Interconnection
high levels of reliable and safe operation, including positive locking mechanisms to prevent accidental disconnects (Figure 4). They are rated at 1500 volts DC (VDC), 120 amperes (A), and for over 100 insertion/withdrawal cycles with an insertion force ≤ 75 Newtons (N) and a withdrawal force of ≥10 N.
Battery pole connector examples The battery pole connector system from Phoenix Contact consists of pairs of cable connectors and panel-mount connectors with silver-plated contacts, having a total contact resistance of ≤5 milliohms (mΩ). The connectors are rated according to UL 4128, the latest UL standard for battery applications. Prior to this standard, most battery connectors were rated using the UL 1977 standard, which is a more generalized standard with a maximum voltage rating of 1,000 VDC. The Phoenix Contact battery pole connectors are rated to 1500 VDC , meeting the UL 4128 standard. In addition to meeting the latest UL 4128 standard (listed below), these battery pole connectors satisfy the requirements of important BESS related international standards, including: • IEC 61984 – Connectors - Safety requirements and tests
• IEC 62933 – Electrical energy storage (EES) systems
• IEC 63066 – Low-voltage docking connectors for removable energy storage units
• UL 9540 – Standard for Energy Storage Systems and Equipment
• UL 4128 – Outline of Investigation for Intercell and Intertier Connectors for Use in Electrochemical Battery System Applications
Cable connectors such as the 1106307 come in black for negative poles, while the 1106306 connector comes in orange for positive poles. A crimp termination on the cable connectors can handle 16 square millimetre (mm²) and 25 mm² cable sizes, with a stripping length of 22 mm. A sliding locking mechanism prevents accidental disconnections.
In addition to fulfilling the technical requirements of installers and system integrators, the panel-mount battery pole connectors offer BESS system designers the flexibility of choosing a busbar or screw post attachment within the system. Like the cable connectors, the panel-mount connectors are offered in orange for positive poles (with a choice of busbar, such as 1130816, or screw post attachments, like 1106303) and black for negative poles (with a choice of busbar, for example 1130814, or screw post attachments, such as 1106304). A summary
www.cieonline.co.uk Components in Electronics April 2022 51
Design and application considerations
To ensure safe and reliable operation, there are several factors that designers and installers need to take into consideration when using pluggable battery pole connector systems: • Do not connect or disconnect the connectors under load.
• The connector must be fully plugged in and interlocked before it is energized.
• Under normal operation, the connector will be warm. Under high-temperature ambient conditions, these connectors can continue to get warmer. If the connector is expected to be used in high ambient temperature conditions, burn warnings such as those required by DIN EN ISO 13732-1:2008-12 may be needed.
• A protective cap should be placed on connectors that are not being used.
• The tensile load on the connectors in a cable assembly cannot exceed the upper limit of the specification.
Figure 3: These pluggable battery pole connectors are mechanically keyed and colour-coded to prevent cross- wiring. A “click” is heard when they plug into the touch-protected socket and lock into position. (Image source: Phoenix Contact).
of performance features and benefits of the battery pole connector system includes: • 75 per cent faster installation time compared with lug connectors, reduces cost of installation
• Colour-coded for polarity identification: Orange (+) positive Black (-) negative • Black and orange connector pairs have unique interfaces to prevent cross-mating
• Positive locking mechanism prevents accidental disconnections
• Cable connectors have crimp terminations for 16 mm² and 25 mm² wire sizes
Figure 4: These pluggable battery pole connectors have a positive locking mechanism: On the left (A) the locking mechanism/release lever is shown in its locked state; the middle (C) shows the pair discon- nected; this disconnection is achieved by sliding the locking mechanism (right, B) forward towards the mating interface. (Image source: Phoenix Contact).
• The mated connector system can be rotated 360° to simplify installation
• Rated for 100 insertion/withdrawal cycles with an insertion force ≤75 N and a withdrawal force of ≥10 N
• Fully touch-proof design for operator safety • IP65 rated housings provide environmental protection
• Silver-plated contacts for a contact resistance ≤5 mΩ and reliable connection interface
• IEC rated for 120 A and 1500 VDC • Operating temperature range of -40°C to +125°C
Conclusion
As the deployment of BESS systems accelerates to ensure reliable power and adapt to renewable energy sources, designers need to pay extra attention to the requirements for the battery pole connectors for these modular battery systems. Using pluggable battery pole connectors, designers can meet core safety and performance requirements, while also supporting the reliability, scalability, maintenance, environmental, and cost requirements of residential, commercial/industrial, and utility BESS installations.
www.digikey.co.uk
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