S A F T

ADVANCED AND INDUSTRIAL BATTERIES

DESCRIPTION OF CHARGE MODE FOR LOW MAINTENANCE STM MODULES

STM 5-100 MRE

1) GENERAL FEATURES

1.1) Introduction

Due to the characteristic of low maintenance modules (designed for topping up only
during regular maintenance of the vehicle), their electrochemical behaviour does not
allow the detection of a voltage threshold at the end of the first phase of charging at
constant current or power, especially for temperatures above 30°C.

In addition, although more pronounced than for flooded STM modules, the
temperature variation at end of the first phase of charging at constant current or
power is not high enough to optimise charge management.

With this in mind, a charge mode that integrates a temperature-compensated voltage

switch threshold, a specific Ah meter (pilot meter) and a module temperature
measurement, has therefore been developed.

1.2) Description of different types of charge

Five different types of charge are used:

Initialisation charge

This is carried out during battery commissioning by the garage technician using an
external command non accessible to the users.

Normal charge

This allows users to charge their batteries at home.

Equalisation charge

This is used to balance the battery to reduce capacity and voltage dispersion.
This charge offers a higher recharge coefficient than a normal charge. It is carried
out periodically and automatically according to vehicle specific criteria.

Maintenance charge

This is carried out during maintenance operations. The battery is fully charged and
the electrolyte is topped up. It is carried out by the garage technician using an
external command non accessible to the users.

Fast charge

This is carried out at a fast charge station, allowing a completely discharged battery
to be 75% charged in 30 minutes. This is not a full charging operation.

DTT/BX/EV/MB/98-640 1/10
 S A F T
ADVANCED AND INDUSTRIAL BATTERIES

Precharge (for normal equalisation and maintenance charge types)

The beginning of a charge on a fully or deep discharged stored battery causes a

voltage increase that may exceed the voltage switch threshold which occurs at the
end of constant current or power phase for the overcharge phase and will therefore
stop the charge prematurely. To avoid this problem, a precharge operates
automatically on low current, time limited criterion before effectively starting the
charging. If necessary, this precharge is carried out before a normal, equalisation or
maintenance charge.

2) Description of method of charging

2.1) End of charge criteria

Different charge management methods are deployed:

1) the detection of a temperature-compensated voltage threshold in the form of

a bilinear function.

2) a charged and discharged amperehour meter which takes into account the
battery self discharge (pilot meter) and simulates voltage threshold detection
to allow charge management at any temperature.

The criteria apply to the different types of charge used.

A specific amperehour meter is also used in which the overcharged capacity is

cumulated to determine when the electrolyte in the modules needs to be topped up.
This amperehour meter must be reset to zero when all the modules of the battery are
topped up.

2.2) Operating the pilot meter

• The meter is reset to zero for a charged module.

• When the battery is inactive, the pilot meter increments the self discharge
capacity (calculated from a parametric model).

• During discharge, the pilot meter increments the measured discharged capacity.

• During charge, the pilot meter decrements the measured capacity charged. The
meter does not count down below zero.

• The meter is set to zero at the end of a constant current or power charge when
one of the end of charge criteria (voltage threshold or pilot meter value) is
reached.

DTT/BX/EV/MB/98-640 2/10
 S A F T
ADVANCED AND INDUSTRIAL BATTERIES

2.3) Temperature Management during charge

2.3.1) Normal, maintenance and equalisation charges

The charge must only be used for the cases given in the following graphs.

N.B. The state of charge is given by the gauge.

Temperature

T2

Charge unadvisable

T1

Charge authorized

State of charge
EC1 100 %

The authorised T1 temperature value of +40°C must not be considered as a value to

start the charge systematically. Actual module temperature around +30°C is strongly
recommended in order to guarantee the life time and the performance of the battery.

2.3.2) Fast charge

The charge must only be utilised in the cases given in the following graph:

Temperature

T4

Charge unadvisable
T3

Charge authorized
TB

Charge unadvisable
State of charge
EC2 75 %

If the temperature exceeds these limits during charging, the charge must be
interrupted and restarted only when the temperature has dropped to the authorised
fast charge temperature.

2.4) Detailed description of different types of charge

DTT/BX/EV/MB/98-640 3/10
 S A F T
ADVANCED AND INDUSTRIAL BATTERIES

2.4.1) Precharge

For a fully discharged battery that has been stored for some time, the beginning of
the charge causes a voltage increase that may exceed the voltage switch threshold
of the constant current or power phase to the overcharge phase and hence stop the
charge prematurely without restoring the full capacity of the battery . The precharge
is automatically triggered at a low current and limited time before charging to avoid
this problem.

