Caterpillar 600V Battery Pack PDF

GLOBAL DEALER LEARNING CAT® BATTERY PACKS 600V Battery Pack MODULE 4 - TEXT REFERENCE SERVxxxx © 2024 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Corporate Yellow”, the “Power Edge” and Cat “Modern Hex” trade dress as well as cor...

GLOBAL DEALER LEARNING CAT® BATTERY PACKS 600V Battery Pack MODULE 4 - TEXT REFERENCE SERVxxxx © 2024 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Corporate Yellow”, the “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -2- Module 4 - 600V Battery Pack TABLE OF CONTENTS SAFETY BRIEFING 3 PURPOSE 4 REASON 5 ASSESSMENT CRITERIA 6 LEARNING OUTCOMES 7 PRODUCT OVERVIEW 8 PRODUCT SPECIFICATIONS 9 BATTERY MODULE CONFIGURATION 10 BATTERY MODULE CONNECTIONS - FRONT 11 BATTERY MODULE CONNECTIONS - REAR 13 BATTERY MODULE COOLING 14 PEM CONNECTIONS 15 PEM ARCHITECTURE 16 HAV CABLES WITH LATCHED PLUGS 17 BMS DATA LINKS AND ANALOG FEEDBACK ARCHITECTURE 18 BMS ECM J1 COMMUNICATION 20 BMS ECM J2 COMMUNICATION 21 BMS ECM ISO-SPI COMMUNICATION 22 600V BATTERY PACK OPERATION - DISCHARGING 23 600V BATTERY PACK OPERATION - CHARGING 24 PURPOSE 25 REASON 26 ASSESSMENT CRITERIA 27 LEARNING OUTCOMES 28 MODULE CONCLUSION 29 Caterpillar: Confidential Yellow SERVxxxx - 10/24 -3- Module 4 - 600V Battery Pack SAFETY BRIEFING Emergency Phone Numbers First Aid Responders Location of Exits Location of Fire Extinguisher Room Alerts or Hazards Designated Location for Evacuation Storm Shelter Hazardous Material Safely Home. Everyone. Every Day.™ 3 SAFETY BRIEFING Provide a safety briefing. Before beginning this module, the following topics will be reviewed: Emergency Phone Numbers First Aid Responders Location of Exits Location of Fire Extinguisher Room Alerts or Hazards Designated Location for Evacuation Storm Shelter Hazardous Material Safely Home. Everyone. Every Day.™ NOTE: Any system or component specifications stated in this training module are used only for training purposes. Components and specifications may change as the product evolves. Always refer to Caterpillar Service information to obtain the most current specifications when servicing Cat® products. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -4- Module 4 - 600V Battery Pack PURPOSE This module covers the components of the 600V Battery Pack. 4 PURPOSE Explain the purpose of this This module covers the components of the 600V Battery Pack. module. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -5- Module 4 - 600V Battery Pack REASON Successful completion validates the knowledge, skills, and behaviors that are required to determine the location, function, and operation of 600V Battery Pack components. 5 REASON Explain the reason of this Successful completion validates the knowledge, skills, and behaviors that are module. required to determine the location, function, and operation of 600V Battery Pack components. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -6- Module 4 - 600V Battery Pack ASSESSMENT CRITERIA Knowledge Assessment Closed Book Minimum passing score of 80% 6 ASSESSMENT CRITERIA Explain the assessment criteria After the completion of this module, the participant must complete a knowledge for this module. assessment with a minimum passing score of 80%. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -7- Module 4 - 600V Battery Pack LEARNING OUTCOMES After the completion of this module, the participant will be able to: Identify 600V Battery Pack components. Describe 600V Battery Pack component function. Explain 600V Battery Pack operation. 7 LEARNING OUTCOMES Explain the learning outcomes of After the completion of this module, the participant will be able to: this module. Identify the components of the 600V Battery Pack. Describe the function of 600V Battery Pack components. Explain the operation of the 600V Battery Pack and its components. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -8- Module 4 - 600V Battery Pack PRODUCT OVERVIEW 3 6 4 4 3 2 5 6 7 8 1 1 8 PRODUCT OVERVIEW Identify the components of the The 600V Battery Pack primarily consists of twelve battery modules (1) whose front 600V Battery Pack. side is protected by a battery cover (2). The battery modules provide Direct Current (DC) power to a battery electric machine or other type of electrical equipment. A Power Electronics Module (3), or PEM, is mounted on top of the left battery rack. When the battery modules are charging, it is responsible for directing incoming DC voltage to the battery modules from a Hazardous Voltage (HaV) source. When the battery modules are discharging, the PEM is responsible for directing stored DC voltage from the battery modules to a HaV load. A Battery Management System (BMS) assembly is mounted on top of the right battery rack. The assembly consists of a BMS Electronic Control Module (ECM) (4) mounted on top of a cradle (5) that contains the wiring harnesses of the system, and a Cat Product Link™ radio (6) which is located behind the PEM. The BMS ECM monitors and controls the electronic components of the battery modules and PEM in order to facilitate proper battery system function. The 600V Battery Pack requires its battery modules to be cooled by an active coolant system; there are lines (7) connecting the coolant ports of the battery modules to coolant tubes (8) positioned vertically along the outer edges of the battery racks. