A150|
90° – HVSL1000082A150
|Receptacle||Part Number||Mating Part Number|
|HV +||HVSL1000023A150||Straight – HVSL1000063A150|
90° – HVSL1000083A150
|HV –||HVSL1000023A150||Straight – HVSL1000063A150|
90° – HVSL1000083A150
To identify polarity and connector coding, you may refer to the figure below, though corresponding polarity labels are provided on the battery itself too. Top receptacle is battery pack Positive. Bottom receptacle is battery pack Negative.
To install the connector, follow these steps:
- Release the handle’s locking feature.
- Insert the connector into the receptacle, ensuring the correct A/B coding match, and ensure the lug sits properly secured in the handle groove.
- Rotate the handle to lock the connector in place and push the sliding lock to secure the handle in position.
6. Install MSD and fuse. #
Hibernium battery systems have a fused MSD, and for safe handling and pack service, ensure the MSD is disconnected.
|Connector||Amphenol – MSDXLM630|
Circuit Protection Device
|Maximum continuous current||630 A|
|Pre-Arc||130,000 A2 Sec|
|Total clearing at 1000V||660,000 A2 Sec|
- To install, insert the MSD fuse into the receptacle as shown and ensure the lug settles in the groove handle.
- Rotate the handle to lock the connector in place and push in the sliding lock to secure the handle in position.
- To remove, unlatch the sliding lock and rotate the handle until the lug is unlocked.
- Remove the MSD connector from the receptacle.
7. Complete commissioning #
Hibernium® battery systems come with commissioning software to test system integration, sequences, and communication between the BMS and VCU in a safe environment to prevent battery or equipment damage.
Commissioning can take place once the battery pack is installed and powered up, and you’ll need to log the commissioning steps to complete the process, using ASC file format if possible.
Perform the procedures of wakeup, power up, charge, power down, and sleep, as described in step three of this guide. You can also head to the Communication Procedures page for detailed instructions.
Once that is done, save and send the log data to [email protected], where our support team will check the log. If everything is correct, you will receive the production software for flashing. Below are the UART communication pins for flashing software:
Pinout 16 is RS232 Transmit for DB9 RS-232 connector of 2.
Pinout 28 is RS232 Receive for DB9 RS-232 connector of 3.
Pinout 33, 34, 35 are Ground for DB9 RS-232 connector of 5.