ELECTRICAL BATERY SAFETY MANUAL PACK SWD EMERSON EDUARDO RODRIGUES

BBG Battery Pack-SWD
Safety Manual
Version：V0
Please read the Safety Manual carefully before using this product.
利用 pdfFactory Pro 测试版本创建的PDF文档 www.pdffactory.com

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Contents
一. Definition of terms and Abbreviations .......................................................... 3
1.1 Definition of terms ................................................................................................. 3
1.2 Abbreviations......................................................................................................... 3
二. Product Introduction................................................................. 4
2.1 product outline drawing ......................................................................................... 4
2.3 Transport and Storage of pruduct .......................................................................... 5
2.4 Assembly/Mounting ............................................................................................... 5
2.5. Operators handling for fitting(including safety risks).............................................. 6
2.6. After-sales(rectification, repair, specific tool to use) .............................................. 6
2.7. Recommendations for driver use.......................................................................... 7
三、Emergency management ....................................................... 8
3.1 Emergency management....................................................................................... 8
3.2 Manual maintenance switch (MSD) installation and removal operation requirements
........................................................................................................................... 10
四、Notes and statements .......................................................... 12
4.1 Matters needing attention .................................................................................... 12
4.2、Statement ............................................................................ 13

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一. Definition of terms and Abbreviations
1.1 Definition of terms
Battery Cell
The minimum energy storage unit, a basic electrochemical
energy storage device, consists of a positive electrode, a
negative electrode, electrolyte, an isolation film, an exhaust
valve and a shell, also known as a battery cell.
Battery Module
The intermediate energy storage unit, which is placed in a
mechanical and electrical unit, is a combination of several
monomers connected by circuits and circuit equipment
(monitoring and protection circuits, electrical and
communication interfaces), also known as modules.
Pack
A power supply system consisting of several battery modules,
circuit equipment (protection circuit, battery management
system, electrical and communication interface) and thermal
management devices, etc. for supplying energy to the
electrical devices.
Nominal Voltage
Under the conditions of 25 °C, 90% RH and 50% SOC, the
potential difference between the positive and negative
electrodes of the battery.
Capacity
The amount of electricity that a fully charged battery can
provide under specified conditions.Usually expressed in Ah.
Energy Capacity
The energy that can be provided by a fully charged battery
under specified conditions.Usually expressed in Wh or kWh.
Nominal Capacity
At the beginning of life (BOL), the minimum capacity that a
fully charged battery can provide by discharging at a rate of
1C (C-rate) under specified conditions.
1.2 Abbreviations
BCU Battery Control Unit
BMS Battery Management System
BMU Battery Management Unit
BOL Begin of Life
Bus-bar Electric core pole connecting strip
CAN Controller Area Network
A-CAN BMU and HCU communicate CAN
C-CAN BMU communicates with CSC CAN

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CH-CAN BMU communicates with charger CAN
CSC Cell Supervision Circuit
EOL End of Life
FSR Full-Scale Range
HV High Voltage
HVIL High Voltage Interlock
Hazardous Voltage Interlock Loop
MSD Manual service switch
OCV Open Circuit Voltage
SOC State of Charge
SOH State of Health
二. Product Introduction
2.1 product outline drawing
2.1. The product outline drawing and external interface are shown below
FA
MSD
HV Connector
LV Connector

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2.3 Transport and Storage of pruduct
1、 The remaining amount of power shall be in the range of 40% to 60%
during storage of battery Pack.
2 、The Pack should not be inverted or horizontal, and mechanical shock or
heavy pressure should be avoided.
3 、
The transportation of Pack shall meet the requirements of GB 21966-2008.
4、 The battery Pack should be transported with incomplete discharge. SOC
should be in the range of 40% ~ 60%..
5、The electrical interface should be protected during transportation to
prevent collisions and falls. The "blocking" requirements in GB / T 20234-2006
can be used.
6、 During the transportation of the electrical box, all MSD plugs must be
removed from the electrical box and the MSD socket interface must be protected.
7 、The Pack should be stored in a well-ventilated, clean, dry room at a
temperature of 5 ° C to 40 ° C. It should avoid direct sunlight, and the distance
from the heat source should not be less than 2m...
2.4 Assembly/Mounting
1、 Keep the end plate direction of the module in the Pack consistent with
the forward direction of the vehicle.
2、 Proper replacement tools should be selected to avoid damage the
Pack.
3、 Avoid anything to fall into the Pack and connector such as foreign metal
objects and water drop and so on, and prevent to occur internal short
circuit.
4、 Ensure that the contact parts of Pack are clean. Need to wipe them
with a dry cloth when necessary. Otherwise, it may lead to poor contact
and functional failure.

