Lithium Phosphate Energy Storage System
Force-H3 Operation Manual
Information Version: V1.0
5PMPA08-00200
This manual introduces Force-H3 from Pylontech. Force-H3 is a high voltage Lithium-Ion
Phosphate Battery storage system. Please read this manual before you install the battery and
follow the instructions carefully during the installation process. In case of any confusion, please
contact Pylontech immediately for advice and clarification.
Contents
1. Safety .......................................................................................................................................................... 1
1.1 Symbols .......................................................................................................................................................... 2
1.2 Abbreviations Used in this Manual ...................................................................................................... 4
1.3 General Safety Instructions ..................................................................................................................... 5
1.4 Safety Instructions Before Connecting the Battery ....................................................................... 6
1.5 Safety Instructions in Using the Battery ............................................................................................. 6
2. System Introduction................................................................................................................................ 7
2.1 Product Introduction ................................................................................................................................. 7
2.2 Specifications ............................................................................................................................................... 7
2.2.1 System Parameters ................................................................................................................................. 8
2.2.1.1 Single String System Parameters .................................................................................................. 8
2.2.1.2 Multi-strings System Parameters (Max. 6 Strings per System) ....................................... 10
2.2.2 Battery Module Specifications ........................................................................................................ 11
2.2.2.1 Battery Module Parameters .......................................................................................................... 11
2.2.3 Control Module Specifications ....................................................................................................... 12
2.2.3.1 Control Module Parameters ......................................................................................................... 12
2.2.3.2 Control Module Display Panel .................................................................................................... 13
2.2.3.3 Control Module Interface Panel .................................................................................................. 16
2.3 System Diagram ....................................................................................................................................... 23
3. Installation .............................................................................................................................................. 24
3.1 Tools .............................................................................................................................................................. 24
3.2 Safety Gear ................................................................................................................................................. 24
3.3 System Working Environment Checking ....................................................................................... 25
3.3.1 Cleaning................................................................................................................................................... 25
3.3.2 Temperature ........................................................................................................................................... 25
3.3.3 Fire-extinguisher System ................................................................................................................... 25
3.3.4 Grounding System ............................................................................................................................... 25
3.3.5 Clearance ................................................................................................................................................ 25
3.4 Handling and Placement ...................................................................................................................... 26
3.4.1 Handling and Placement of the Battery Module ..................................................................... 26
3.4.2 Handling and Placement of the Base .......................................................................................... 26
3.4.3 Requirements of Installation Site ................................................................................................... 26
3.4.4 Packing List ............................................................................................................................................ 27
3.4.5 Mounting and Installation of the Battery Rack Basement ................................................... 28
3.4.6 Installation of the Battery Module onto the Base .................................................................... 29
3.4.7 Battery Modules and Control Module (BMS) Pile up ............................................................. 30
3.4.8 Installation of the Metal Brackets for the System .................................................................... 31
3.4.9 Installation of the Anti-Toppling Brackets for the System .................................................... 31
3.5 Cables Connection ................................................................................................................................. 38
3.5.1 Grounding ............................................................................................................................................... 38
3.5.2 Cables ....................................................................................................................................................... 39
3.5.3 Multi-strings’ Battery Wiring Diagram .......................................................................................... 40
3.5.3.1 Electrical Wiring ................................................................................................................................ 40
3.5.3.2 Communication Cables Connection of Master and Slave Battery Strings ................ 42
4. Operation ................................................................................................................................................. 43
4.1 System Power On ..................................................................................................................................... 43
4.1.1 Single String System Power On ...................................................................................................... 43
4.1.2 Multi-strings System Power On....................................................................................................... 45
4.2 System Power Off ..................................................................................................................................... 46
5. System Debug ........................................................................................................................................ 47
6. Maintenance ........................................................................................................................................... 48
6.1 Trouble Shooting ..................................................................................................................................... 48
6.2 Replacement of Main Components ................................................................................................. 50
6.2.1 Replacement of Battery Module .................................................................................................... 50
6.2.2 Replacement of Control Module (BMS) ...................................................................................... 51
6.3 Battery Maintenance .............................................................................................................................. 52
7. Remarks ................................................................................................................................................... 53
7.1 Storage ......................................................................................................................................................... 53
7.2 Capacity Expansion ................................................................................................................................ 53
8. Shipment ................................................................................................................................................. 54
Annex 1: Installation and System Power On Process List ....................................................................... 55
Annex 2: System Power Off Process List ..................................................................................................... 56
1. Safety
The Force-H3 is a high voltage DC system, operated by skilled/qualified personnel only. Read all
safety instructions carefully prior to any work and observe them at all times when working with
the system.
