MonoLith™ Integration Data
Integration Data
Mechanical, electrical, and control interface data for vehicle integration planning. Configuration-specific values are issued with the quote; the figures below apply platform-wide unless noted.
| Mounting | Two structural rails, one along each long face of the enclosure |
| Rail fittings | Embedded T-nut fittings, positionable at any point along the rail length |
| Fastener spec | [[THREAD SIZE]] · [[TORQUE SPEC]] Nm |
| Load path | Distributed along the enclosure long faces — not discrete corner points |
| Isolation mounting | Supported. Isolator selection, count, and placement are customer-defined |
| Lifting / pick points | [[DESCRIBE PICK POINT LOCATIONS]] |
| Rigging guidance | Full lifting and rigging procedure issued in the shipped documentation package |
| Orientation | [[PERMITTED MOUNTING ORIENTATIONS]] |
| Sustained incline | [[MAX SUSTAINED GRADE]] |
| CAD | STEP model issued with quote for configuration-specific envelope and CG |
Rail-mounted load distribution suits high-vibration and shock applications better than a discrete-point interface. Customers design their frame interface to the rail pattern; no mounting hardware modification is required on the pack.
| HV connectors | [[MANUFACTURER + SERIES + PART NUMBER]] |
| HV connector rating | [[CURRENT RATING]] A · [[VOLTAGE RATING]] Vdc |
| Mating half supplied | [[YES / NO — and whether pre-terminated]] |
| LV / signal connector | [[MANUFACTURER + SERIES + PART NUMBER]] · sealed multi-pin |
| LV signal set | CAN H/L, auxiliary power, wake, HVIL out/return, contactor aux, charge enable |
| Auxiliary supply | 12 Vdc nominal, 6–35 Vdc range · 150 mA max |
| Interface face | [[STATE WHICH FACE CARRIES HV, LV, AND COOLANT]] |
| Coolant ports | [[PORT TYPE / SIZE]] · located [[FACE / POSITION]] |
| HVIL | Discrete interlock loop routed through the HV connector system |
| Isolation monitoring | Continuous, per ISO 6469-3. Threshold configurable independently for ready, load, and charge states |
| Grounding | Floating HV, chassis bond at designated points; bonding plan issued with pack |
[[STATE PLAINLY WHETHER ALL INTERFACING CONNECTIONS ARE ON A SINGLE FACE. If they are, say so — it is a genuine packaging advantage. If not, state which face carries what so integrators can plan routing.]]
| Main contactors | Four-contactor architecture — load positive, load negative, precharge, charge negative |
| Contactor control | Driven directly by the BMS. Not commandable over CAN |
| Precharge | BMS-sequenced with contactor feedback verification at each state change; sequence aborts on feedback mismatch |
| Contactor state feedback | Auxiliary switch per contactor, monitored on BMS I/O and published on CAN |
| Contactor opening | Delayed until pack current falls below the safe break threshold, or until the configured timeout expires |
| Service disconnect | Rincon manual disconnect switch, face-plate mounted |
| Disconnect access | [[STATE WHICH FACE / WHETHER ACCESSIBLE WITHOUT REMOVING THE PACK]] |
| Disconnect rating | [[CURRENT / VOLTAGE RATING]] |
| Disconnect sense | [[STATE WHETHER POSITION IS REPORTED ON CAN OR VIA DISCRETE I/O]] |
| Main fuse | Pyro fuse, control-shelf mounted. Fitted to every pack |
| Pyro fuse rating | [[RATING]] · [[MANUFACTURER / PART]] |
| Pyro activation | BMS-driven with activation-circuit diagnostics |
| Fuse coordination | Cell CID → wire-bond redundancy → pack main fuse |
| Compliance testing | EMC per CISPR 12/16/22/25 and ISO 11452; electrical transients per ISO 7637-2; climatic and mechanical loads per ISO 16750 |
| Type approval basis | UN ECE Regulation 10 rev. 5 |
| HV isolation standard | ISO 6469-3 |
Contactors are driven by the BMS rather than commanded over CAN. The BMS opens them on its own protection logic without depending on bus traffic — a bus fault cannot strand the contactors closed. The VCU commands loads within published limits; it does not command the contactors.
Protection thresholds fall into three categories. Cell protection limits are set by chemistry and are identical across every pack on the platform. Current limits scale with configuration and are published on the configuration datasheet. Operating limits are broadcast live on CAN and derate continuously with temperature, state of charge, and cell voltage spread — these are the values vehicle controls should be designed against. All thresholds are configured and validated during the pack build and locked at delivery.
| Parameter | Warning | Cutoff |
|---|---|---|
| Cell overvoltage | 4.20 V | 4.25 V |
| Cell undervoltage | 2.80 V | 2.50 V |
| Cell voltage deviation | 50 mV | 150 mV |
| Condition | Warning | Cutoff |
|---|---|---|
| Charge, low | −15 °C | −20 °C |
| Charge, high | 55 °C | 60 °C |
| Discharge, low | −35 °C | −40 °C |
| Discharge, high | 55 °C | 60 °C |
Charge is inhibited below −20 °C. Regenerative braking is a charge event and is unavailable on a cold pack — applications operating below this range require pack preheat before charge or regen capability is enabled.