Before carrying out a normal, equalisation or maintenance charge, the battery

voltage should be checked. If it is lower than the UP threshold, carry out a precharge
at I2 during DP, then begin the desired charging.

If the voltage remains lower than UP after precharge a battery defect indication must
be displayed.

2.4.2) Initialisation charge

This charge is carried out to initialize the pilot meter and the battery when the vehicle
is commissioned. After this charge, the pilot meter must be reset to zero and the
electrolyte in the battery should be topped up.

This is a constant current charge.

2.4.2.1) Constant current Phase (I)

This is a I2 charge of duration DI with:

maximum initial module temperature T5

maximum module temperature during charging is T6.

2.4.2.2) Electrolyte topping-up phase

This second phase allows the topping up of modules to be optimised. It comprises

current pulses of I2 (lasting DM minutes every DR minutes applicable for a maximum
of 72 hours). The pulse charging can be stopped at any time, at least 30 minutes
after the overcharge phase is ended, to carry out topping up in a 30 minute period.
After the topping up the pulse charging is not restarted.

Status of meters at end of charge

At the end of this phase, the pilot meter is reset to zero.

The amperehour meter dedicated to cumulate overcharged capacity is reset to zero
after the electrolyte has been topped up.

DTT/BX/EV/MB/98-640 4/10
 S A F T
ADVANCED AND INDUSTRIAL BATTERIES

2.4.3) Normal and equalisation charge

The charge profile is (I or P) - I1.

2.4.3.1) Constant current (I) or Constant power phase (P)

Detection of end of phase

• using a temperature compensated threshold voltage

threshold Ue = f(T, L1, L2) as a bilinear function

for T > TR: Ue = Uo + L1 * (T-TR)

where T is the actual module temperature

for T < TR: Ue = Uo + L2 * (T-TR)

or

• using the pilot meter value (VP1)

the first of the two conditions reached ends phase I or P.

Pilot meter status at end of Phase I or P

The pilot meter is reset to zero at the end of Phase I or P.

Safety

maximum time (t1)

If this criterion is met, the charge is stopped, the pilot meter is reset to zero and the
maintenance meter increments by one set overcharged capacity (VS1)
In this case, a «defective system» indication must be displayed.

2.4.3.2) Constant Current overcharge phase (Phase I1)

2.4.3.2.1) Normal charge

This is a I1 constant current overcharge phase. Its duration is a function of the

constant current or power phase charged capacity and must respect the value of the
K1 overcharge coefficient:

Phase I1 charged capacity

K1 = x 100
Phase I or P charged capacity

Status of meters at end of charge:

During this phase, the pilot meter is reset to zero.

DTT/BX/EV/MB/98-640 5/10
 S A F T
ADVANCED AND INDUSTRIAL BATTERIES

The amperehour meter dedicated to cumulate overcharged capacity is incremented

by the measured overcharged capacity.

Safety:

Maximum time (t2)

If the maximum time (t2) is reached, the charge is stopped. In this case, a « defective
system » indication must be displayed.

2.4.3.2.2) Equalisation charge

This is an I1 constant current phase with a set DE duration irrespective of the Phase I
or P charged capacity.

Status of meters at end of phase:

During this phase, the pilot meter remains at zero.

The amperehour meter dedicated to cumulate overcharged capacity is incremented
by the measured overcharged capacity.

2.4.4) Maintenance charge

The charge profile is (I or P) - I2 type.

The electrolyte should be topped up after this charge.

2.4.4.1) Constant current (I) or constant power (P) phase

Detection of end of charge

• using a temperature compensated threshold voltage

threshold Ue = f(T, L1, L2) as a bilinear function

or

• using the pilot meter value (VP1)

Meeting any of these two conditions will end Phase I or P.

Pilot meter status at end of Phase P

The pilot meter is reset to zero at the end of Phase I or P.

Safety

maximum charge time (t1)

If maximum charge time (t1) is reached, the charge is stopped, the pilot meter is
reset to zero and the maintenance meter increments by one set overcharged
capacity (VS1)
In this case, a « defective system » indication must be displayed.

DTT/BX/EV/MB/98-640 6/10
 S A F T
ADVANCED AND INDUSTRIAL BATTERIES

2.4.4.2) Constant current overcharge phase (I2)

This is an I2 constant current phase with a set DEN duration irrespective of the
Phase I or P charged capacity.

2.4.4.3) Electrolyte topping-up phase

This second phase allows the topping up of modules to be optimised. It comprises of

current pulses of I2 (lasting DM minutes every DR minutes applicable for a maximum
of 72 hours). The pulse charging can be stopped at any time, at least 30 minutes
after the overcharge phase is ended, to carry out topping up in a 30 minute period.
After the topping up the pulse charging is not restarted.

