Global Dealer Learning - CAT Battery Packs 600V

HaV cables provide DC voltage to battery modules during charging and supply voltage to the PEM during discharging.

Each battery module is connected to a bonding cable by a clamp. The bonding cable connects modules/PEM to the ground.

Bonding cables are made of continuous stainless steel braided cable.

Bonding cables ensure all components (modules, PEM, base frame) are at the same potential during a ground fault.

A continuous bonding cable prevents potential issues with bonding points.

PEM terminal receptacles connect to bottom row of battery modules via HaV cables.

Connects the bonding cable to the battery pack's base frame

Connects the bonding cable to a ground inside the PEM (Power Electronic Module).

Terminals on the PEM that control and monitor the voltage and current flow in a 600V battery pack during discharge and charge.

The state of the battery pack when releasing power to the electrical system.

The state of the battery pack when receiving power from the electrical system.

The negative terminals of the battery pack.

The positive terminals of the battery pack.

Bus bars carrying DC voltage to the electrical system (either receiving or discharging).

A connection that bonds the external cable to the internal ground of the PEM.

Connectors that allow communication between the PEM and the BMS ECM.

The BMS ECM communicates with the Power Electronic Module (PEM) and other BMS components using CAN Data Links and analog feedback.

A 31-pin connector that connects the BMS ECM to the front interface of the PEM.

A 29-pin connector that lets the BMS ECM communicate with an external control system.

A 14-pin connector that enables the BMS ECM to communicate with the Cat Product Link radio.

The CAN B Data Link connects the BMS ECM to the PEM, including a terminal resistor near the J3 and J4 connectors.

The CAN D Data Link connects the BMS ECM to the Cat Product Link radio, with two external terminal resistors near the J1 connector.

Battery modules are connected to each other, forming a loop to the J3 and J4 ports of the BMS ECM.

The J1 connector allows the BMS ECM to communicate with the PEM, external control systems, and the Cat Product Link radio.

The 600V Battery Pack is made of two battery racks placed side-by-side. Each rack has six battery modules stacked vertically. Modules within a rack are connected in series, and the two racks are also connected in series.

Connecting battery modules in series increases the overall voltage but keeps the electric charge the same.

Each battery rack has a nominal voltage of around 304.1 VDC, calculated by multiplying the individual module voltage (50.7 VDC) by the number of modules (6).

The total nominal voltage of the Battery Pack is around 608.2 VDC, obtained by multiplying the voltage of a battery rack by 2.

The electric charge (Ah) of the battery pack is the same as the charge of one battery rack, because the racks are connected in series.

The Series connection allows for a high overall voltage while retaining the charge of a single battery rack, making it efficient for high-voltage applications.

Each battery module has a nominal voltage of 50.7 VDC and a charge of 105.1 Ah. This means it can provide 50.7 volts of electricity and store 105.1 Ampere-hours of energy.

The total energy stored in the 600V Battery Pack is 63.9 kWh, calculated by multiplying the pack's voltage by its charge.

The 600V Battery Pack utilizes an active coolant system to keep its battery modules cool. Coolant is circulated through connected tubes and ports within the battery modules.

Coolant lines connect the innermost coolant ports of each row of battery modules, allowing coolant to flow from one module to another.

Two vertically aligned coolant tubes run along the outer edge of the battery racks. One delivers coolant to the modules, while the other collects heated coolant and sends it to the heat exchanger.

The top and bottom of each coolant tube acts as a connection point to the active coolant system of a machine or other equipment.

When disconnected from an active coolant system, caps cover the connection points on the coolant tubes.

A system that actively circulates coolant to regulate the temperature of battery modules, preventing overheating.

Coolant flows from the innermost ports to the outermost ports of each row of battery modules, then to the heat exchanger for cooling.

The heat exchanger in the active coolant system cools the heated coolant collected from the battery modules before it's recirculated.

The total energy capacity of a battery pack is calculated by multiplying its voltage by its amp-hour rating. This gives the energy in watt-hours (Wh) or kilowatt-hours (kWh).

Battery modules are connected in series to form a battery string. They have positive and negative terminals connected by high-voltage (HaV) cables. Specialized HaV cables connect the string to the Power Electronic Module (PEM).

In the left battery rack, the negative terminal of each battery module is connected to the positive terminal of the module above it with HaV cables. The topmost module's negative terminal and the bottommost module's positive terminal connect to the PEM.

In the right battery rack, the positive terminal of each battery module is connected to the negative terminal of the module above it with HaV cables. The topmost module's positive terminal and the bottommost module's negative terminal connect to the PEM.

High-Voltage (HaV) cables connect the battery modules together in a series configuration, forming the battery string. They carry the high voltage DC current required for the battery pack's operation and for charging.

The Power Electronic Module (PEM) has terminal receptacles that connect to the top and bottom battery modules in the battery string. These connections complete the circuit and allow for charging and discharging.

A bonding cable made of continuous stainless steel braid connects all the battery modules, the PEM, and the base frame to ensure they are at the same electrical potential. This helps protect the system during a ground fault.

The PEM (Power Electronic Module) is the heart of the battery pack's control system. It manages the charging and discharging processes of the battery pack and interacts with the Battery Management System (BMS) via communication links.

Terminals on the PEM that control and monitor voltage and current flow in a 600V battery pack during charging and discharging. They allow HaV electric power to flow into and out of the PEM.

The state of the battery pack when releasing power to the electrical system of the machine or equipment.

The state of the battery pack when receiving power from the electrical system of the machine or equipment.

Bus bars connected to the two negative battery terminal receptacles. These bus bars carry negative DC voltage.

Bus bars connected to the two positive battery terminal receptacles. These bus bars carry positive DC voltage.

These bus bars supply DC voltage to the HaV system during discharge and receive it from the system during charging.

The BMS ECM communicates with the BMS boards within the battery modules using ISO-SPI data links via the J3 and J4 connectors.

External terminal resistors are components used in CAN data links to terminate the signal, preventing signal reflections that can interfere with communication.

The BMS ECM communicates with the PEM via a 29-pin PEMIC connector located on the rear interface of the PEM. This communication uses analog feedback.

The ISO-SPI data links enable communication between the BMS ECM and the BMS boards within the battery modules, allowing for monitoring and control of the battery pack.

J3 and J4 connectors on the BMS ECM facilitate the ISO-SPI data links, which connect to the BMS boards in the top row of battery modules.

The BMS boards in the battery modules are interconnected via ISO-SPI data links, ensuring that all modules within the battery pack are communicating and monitored.

The BMS ECM uses analog feedback to control the contactors inside the PEM. These contactors are responsible for switching the flow of current within the battery pack.

The process of supplying DC voltage to the battery modules through the Power Electronic Module (PEM) and HaV cables, increasing the State of Charge (SoC) over time.

The PEM acts as a gatekeeper, controlling the flow of DC voltage from the main drive bus bars to the battery terminal bus bars, which then energizes the battery modules.

The Battery Management System (BMS) Electronic Control Module (ECM) continually monitors the charging process, adjusting the rate of charge or isolating the pack if needed.

High-Voltage (HaV) cables connect the battery modules to the PEM, carrying DC voltage during charging and discharging.

Connecting battery modules in series allows for a higher overall voltage, increasing the effectiveness of the battery pack for high-voltage applications.

A continuous stainless steel bonding cable connects all battery modules, the PEM, and the base frame to ensure they are at the same electrical potential, preventing issues during a ground fault.

The active coolant system circulates coolant through the battery modules to regulate their temperature and prevent overheating.

The PEM communicates with the BMS ECM, enabling data exchange and control over the charging and discharging processes.