This guide is an abbreviated version of the Detailed Start Guide intended for users who are highly familiar with the Hibernium installation process.
Use only the designated lifting points 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).
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. For battery pack details such as certification, identification numbers, and assembly ratings, head to the dedicated Battery Pack Details page.
1. Unpack and install the battery into the plant. #
Remove the crate and remove the M12 locknuts and washers from the shipping feet to release the pack from the pallet. Install the lifting eyes, using four corner mounts minimum. Please note that lifting eyes are not included with the battery pack. After that, position the lifting chains or straps, ensuring a minimum 45° angle between chain and top surface and lift the battery with the shipping feet attached. Remove the shipping feet’s mounting bolts and washers to detach them from the battery, after which you’re ready to install the battery in the plant. Please note that lifting eyes are not included with the battery pack.
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2. Connect the communication connector with the power supply to the Battery Management System (BMS) and telematics. #
Communication is achieved through the communication connector where the BMS receives and transmits controller area network (CAN) messages to the VCU using J1939 protocol. A TE 776163-5 receptacle to pair with a TE 776164-5 mating connector will be required for this step.
| Protocol | CAN J1939 |
| Baud rate | 250 (optional) / 500kbps (default) |
Follow the table below for connector pinouts. 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.
| Pinout | Signals Required | Function |
|---|---|---|
| 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 |
| 22 | PMIC_IGNITION_F | KL15 Ignition |
| 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 |
| 33 | GND | 12/24V Negative |
| 34 | GND | 12/24V Negative |
| 35 | GND | 12/24V Negative |
For BMS communication and power supply in parallel packs, connect each battery communication connector with the VCU CAN and power supply.
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.
3. Perform a full wakeup-sleep cycle. #
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 succesfully
- 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
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
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.
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”.
To stop charging, send VCU_EnfOfChargingCmd = 1 and VCU_ PlugInChrgCmd = 0, and check that BMS_Mode reads “OPERATIONAL”.
To commence the power down sequence, send VCU_NormalPowerDownCmd = 1 and observe BMS_Mode reads “POWER DOWN”.
For the sleep procedure, send VCU_SleepCmd = 1, and check that BMS_Mode reads “SLEEP”.
4. Connect the thermal management system. #
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.
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, ensuring 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 water pump 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 #
Release the locking feature on the handle and insert the connector into the receptacle, ensuring the correct A/B coding match, and rotate the handle to lock the connector in place. After that, push the sliding lock to secure the handle in its correct position.
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.
2-Pin Connectors
| Receptacle | Part Number | Mating Part Number |
|---|---|---|
| HV + | HVSL1000022B150 | Straight – HVSL1000062B150 90° – HVSL1000082B150 |
| HV – | HVSL1000022A150 | Straight – HVSL1000062A150 90° – HVSL1000082A150 |
3-Pin Connectors
| Receptacle | Part Number | Mating Part Number |
|---|---|---|
| HV + | HVSL1000023A150 | Straight – HVSL1000063A150 90° – HVSL1000083A150 |
| HV – | HVSL1000023A150 | Straight – HVSL1000063A150 90° – HVSL1000083A150 |
6. Install Manual Service Disconnect (MSD) and fuse #
Before proceeding with this step, make sure that rest of the battery pack installation has been completed, but also ensure that the MSD is disconnected.
After doing so, insert the MSD fuse into the receptacle, ensuring that the lug settles into the handle groove. Rotate the handle to lock the connector in place, and push the sliding lock in to secure the handle into position.
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To remove, unlatch the sliding lock, rotate the handle until the lug is removed and remove the MSD connector from the receptacle.
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7. Complete commissioning #
Start with the Wake Up procedure by setting KL15 (ignition) to high, and send VCU_SleepCMD value 0. After that, BMS_Mode should read “INITIALIZATION” during self-check sequences, before changing to “READY” when the system completes these sequences correctly.
To go back to “INITIALIZATION“, send VCU_NormalPowerDownCmd value 1; after a few seconds, send VCU_SleepCmd value 1, and after a few more seconds send VCU_SleepCmd value 0.
This guide is an abbreviated version of the Detailed Start Guide intended for users who extremely familiar with the Hibernium installation process. Visit the full guide or our Resource Centre for additional information.