Status of meters at end of phase:

At the end of this phase, the pilot meter is reset to zero.

The amperehour meter dedicated to cumulate overcharged capacity is reset to zero
after the electrolyte has been topped up.

2.4.5) Fast charge

Charge phase: IMCR maximum current

Detection of end of charge

• using a threshold voltage Ucr corrected according to the temperature and value
of the intensity of the charge (ICR)

Ucr = f(T, L3, L4, I) (linear function)

Ucr = U1 + L3 * (T-TCR) + L4 * (I-ICR)

where T is the actual module temperature and I is the selected fast charge
current

or

• using a pilot meter value (VP2)

Safety

maximum charge time (t3)

If this criterion is met, the charge is stopped. In this case, a « defective system »
indication must be displayed.

DTT/BX/EV/MB/98-640 7/10
 S A F T
ADVANCED AND INDUSTRIAL BATTERIES

Pilot meter status at end of charge

The pilot meter is not reset to zero at end of charge.

2.5) Special cases

2.5.1) Prolonged inactivity of vehicle

If the vehicle is inactive for a long period (more than one month), self-discharge will
cause a battery modelling mismatch. It will then be difficult to handle vehicle
charging.

Because of this, the first recharge after the period of inactivity must be an
equalisation charge to correct any mismatch between the pilot meter and the real
state of charge of the battery.

2.5.2) Operations on the vehicle (changing the calculator or module)

In this case, information about pilot meter values becomes erroneous. An initialisation
charge must be carried out to re-commission the battery and at the end of charge the
pilot meter must be reset to zero.

DTT/BX/EV/MB/98-640 8/10
 S A F T
ADVANCED AND INDUSTRIAL BATTERIES

CHARGE PARAMETERS FOR LOW MAINTENANCE STM MODULES

STM 5-100 MRE

All charge parameters must be configurable

PARAMETERS CODE UNIT Value

PRECHARGE

Triggering conditions U < UP UP V/module 6

Charge current I2 A 10
Duration of charge at constant current DP min 10

INITIALISATION CHARGE

Max temp at start of charge T5 °C 35

Max temp during charge T6 °C 50
Charge current I2 A 10
Duration of charge at constant current DI h 15

NORMAL, EQUALISATION AND MAINTENANCE CHARGES

Max temperature during charge

if State of Charge < EC1 T2 °C 50
if State of Charge > EC1 T1 °C 40
State of charge EC1 % 40
Discharged capacity before equalisation CDEG Ah 2000
Overcharged capacity before maintenance CSE Ah 1000

CONSTANT CURRENT OR POWER PHASE

Current of constant current phase I A 20

Power of constant power phase P W/module 140
End of constant current or power charge criteria
Voltage threshold at TR = 10°C U0 V/module 8.15
Voltage threshold compensation
- for T > TR L1 V/°C - 0.015
- for T < TR L2 V/°C - 0.030
Pilot meter value at end of phase VP1 Ah 0
Safety
Max. constant current or power charge duration t1 h 6.5
Set overcharged capacity VS1 Ah 40

DTT/BX/EV/MB/98-640 9/10
 S A F T
ADVANCED AND INDUSTRIAL BATTERIES

PARAMETERS CODE UNIT Value

CONSTANT CURRENT OVERCHARGE PHASE

NORMAL CHARGE

Overcharge current I1 A 5
Normal charge overcharge coefficient K1 % 15
Safety
Max duration of constant current charge I1 t2 h 8

EQUALISATION CHARGE

Overcharge current I1 A 5
Duration of constant current I1 charge DE h 5

MAINTENANCE CHARGE

Overcharge current I2 A 10
Duration of constant current I2 charge DEN h 5
Electrolyte topping up phase
Duration of peaks at I2 DM min 2
Rest between peaks at I2 DR min 30

FAST CHARGE

Minimum temperature of fast charge TB °C - 10

Max temp during fast charging
if State of charge < EC2 T4 °C 60
if State of charge > EC2 T3 °C 50
State of charge EC2 % 40
Max. current of fast charge IMCR A 150
End of fast charge criteria
End of fast charge voltage at TCR and ICR U1 V/module 8.00
Reference temperature TCR °C 20
Reference current ICR A 150
Compensation according to temperature L3 V/°C/module - 0.010
Compensation according to current L4 V/A/module 0.005
Pilot meter value at end of phase VP2 Ah * 75
Safety
Max. duration of fast charge t3 min 40

* measured capacity

DTT/BX/EV/MB/98-640 10/10