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -9- Module 4 - 600V Battery Pack PRODUCT SPECIFICATIONS Variable Value Nominal Voltage 608.2 VDC Electric Charge 105.1 Ah Energy 63.9 kWh 9 PRODUCT SPECIFICATIONS Identify the specifications for the The specifications for the 600V Battery Pack are as follows: 600V Battery Pack. Nominal Voltage (Vnom): 608.2 VDC Electric Charge (Q): 105.1 Ah Energy (E): 63.9 kWh Caterpillar: Confidential Yellow SERVxxxx - 10/24 -10- Module 4 - 600V Battery Pack BATTERY MODULE CONFIGURATION 10 BATTERY MODULE CONFIGURATION Explain the configuration of the The 600V Battery Pack has its battery modules organized into two racks that are battery modules. positioned side-by-side with one another. Each battery rack consists of six battery modules stacked on top of one another vertically. The battery modules of each battery rack connect to one another in series. The two battery racks connect to one another in series as well. Since the battery racks have their battery modules arranged in series, each battery rack has a nominal voltage of around 304.1 VDC. This is calculated by multiplying the nominal voltage of a battery module (50.7 VDC) by 6, the number of battery modules in the battery rack. However, each battery rack has an electric charge identical to each of its battery modules (105.1 Ah). The overall nominal voltage of the 600V Battery Pack is around 608.2 VDC. This is calculated by multiplying the nominal voltage of a battery rack (304.1 VDC) by 2, the number of battery racks. Its overall electric charge, however, is the same as the two battery racks that comprise it, because the battery racks are arranged in series. The total energy of the 600V Battery Pack is thus calculated to be: 608.2 VDC x 105.1 Ah = 63,922 Wh, or 63.9 kWh Caterpillar: Confidential Yellow SERVxxxx - 10/24 -11- Module 4 - 600V Battery Pack BATTERY MODULE CONNECTIONS - FRONT 4 1 2 3 11 BATTERY MODULE CONNECTIONS - FRONT Identify the connections at the Each battery module has a negative (DC-) terminal receptacle (1) and a positive front of the battery modules. (DC+) terminal receptacle (2). HaV cables (3) connect these terminal receptacles to form a single battery string. The six battery modules that comprise the left battery rack have their battery modules’ negative terminal receptacles connected to the positive terminal receptacles of the battery modules above them by HaV cables. Specialized HaV cables connect the negative terminal receptacle of the topmost battery module and the positive terminal receptacle of the bottommost battery module to battery terminal receptacles (4) at the front of the PEM. The six battery modules that comprise the right battery rack have their modules’ positive terminal receptacles connected to the negative terminal receptacles of the battery modules above them by HaV cables. Specialized HaV cables connect the positive terminal receptacle of the topmost battery module and the negative terminal receptacle of the bottommost battery module to battery terminal receptacles at the front of the PEM. To complete the battery string, the two battery terminal receptacles of the PEM that connect to the terminal receptacles of the bottom row of battery modules by specialized HaV cables are connected to one another inside the PEM. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -12- Module 4 - 600V Battery Pack The HaV cables going to the terminal receptacles of each battery module provide DC voltage to the battery modules from the PEM when the battery system is charging, and supply voltage to the PEM from the battery modules when the battery system is discharging. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -13- Module 4 - 600V Battery Pack BATTERY MODULE CONNECTIONS - REAR 3 2 1 5 4 13 BATTERY MODULE CONNECTIONS - REAR Identify the connections at the Each battery module is connected to a bonding cable (1) by a clamp (2). One end rear of the battery modules. of the bonding cable runs to a ground inside the PEM (3), and along the bonding cable is a clamp (4) that connects the cable to the battery pack’s base frame (5). The bonding cable is made of a continuous stainless steel braided cable. The cable ensures that the battery modules, PEM, and base frame are kept at the same potential in the event of a ground fault. A continuous cable is used to ensure in a scenario where if a bonding point becomes loose or not fitted, the whole bonding architecture is not compromised. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -14- Module 4 - 600V Battery Pack BATTERY MODULE COOLING 3 5 2 4 1 3 2 4 5 1 14 BATTERY MODULE COOLING Explain the battery module active The 600V Battery Pack has its battery modules cooled by an active coolant system. coolant system. There are coolant lines (1) that connect the innermost coolant ports (2) to one another for each row of battery modules. These lines enable coolant to flow from one battery module to another. There are two vertically aligned coolant tubes (3) along the outer edge of the two battery racks that connect directly to the outermost coolant ports (4) of each row of battery modules. One of these tubes delivers coolant to its connected battery modules, while the other directs heated coolant away from its connected battery modules and towards the heat exchanger of the active coolant system. The top and bottom of each coolant tube serves as a connection point to the active coolant system of a machine or other type of electrical equipment. These connection points are covered by caps (5) when disconnected from an active coolant system. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -15- Module 4 - 600V Battery Pack PEM CONNECTIONS 4 5 3 1 2 6 15 PEM CONNECTIONS Identify the PEM connections. The PEM is designed to control and monitor the voltage and current leaving the battery modules when the 600V Battery Pack is in a discharging state. It also controls and monitors the voltage and current entering the battery modules when the 600V Battery Pack is in a charging state. In order to do this, the PEM contains multiple terminals that permit flow of HaV electric power into and out of it. At the front of the PEM, there are three pairs of terminals connected to bus bars. There are separate negative (DC-) battery terminal bus bars (1) that connect to the two negative battery terminal receptacles, and separate positive (DC+) battery terminal bus bars (2) that connect to the two positive battery terminal receptacles. The negative main bus bar (3) and positive main bus bar (4) supply DC voltage to the HaV electrical system of a machine or other type of electrical equipment when the 600V Battery Pack is in a discharging state. When the battery pack is in a charging state, these bus bars receive DC voltage from the HaV electrical system of the machine or other type of electrical equipment instead. At the rear of the PEM is a ground connection (5). This connects the bonding cable outside of the PEM to a ground inside the PEM. On the right side of the PEM are a pair of interface connectors (6). These allow the interface board inside the PEM to communicate with the BMS ECM. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -16- Module 4 - 600V Battery Pack PEM ARCHITECTURE 5 6 2 4 3 1 16 PEM ARCHITECTURE Identify the internal components The internal components of the PEM provide the BMS with a means to monitor and of the PEM. control the flow of hazardous voltage into and out of the PEM. This enables the 600V Battery Pack to enter either a charging state or discharging state. The PEM main circuit board (1) contains contactors (2) which can isolate the PEM outputs from the battery modules. There is also a precharge contactor (3) that is located near the interface connections (4). Between the negative battery terminal receptacles and main drive terminal receptacles is a removable Manual Service Disconnect (MSD) (5). The MSD contains a string fuse that prevents excess current from entering or leaving the PEM in a fault condition or when the MSD is removed. It separates a negative (DC-) bus bar inside the PEM from the negative battery terminal bus bar connected to the negative terminal receptacle of the right battery rack. Near the center of the main circuit board is an IVT-S sensor (6) that monitors the current and voltage of the battery string. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -17- Module 4 - 600V Battery Pack HAV CABLES WITH LATCHED PLUGS 5 4 3 2 1 17 HAV CABLES WITH LATCHED PLUGS Explain how to disconnect and Both the battery terminal receptacles and main drive terminal receptacles of the connect the HaV cables with PEM have a catch at the top of them; this means that HaV cables with latched latched plugs. plugs must be used to connect to them. This is done so that the HaV cable is oriented in a very specific direction relative to the PEM. The terminal receptacles are also keyed, eliminating the ability to insert the plugs into the incorrect terminal receptacle. When disconnecting a HaV cable with a latched plug (1), press down on the latch release button (2) prior to removing the plug from the terminal receptacle (3). When connecting a HaV cable with a latched plug to a terminal receptacle of the 600V Battery Pack, align the latch (4) of the plug with the catch (5) of the terminal receptacle. Once the latch of the plug is correctly aligned, press the latch release button and then push the plug directly into the terminal receptacle. Once the plug is in place, release the latch release button. The slot of the plug’s latch should encase the catch of the receptacle. These plugs and terminal receptacles also make use of a Hazardous Voltage Interlock (HVIL) circuit. This circuit ensures that the electrical architecture is connected and eliminates the possibility of hazardous voltage being present when connections are exposed. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -18- Module 4 - 600V Battery Pack BMS DATA LINKS/ANALOG FEEDBACK ARCHITECTURE 18 BMS DATA LINKS AND ANALOG FEEDBACK ARCHITECTURE Identify the BMS Data Links and The diagram shows the overall electronic architecture of the BMS and illustrates the analog feedback architecture. the connectivity between all the electronic devices over the data links and analog feedback. The J1 port (6) of the BMS ECM (5) uses CAN Data Links for communications with external monitoring or control systems and the PEM. The CAN A and CAN C Data Links allow communications between the BMS ECM and the electronic control system of a machine or other type of electrical equipment via the Battery Interface Connector (BIC) (2). The CAN B Data Link allows communications between the BMS ECM and the sensors inside the PEM (4) via the front Power Electronics Module Interface Connector (PEMIC) (10). The CAN D Data Link allows communications between the BMS ECM and the Cat Product Link radio (3). The BMS also incorporates analog feedback connections. The BMS ECM directs analog feedback communications between it and the PEM, Cat Product Link radio, and an external electronic control system using its J1 port. There is an additional analog feedback connection between the J2 port (7) of the BMS ECM and the rear PEMIC (11) of the PEM. This allows the BMS ECM to monitor and control the contactors inside the PEM. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -19- Module 4 - 600V Battery Pack There are also ISO-SPI Data Link connections that allow communications between the BMS boards of the battery modules (1) and the BMS ECM. The battery modules connect to one another, then to the J3 port (8) and J4 port (9) of the BMS ECM, forming a ring or loop of connections. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -20- Module 4 - 600V Battery Pack BMS ECM J1 COMMUNICATION 3 6 1 5 2 4 20 BMS ECM J1 COMMUNICATION Explain BMS ECM The J1 connector (1) of the BMS ECM communicates with the PEM and other communication via the J1 port. components of the BMS using both CAN Data Links and analog feedback. Communication with the PEM is done via a 31-pin PEMIC (2) that is fitted to the front interface connector of the PEM. CAN B Data Link and analog feedback communication enables the BMS ECM to monitor the sensors inside the PEM. The J1 connector enables the BMS ECM to communicate with an external electronic control system by way of the 29-pin BIC (3) at the front of the BMS assembly. The J1 connector enables the BMS ECM to communicate with the Cat Product Link radio by way of the 14-pin connector (4) near the rear of the BMS assembly. The CAN B Data Link going to the PEM has an external terminal resistor (5) located near the J3 and J4 connectors. There are also two external terminal resistors (6) located near the J1 connector for the CAN D Data Link between the BMS ECM and the Cat Product Link radio. There are no external terminal resistors for the CAN A and CAN C Data Links between the BMS ECM and the BIC. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -21- Module 4 - 600V Battery Pack BMS ECM J2 COMMUNICATION 1 2 21 BMS ECM J2 COMMUNICATION Explain BMS ECM The J2 connector (1) of the BMS ECM communicates with the PEM using only communication via the J2 port. analog feedback. Communication with the PEM is done via a 29-pin PEMIC (2) that is fitted to the rear interface connector of the PEM. This line of communication enables the BMS ECM to monitor and control the contactors inside the PEM. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -22- Module 4 - 600V Battery Pack BMS ECM ISO-SPI COMMUNICATION 2 1 3 22 BMS ECM ISO-SPI COMMUNICATION Explain BMS ECM The BMS ECM forms a communication network with the BMS boards of the battery communication via ISO-SPI (J3 modules using ISO-SPI Data Links. and J4) ports. The J3 and J4 connectors (1) of the BMS ECM connect to the upper data link connectors (2) of the BMS boards in the top row of battery modules. The lower data link connectors of these BMS boards are connected to the upper data link connectors of the BMS boards in the battery modules of the row directly below them. Such connections continue until reaching the bottom row of battery modules, where the lower data link connectors (3) of the BMS boards in the bottom row of battery modules are connected to one another, completing the communication loop. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -23- Module 4 - 600V Battery Pack 600V BATTERY PACK OPERATION - DISCHARGING 2 1 23 600V BATTERY PACK OPERATION - DISCHARGING Explain the operation of the 600V When the 600V Battery Pack is in a discharging state, it is considered to be in its Battery Pack when discharging. normal mode of operation. DC voltage from the battery modules is directed to the PEM by way of HaV cables connected to its battery terminal receptacles (1) and ENERGIZES the battery terminal bus bars inside the PEM. The BMS ECM configures the contactors of the PEM such that DC voltage is supplied to its main drive bus bars. Once DC voltage has traversed through the PEM and ENERGIZES the main drive bus bars, HaV cables connected to the main drive terminal receptacles (2) of the PEM supply a machine or other type of electrical equipment with the electric charge stored by the battery modules, causing the State of Charge (SoC) of the battery modules to decrease over time. While the 600V Battery Pack is in a discharging state, the BMS ECM continually monitors the system for any conditions which may require the rate of discharge to be reduced, or if the product must become isolated from the HaV electrical system of the machine or other type of electrical equipment the product is supplying. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -24- Module 4 - 600V Battery Pack 600V BATTERY PACK OPERATION - CHARGING 1 2 24 600V BATTERY PACK OPERATION - CHARGING Explain the operation of the 600V When the 600V Battery Pack is in a charging state, it is considered to be in its Battery Pack when charging. charging mode of operation. DC voltage from a machine or other type of electrical equipment is directed to the PEM by way of HaV cables connected to its main drive terminal receptacles (1) and ENERGIZES its main drive bus bars. The BMS ECM configures the contactors of the PEM such that DC voltage is supplied to its battery terminal bus bars. Once DC voltage has traversed through the PEM and ENERGIZES the battery terminal bus bars, HaV cables connected to the battery terminal receptacles (2) of the PEM then supply this DC voltage to the battery modules, causing their SoC to increase over time. While the 600V Battery Pack is in a charging state, the BMS ECM continually monitors the system for any conditions which may require the rate of charge to be reduced, or if the product must become isolated from the HaV cables supplying the main drive bus bars with electric power. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -25- Module 4 - 600V Battery Pack PURPOSE This module covers the components of the 600V Battery Pack. 25 PURPOSE Explain the purpose of this This module covers the components of the 600V Battery Pack. module. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -26- Module 4 - 600V Battery Pack REASON Successful completion validates the knowledge, skills, and behaviors that are required to determine the location, function, and operation of 600V Battery Pack components. 26 REASON Explain the reason of this Successful completion validates the knowledge, skills, and behaviors that are module. required to determine the location, function, and operation of 600V Battery Pack components. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -27- Module 4 - 600V Battery Pack ASSESSMENT CRITERIA Knowledge Assessment Closed Book Minimum passing score of 80% 27 ASSESSMENT CRITERIA Explain the assessment criteria After the completion of this module, the participant must complete a knowledge for this module. assessment with a minimum passing score of 80%. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -28- Module 4 - 600V Battery Pack LEARNING OUTCOMES After the completion of this module, the participant will be able to: Identify 600V Battery Pack components. Describe 600V Battery Pack component function. Explain 600V Battery Pack operation. 28 LEARNING OUTCOMES Explain the learning outcomes of After the completion of this module, the participant will be able to: this module. Identify the components of the 600V Battery Pack. Describe the function of 600V Battery Pack components. Explain the operation of the 600V Battery Pack and its components. Caterpillar: Confidential Yellow SERVxxxx - 10/24 -29- Module 4 - 600V Battery Pack MODULE CONCLUSION 29 MODULE CONCLUSION Conclusion This concludes the 600V Battery Pack module for the Cat Battery Packs course. When used in conjunction with the service manuals, the information in this module will enable the participant to determine the location, function, and operation of 600V Battery Pack components. For service recommendations, always refer to the Operation and Maintenance Manual (OMM), service manuals, and other related Cat service publications. Caterpillar: Confidential Yellow