Incorrect operation or work may cause:
injury or death to the operator or a third party;
damage to the system hardware and other properties belonging to the operator or a third
party.
Skills of Qualified Personnel
Qualified personnel must have the following skills:
training in the installation and commissioning of the electrical system, as well as the dealing
with hazards;
knowledge of this manual and other related documents;
knowledge of the local regulations and directives.
1
1.1 Symbols
Lethal voltage!
perform the wiring of the
Risk of battery system damage or personal injury
not pull out the connectors while the system is
Risk of battery system failure or life cycle reduces.
Symbol in
Read the product and operation manual before operating
the battery system!
Symbol in
Danger! Safety!
Symbol in
Warning electric shock!
Symbol in
Do not place near flammable material.
Danger
Warning
Caution
Battery strings will produce HIGH DC power and can
cause a lethal voltage and an electric shock.
Only qualified person can
battery strings.
Do
working!
De-energize from all multiple power sources and verify
that there is no voltage.
label
label
label
label
2
Symbol in
label
Do not reverse connection the positive and negative.
Symbol in
Do not place near open flame.
Symbol in
Do not place at the children and pet touchable area.
Symbol in
Recycle label.
Symbol in
Label for Waste Electrical and Electronic Equipment
(WEEE) Directive (2012/19/EU).
Symbol in
The certificate label for EMC.
Symbol in
The certificate label for Safety by TÜV SÜD.
label
label
label
label
label
label
3
1.2 Abbreviations Used in this Manual
Abbreviation
Designation
Pylontech
Pylon Technologies Co., Ltd.
QC Quality Control
BMS Battery Management System
PCS Power Conversion System
SOC
UPS
BESS
State of Charge
Uninterruptible Power Supply
Battery Energy Storage System
EMS Energy Management System
PMU Power Management Unit
CMU Control Management Unit
4
1.3 General Safety Instructions
Danger: Batteries deliver electric power, resulting in burns or a fire hazard when they are
short circuited, or wrongly installed.
Danger: Lethal voltages are present in the battery terminals and cables. Severe injuries or
death may occur if you touch the cables and terminals.
Warning: DO NOT open or deform the battery module, otherwise the product will be out
of warranty scope.
Warning: Whenever working on the battery, wear suitable personal protective equipment
(PPE) such as rubber gloves, rubber boots and goggles.
Warning: Force-H3 system working temperature range:-10℃~55℃; Optimum
temperature: 18℃~28℃
. Out of the working temperature range may cause the battery
system over / low temperature alarm or protection which will further lead to the cycle life
reduction. It will affect the warranty terms as well.
Warning: For battery installation, the installer shall refer to NFPA70 or similar local
installation standard for operation.
Caution: Improper settings or maintenance can permanently damage the battery.
Caution: Incorrect inverter parameters will lead to a further faulty/damage to battery.
Reminding
1. It is very important and necessary to read the user manual carefully before installing or using
the battery. Failure to do so or to follow any of the instructions or warnings in this document
can result in electrical shock, serious injury, death, or can damage battery, potentially
rendering it inoperable.
2. If the battery is stored for long time, it is required to charge them every six months, and the
SOC should be no less than 90%.
3. Battery needs to be recharged within 12 hours, after fully discharged.
4. Do not expose cable outside.
5
1.4 Safety Instructions Before Connecting the Battery
Caution:
1. After unpacking, please check product and packing list first, if the product is damaged or
lack of parts, please contact the local retailer.
2. Before installation, be sure to cut off the grid power and make sure the battery is in the
switched-off mode.
3. Wiring must be correct, do not mistake the positive and negative cables, and ensure no
short circuit with the external device.
4. It is prohibited to connect the battery with AC power directly.
5. Battery system must be well grounded and the resistance must be less than 100mΩ.
6. Please ensure the electrical parameters of battery system are compatible to related
equipment.
7. Keep the battery away from water and fire.
1.5 Safety Instructions in Using the Battery
Caution:
1. If the battery system needs to be moved or repaired, the power must be cut off and the
battery is completely shut down in advance.
2. It is prohibited to connect the battery with different type of battery.
3. It is prohibited to put the batteries working with faulty or incompatible inverter.
4. It is prohibited to disassemble the battery (QC tab removed or damaged).
5. In case of fire, only dry powder fire extinguisher can be used, liquid fire extinguishers are
prohibited.