Cell-level limits are fixed. Pack-level limits are the cell limit multiplied by the parallel count, or the pack hardware ceiling, whichever is lower.
| Parameter | Per cell | Pack limit |
|---|---|---|
| Continuous discharge | 60 A | 60 A × parallel count, or hardware ceiling |
| Maximum charge | 25 A | 25 A × parallel count, or hardware ceiling |
| Standard charge | 5.0 A | 5.0 A × parallel count |
Worked example. An 8P configuration is cell-limited: 8 × 60 A = 480 A continuous discharge, 8 × 25 A = 200 A maximum charge. A 12P configuration would be 720 A on the cell basis, but pack hardware — contactors, busbars, main fuse, connectors — caps continuous discharge below that. The configuration datasheet states the governing figure for your build.
| Discharge current limit (DCL) | Broadcast on CAN, derated live |
| Charge current limit (CCL) | Broadcast on CAN, derated live |
| Derating inputs | Cell temperature and state of charge, mapped across the full operating range |
| Broadcast interval | 100 ms |
| Command reception | BMS accepts inbound CAN at up to 100 Hz |
| CAN interfaces | Two independent channels, 11-bit and 29-bit identifiers, 125/250/500/1000 kbit/s |
| Message configuration | Up to 20 transmit frames, individually configured and locked at delivery |
| Supported protocols | ISO 14229 (UDS) and CANopen. Custom frame definitions supplied as a DBC file |
Protocol note. Message content and identifiers are defined during the pack build and issued as a DBC file for VCU integration. Frames can be configured on 11-bit or 29-bit identifiers to suit the receiving controller. If your application requires a specific higher-layer protocol stack, raise it during configuration review — protocol support is determined at build time and cannot be changed after delivery.
Design controls against the published limits, not against static numbers. A fixed current ceiling is meaningless across temperature — a pack that accepts 200 A of regen at 25 °C accepts none at −25 °C. The BMS calculates and broadcasts the current limits every cycle. A VCU that respects DCL and CCL stays inside the protection envelope at every operating point without needing the cutoff table at all. The fixed thresholds above are published so you know where the hard trips sit, not so they can be hard-coded as operating targets.
| Method | Passive resistive bleed |
| Balance current | 200 mA maximum, at 4.2 V per cell |
| Trigger | Enabled by discrete input, typically asserted on charge request |
| Target | Balances toward the lowest cell voltage plus a configured deadband |
| Completion | Ends when all series groups fall inside the deadband |
| Thermal management | Duty cycle automatically derated as balancing circuit temperature rises |
| Voltage sensing | One tap per series group, all groups |
| Measurement units | Up to 32 per pack, 12 voltage channels each — 384 series groups maximum |
| Cell voltage accuracy | ±1.5 mV across the full operating temperature range |
| Cell sampling rate | 10 Hz |
| Temperature inputs | 12 external channels per measurement unit, plus 11 at the controller |
| Thermistor type | 10 kΩ NTC at 25 °C, β = 3900 |
| Temperature accuracy | ±1 °C from 0 to 40 °C · ±2 °C outside that range, sensor tolerance additional |
| Standard thermistor density | [[STATE PLATFORM STANDARD — e.g. one per module]] |
| Additional sensors | Coolant and cold-plate thermistors at the controller |
| Pack voltage measurement | Up to 1000 Vdc, ±1 V |
Worked example. A 192-series configuration uses 16 measurement units at 12 channels each, giving one voltage tap per series group with no spare capacity required. The same 16 units provide 192 external temperature inputs, so thermistor density is set by pack design rather than by monitoring hardware limits.
Thresholds are locked at delivery. This is deliberate — protection parameters are validated as part of the pack build and are not field-adjustable. The full threshold table, including configuration-specific current limits and isolation thresholds, is issued in the ICD with the quote so vehicle controls can be designed against known values.
| Cooling type | Liquid, structural manifold with per-array flow balancing |
| Flow balancing | Set by manifold design at build. Not field-adjustable |
| Coolant | 50/50 ethylene glycol / water standard |
| Alternative blends | Only where minimum ambient requires it — see note below |
| Port type / size | -8AN |
| Flow requirement | Configuration-specific. Scales with array count and duty cycle |
| Heat load | Duty-cycle dependent. Estimate issued with the configuration datasheet |
| Differential pressure | Not characterized as a published curve — see note below |
| Leak integrity | 24 h dry nitrogen pressure hold, pressure-decay logged to serial number |
| Array proof test | Each array pressure-tested prior to installation |
Coolant. 50/50 ethylene glycol and water is the standard recommendation and the right choice for most applications. It carries more heat per unit mass and pumps more easily than a richer mix. A higher glycol fraction is a trade, not an upgrade: it lowers specific heat and raises viscosity, which increases pumping power — most noticeably at cold start. Move to a richer blend only where minimum ambient demands it. 50/50 protects to approximately −37 °C; below that, size the blend to your ambient and size the pump for the resulting cold-start viscosity rather than the nominal case.
Flow and differential pressure. Flow requirement and pressure drop both scale with array count and duty cycle, so there is no single platform figure to publish — a number that fits an eight-array pack is wrong for a single-array pack. We issue a heat load estimate with the configuration datasheet; required flow follows from that and your target coolant ΔT.
We do not publish characterized dP curves. Array length and count vary widely enough that generating one per permutation isn't practical. Our standard cooling-circuit acceptance is a pressure proof and leak test on each array before installation — an integrity test, not a flow characterization. Wet flow characterization on a first article is available as a separate time-and-materials test program, quoted once the array configuration is locked. Contact us to scope it.
Configuration-specific interface control document, DBC file, harness pinout, electrical schematic, STEP model, mass properties and CG, lifting and rigging procedure, threshold table, and commissioning procedure.
Voltage vs. SOC, DC internal resistance, discharge rate curves, and temperature characteristics are published by the cell manufacturer. Pack values scale by series count — multiply cell values by the series group count for your configuration. We identify the specific cell in the configuration datasheet.