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5、 Notice: The connection should be correct, reliable (not loose), good
contact (no contact resistance), and prohibit any forms of short circuit.
6、 Ensure that the Pack connector mated correct vehicle connector and
put in place.
7、 Prohibit the non-professional technicians to install, maintain, repair and
disassemble the module.
8、 Prohibit operators to work by hand without wearing protective gloves.
9、 Prohibit the human body to contact the positive and negative poles of
the Pack at the same time.
2.5. Operators handling for fitting(including safety risks)
1、
Avoid external short circuit to prevent failure of BMS and circuit connection.
2、Prohibit any forms of short circuit during connection.
3、Ensure that the connector interface is closed to prevent foreign matter
from entering the connector, which may lead to short circuit of cell and voltage
sampling line.
4、Do not try to disassemble the module or penetrate it with sharp knife. The
electrolyte inside the module can damage skin and clothing.
5、If the battery leaks and the electrolyte splashes into the eyes, rinse the
eyes with clean running water immediately for at least 15 minutes, and go to
hospital for treatment if necessary.
2.6. After-sales(rectification, repair, specific tool to use)
1、Do not store and use in environments with high static electricity or high
electromagnetic radiation.
2、Do not get wet or even soak in water. Otherwise, it may cause internal
short circuit, loss of function or abnormal chemical reaction, and cause fire, smoke,
explosion and other accidents;

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3、Ensure that the module is completely on the outer surface. Ensure that
the module is fixed accurately in the Pack.
4、Prohibit to discard abandoned products in fire or in hot stoves. The
abandoned module should be recycled by professional institutions or
organizations.
5、If the module is on fire and the flame does not spread to the high-pressure
battery section, a carbon dioxide or ABC dry powder fire extinguisher can be used
to extinguish a fire.
6 、 If any smoke, heat, discoloration or deformation, or any abnormal
phenomenon are found in use, storage, transportation and service, you should
immediately contact the professional department to further observe and control
the risks;
7、Do not contact any high voltage parts before thoroughly checking the fire.
2.7. Recommendations for driver use
1、Need to extinguish the fire by a large amount water when the Pack is
fired.
2、Notice: It may take 24 hours to completely extinguish when the Pack
is on fire. Warning for use during malfunction.
3、If a warning message appears in the heat management system, stop
using and stay away from the vehicle immediately. Please inform the relevant
technical personnel to carry out a comprehensive inspection. Warning for use
during malfunction.
4、If the Pack occur smoking, heating or any abnormal phenomenon in
use stage, please contact the professional department immediately to further
observe and control the risk. Warning for use during malfunction.
5、Prohibit the module abuse to prevent thermal runaway caused by
internal short circuit.

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6、Before the vehicle is started, it should check the state of charge of the
battery system, etc. to confirm whether the conditions for starting the vehicle are
met:
(1) Observe the instrument panel of the vehicle to confirm that the
battery system is in a normal state and there is no abnormal fault alarm.
(2) Confirm the SOC status of the vehicle battery system. When the
SOC value is greater than 3%, the vehicle can be normally started on
the road.
(3) When the SOC state of the battery system is less than 3%, it is a
low-battery state. It is recommended to charge as soon as possible, and
start the vehicle on the road after charging more than 50%.
(4) When the SOC value is less than 10%, the vehicle needs to drive
to the charging station to recharge immediately.
三、Emergency management
3.1 Emergency management
Smoke or fire
When smoke or fire occurs in the whole vehicle or battery system, the
following measures should be taken immediately:
(1) Turn off the vehicle key, disconnect the low-voltage power supply,
and evacuate personnel.
(2) If the battery harness emits smoke or fire, it should be sprayed with
carbon dioxide or dry powder fire extinguisher.
(3) If the battery catches fire, use a high-pressure water gun to
extinguish the fire from a long distance.

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(4) If you inhale the thick smoke caused by the fire of the battery, it will
cause difficulty in breathing.
(5) Contact the vehicle manufacturer to arrange system maintenance.
Note: If there is smoke or fire caused by abnormal charging,please
turn off the charging power before performing fire extinguishing
operation.
Flood
The protection rating of the battery system is IP67, but the protection
rating of a single battery box (when the power cable between the
boxes is not plugged in) does not meet IP67. In this case, if you
encounter flooding, please follow the requirements below:
(1) Evacuate personnel.
(2) Pull out the battery system from the water and drain it within 30min,
and pay attention to safety.
(3) Notify the after-sales personnel of the manufacturer in time and
arrange system maintenance.
When flooding under normal loading conditions, the following measures
should be taken:
(1) When the vehicle enters the water (≤30cm) for a short time, the
performance is not affected, and it can be driven out of the water as
soon as possible.
(2) When the instrument has an insulation alarm, turn off the vehicle
key, disconnect the low-voltage power supply, evacuate personnel
and arrange system maintenance.
(3) After the vehicle is immersed in deep water for a long time, turn off the
vehicle key,
disconnect the low-voltage power supply, and evacuate personnel; Pull the
vehicle out of the water and drain it; arrange for system maintenance.