6
2. System Introduction
2.1 Product Introduction
Force-H3 is a high voltage battery storage system based on lithium iron phosphate battery, which
is one of the new energy storage products developed and produced by Pylontech. It can be used
to provide reliable power for various types of equipment and systems. Force-H3 enables multiple
strings parallel operation feature, which provides tremendous flexibility in system design and
configuration. Force-H3 is especially suitable for those application scenes which require flexible
capacity extension, high power output, limited installation space, restricted load-bearing and
long cycle life.
2.2 Specifications
NOTE
: The above picture is just for reference. The quantity of the battery modules is based on your
practical system.
7
2.2.1 System Parameters
Product Type
Force-H3
2 3 4 5 6
7
2.2.1.1 Single String System Parameters
Battery System
Capacity(kWh)
Battery System
Voltage (VDC)
Battery System
Capacity (Ah)
Battery Controller
Name
Battery Module
Name
Battery Module
Quantity (pc)
Battery Module
Capacity(kWh)
Battery Module
Voltage (VDC)
Battery Module
Capacity (Ah)
10.24 15.36 20.48 25.6 30.72 35.84
204.8 307.2 409.6 512 614.4 716.8
50
FC1000
FH10050
5.12
102.4
50
Battery System
Charge Upper
Voltage (VDC)
Battery System
Charge Current
(Amps, Standard)
Battery System
Charge Current
(Amps, Rated)
Battery System
Charge Current
(Amps,
Max.@15min)
Battery System
Discharge Lower
Voltage (VDC)
Battery System
Discharge Current
(Amps, Standard)
230.4 345.6 460.8 576 691.2 806.4
10
50
55
185.6 278.4 371.2 464 556.8 649.6
10
8
Product Type
Force-H3
Depth of Discharge
IP Rating/Protection
Module Dimensions
Battery System
Discharge Current
(Amps, Normal)
Battery System
Discharge Current
(Amps,
Max.@15min)
Short circuit rating
(Amps/ms)
Efficiency (% at
0.5C-rate)
50
55
3000/2
96
(%)
Dimension
(W*D*H, mm)
Communication
Class
540*350*5
30
540*350*7
00
540*350*8
70
CANBUS/Modbus RTU
95
540*350*1
IP55/I
Pollution Degree PD3
Weight (kg)
92 131 170 209 248 287
Design Life (year) 15+
Operation
Temperature(℃)
*
-10~55
Storage
Temperature(℃)
-20~60
Altitude(m) <4000
Humidity (%, RH)
5~95
UL1973、EC62619、IEC63056、VDE-AR-E 2510-50
Product Certificate
UL9540A、CE RED、C E LVD
Transfer Certificate
Environmental
certification
RoHS、Reach、WEEE
UN38.3
Single Battery
Controller
540(W)*350(D)*150(H)
Dimensions (mm)
Single Battery
540(W)*350(D)*170(H)
(mm)
Battery bottom
base Dimensions
540(W)*350(D)*40(H)
(mm)
040
540*350*1
210
540*350*1
380
* In high(>40℃) or low temperature (<10℃) environment, the charging and discharging power of the battery system
will be limited according to BMS operation logic.
9
2.2.1.2 Multi-strings System Parameters (Max. 6 Strings per System)
Product Type
Force-H3 in multi-strings
2 3 4 5 6
For multi-strings operation, please make sure:
the battery type in the whole system is the same;
the battery amount of each string is the same.
Battery System Voltage(VDC)*
204.8/307.2 / 409.6 /512 / 614.4 / 716.8
Battery System string amount(pcs)
Battery System capacity (Ah) 100 150 200 250 300
Battery System Operation
Current(Amps, Standard)
Battery System Operation
Current(Amps, Normal)
Battery System Operation Current
(Amps, Max.@15min)
P-Combiner 3/6-V2 Operation Current
(Amps, Normal)
P-Combiner 3/6 Operation Current
(Amps, Max.@15s)
*The Battery System Voltage varies depending on battery amount in serial per string.
**The current is based on BMS theoretical operation current. If using P-Combiner 3-V2 as the combiner box of the
multi-strings` battery system wiring connection, the max. continuous operation current is 50Amps, max. peak
operation current is 80Amps for 15 seconds. Please make sure the real operation current not exceed the combiner
box power rating.
The current is based on BMS theoretical operation current. If using P-Combiner 6-V2 as the combiner box of the
multi-strings` battery system wiring connection, the max. continuous operation current is 100Amps, max. peak
operation current is 160Amps for 15 seconds. Please make sure the real operation current not exceed the
combiner box power rating.
20 30 40 50 60
80 120 160 200 240
110 165 220 275 330
50**
80**
100
160
IMPORTANT,
DO NOT use P-Combiner-HV-3/6-V2 or similar concept of multi-strings connection method
in case the multiple battery strings need to be operated independently.
10
2.2.2 Battery Module Specifications
Product Type
FH10050
**
2.2.2.1 Battery Module Parameters
Cell Technology Li-ion (LFP)
Battery Module Capacity (kWh) 5.12
Battery Module Voltage (VDC) 102.4
Battery Module Capacity (Ah) 50
Battery Module Serial Cell Quantity (pc) 32
Battery Cell Voltage (VDC) 3.2
Battery Cell Capacity (Ah) 50
Dimension (W*D*H, mm) 540*350*170
Weight (kg) 39
Operation Life (year) 15+
Operation Cycle Life (cycle) * 8,000
Operation Temperature (℃)
Storage Temperature (℃)
-10~55
-20~60
Transfer Certificate UN38.3
* Operation Cycle Life is defined based on specific operation conditions, for more details please check with
Pylontech service team.
**
In high(>40℃) or low temperature(<10℃) environment, the charging and discharging power of the battery
system will be limited according to BMS operation logic.
11
2.2.3 Control Module Specifications
Product Model
FC1000
2.2.3.1 Control Module Parameters
Related Product FH10050
Controller Working Voltage(VDC) 80-1000
System Operation Voltage(VDC) 172.8-921.6
Charge Current(Amps, Max.@15min) 55
Discharge Current(Amps, Max.@15min) 55
Self-consumption (W)
＜16
Dimension (W*D*H, mm) 540*350*150
Weight (kg) 12
Communication Protocol CANBUS/Modbus RTU
Operation Life (year) 15+
Operation Temperature (℃)
Storage Temperature (℃)
-10-55
-20-60
12
2.2.3.2 Control Module Display Panel
Button
Action
Instructions
Battery
Module
Status Light
LED Button
System
Status LED
System
Capacity
Status
LED Button
Short Press Display the LED panel for 20sec.
(1) When System Status LED fast flashes blue , release the
button, then it is 115200 baud rate of RS485.
Long Press 1
(about 5~10
secs)
Long Press 2
(>10secs)
(2) When System Status LED fast flashes orange , release the
button, then it is 9600 baud rate of RS485.
(3) If a special protocol (except Pylontech Protocol) is selected,
follow ‘Long Press 2’, then the baud rate changing described
here is ineffective.
Communication Protocol Selection, for details please check with
Pylontech service team. Communication Protocol Selection
Guidance
13
System Status LED
LED Indicators
Instructions
Refer to Instructions of the
Below.
Battery Module Status
Blue light
1
2
3
Normal
4
5
6
7
Instructions:
(1) Each Status LED (1~7) represents one individual battery module from number 1 (the one right
beneath the control module) to number 7 (the one next to the base), as shown in the above
illustration.
(2) If your system has less than 7 battery modules, the Status LED without corresponding battery will
be always OFF.
System Capacity Status Light
Indicate the system SOC.
Orange light
Individual module alarm or protection
occurs.
See trouble shooting steps in section
5.1
Each LED indicates 25%SOC
14
LED Indicators Instructions
Status
Remark
Self-checking Blue, Flashing* All flashing*
See trouble
shooting steps in
section 5.1
Self-checking failure
Orange, Slow
flashing**
Off
Black start success Blue, fast flashing Off
See trouble
Black start failure Orange, fast flashing Off
shooting steps in
section 5.1
Communication Lost
or BMS error
Orange, solid
Idle Blue, slow flashing**
Indicating SOC,
Blue, solid
Indicating SOC,
Blue, solid
See trouble
shooting steps in
section 5.1
Charge Blue, solid
Floating charge Blue, solid
Discharge Blue, flashing*
System sleep Blue, flashing* Off
*
Flashing: 0.5s ON/0.5s OFF.
**
Slow flashing: 2.0s ON/1.0s OFF.
Fast flashing: 0.1s ON/0.1s OFF.
Indicating SOC,
blue, solid
All flashing, horse
race lamp
Indicating SOC,
blue, solid
Battery module
status off
15
2.2.3.3 Control Module Interface Panel
Communication
Terminals
LAN
Wi-Fi
Power Switch
Start Button
Power Terminals
Grounding
Power Switch (under the protection cover)
ON: Power Switch ON, able to turn on battery system by Start Button.
OFF: Power Switch OFF, able to turn off system completely, no power output.
Caution: If the power switch is tripped off due to over current or short circuit, be sure to
wait more than 30mins, then you can turn it on again; otherwise it may cause
damage to the switch.