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Note: When handling high-voltage wiring harnesses or high-voltage components, wear
high-voltage insulating gloves!
3.2 Manual maintenance switch (MSD) installation and removal
operation requirements
The manual maintenance switch is not allowed to be powered on before
being locked, and it is strictly forbidden to be plugged and unplugged while it is
powered on; the following steps should be followed when removing the manual
maintenance switch:
1、Turn the electric vehicle key switch to the "OFF" position;
2、Turn off the main power control rocker switch;
3、After 15 minutes, pull out the manual maintenance switch and cut off
the vehicle power.
Battery box MSD installation:
Check whether the plug of the MSD base is clean and free of oil, etc., to
ensure that no metal dust and foreign matter have fallen into the device. See the
following diagram for the installation diagram and plug type:
Figure 1
MSD components (with insurance)
Adjust the handle on the plug seat to the position shown in Figure 2, and
rotate the handle to the top surface of the plug by 90 degrees;

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Figure 2
(1) According to the assembly sequence in Figure 3, press down
on the positions of the plugs and sockets into the slots, and turn
the handle firmly until you hear a "click" sound, and then press
the CPA button to complete the installation.
Figure 3
Disassembly of battery box MSD
Notice:
1. The manual maintenance switch should be stored in a
warehouse with a temperature of -5 ° C to 35 ° C, a relative
humidity of not more than 80%, and no acid or alkali and other

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corrosive gases, and the storage period is 5 years;
2. When the manual maintenance switch is separated from
the circuit breaker base and not used temporarily, the manual
maintenance switch should be protected to prevent dirt from
entering.
四、Notes and statements
4.1 Matters needing attention
1、Power battery assembly products belong to high-voltage power supply,
whose voltage far exceeds the safe voltage range of human body. Direct contact
with high-voltage terminals may lead to electric shock risk, while indirect contact
through conductors may also lead to electric shock risk, so the operating
specifications of this product must be observed. Any installation, maintenance and
use of this product must strictly abide by the relevant safety regulations.
2、It is forbidden to store or use at high temperature and must be far away
from heat source. These environments above the safe temperature range will lead
to a significant decline in the performance and service life of the product, and even
lead to serious consequences such as combustion and explosion.
3、
It is forbidden to store and use in the environment with high static electricity
or high electromagnetic radiation. Otherwise, the electronic devices in this product
will be damaged, which may lead to potential safety hazards.
4、Do not be affected with damp or even soak in water. Otherwise, it may
cause internal short circuit, function loss or abnormal chemical reaction of the
product, and cause fire, smoke, explosion and other accidents.
5、If smoke, heat, discoloration or deformation are found, or any abnormal
phenomenon occurs in use, storage, transportation and service, the professional
department shall be contacted immediately to further observe and control risks;

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6、Installation, maintenance, repair and disassembly of non-professional
personnel are prohibited, except for repair operations by professional and
technical personnel.
7、It is forbidden to discard the discarded products in the fire or hot stove.
Discarded batteries should be recovered and recycled by professional institutions
or organizations.
8、Do not press heavy objects on this product or stack them on top of each
other.
4.2、Statement
Before you use this product, make sure that you have read and fully accept
the following information:
Sunwoda Electric Vehicle Battery Co., Ltd. will not be held responsible for the
loss of personnel and property caused by violation of the product specifications,
operating conditions, scope of work, precautions and other provisions specified in
this document.
This product has potential risks and hazards during installation, storage,
transportation, use, maintenance and repair. Please follow the corresponding
requirements.
In the use, service and maintenance of products, users should establish
correct rules and Sunwoda Electric Vehicle Battery Co., Ltd. will provide
necessary technical support.
Sunwoda Electric Vehicle Battery Co., Ltd. reserves the right of final
interpretation of all problems of this product. If you have any questions or
objections about the product, please contact the professional department of
Sunwoda electric vehicle battery co., lt

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ELECTRICAL BATERY SAFETY MANUAL PACK SWD EMERSON EDUARDO RODRIGUES

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