NOTE
Start
Caution:
Start button: press this button and hold
more than 5 secs until the buzzer rings to turn on the controller.
: After using the power switch, lock the protection cover by tightening the two screws
on the cover to make it water-proof.
16
Multi-strings starting sequence: please start up the last string (from communication
Communication Structure
Starting Sequence
Basic Information of Wi-Fi
structure, the last slave string, see the table blow) of battery system first, one by one to the
first string which shall be started up lastly. Details as below table.
Master string* Last Start up
Slave string 1 5th Start up
Slave string 2 4th Start up (if has)
Slave string 3 3rd Start up (if has)
Slave string 4 2nd Start up (if has)
Slave string 5 1st Start up (if has)
* BMS of the rack with Link Port 0 EMPTY is defined as the Master string, which communicates with the
inverter or upper controller. In one system, there’s ONLY
slave strings.
ONE Master string, the rest are defined as the
Black start function: When the system is turned on, and relay is OPEN, press the Start Button
more than 10 secs. Then relay will be CLOSE for about10mins without communication
(depending on conditions).
Multi-strings Black Start: Black start operation is ONLY needed to be performed on Mater
string. And it will close circuit for one of the strings within the system for 10mins. The slave
string black start function is ONLY controlled by master string.
Wi-Fi
Manufacturer: Pylon Technologies Co., Ltd.
Address: Plant 8, No.505 Kunkai Road, JinXi Town, 215324 Kunshan City, Jiangsu Province,
PEOPLE'S REPUBLIC OF CHINA
Importer: XXXX （Located in installed country）
Address: XXXX （Located in installed country）
Wireless Max. Output Power
Operating frequency
Gain of antenna
Modulation system
Modulating Repetition
Channel spacing
15dBm
2412-2472MHz
Max 3dBi
DBPSK/DQPSK/CCK(DSSS)
BPSK/QPSK/16QAM/64QAM(OFDM)
1Mbps/2Mbps/5.5Mbps/11Mbps (DSSS)
6Mbps/9 Mbps/12 Mbps/18 Mbps/24 Mbps/36 Mbps/48
Mbps/54 Mbps (OFDM)
MCS0~MCS7 (802.1 1n 20MHz)
5MHZ
Type of antenna
2.4G IPEX-SMA Antenna
17
NOTE:
For network connection, please san the QR code below to get Network Connecting
Instructions or contact Pylontech service team for further questions.
Power Terminals (+/-)
Connect power cables of battery system with Inverter.
During multi-strings operation, you can select P-Combiner-HV-3-V2 (up to 3 strings,
max.50Amps) or
P-Combiner-HV-6-V2 (up to 6 strings, max.100Amps) for connection.
For more details of P-Combiner, please check with your distributor or Pylontech service
team.
18
Communication Terminals (RS485 / CAN / RS232/Link0/Link1)
CAN
RS485
Link 1
Link 0
Pin 1~10
LAN
NOTE
: Before connecting the communication terminals, loosen the two screws on the cover as
follows, then you will see the communication terminal as follows. Following instructions
are for your reference:
LAN: Used for where the Wi-Fi signal is not good or there is no Wi-Fi. To connect to the
online portal directly through a network cable (another side to the internet router).
Link0/Link1 Communication Terminal: (RJ45 port) designed only for multi-strings
operation, connecting from the first BMS Link 1 to second BMS Link 0, then from second
BMS Link 1 to third BMS link 0 (if has), all the way to the last BMS Link 0. The BMS with Link
Port 0 EMPTY is defined as the
Master string, which communicates with the inverter or
upper controller.
19
NOTE
No.
CAN
RS485
- + GND H L
IN+
IN-
TX
RX
GND
E-Stop
CAN
For SMA
RS232
: For multi-strings operation, please firstly make sure the communication cables between
multiple BMSs are properly connected between Link 1 and Link 0, prior to the startup
process.
CAN Communication Terminal: (RJ45 port) follows CAN protocol, for communication
between battery system and inverter.
RS485 Communication Terminal: (RJ45 port) follows MODBUS 485 protocol, for
communication between battery system and inverter.
Definitions of RJ45 Port PIN
1 --- ---
2 GND ---
3 --- ---
4 CANH ---
5 CANL ---
6 --- ---
7 --- RS485A
8 --- RS485B
Pin 1~10 Assignment Table:
1 2 3 4 5 6 7 8 9 10
E-STOP: Emergency stop feature is default inactivated. If you need to use such function,
please contact Pylontech service team.
IN+/IN-: PIN6/PIN7 terminals are used for SMA inverter Enable Line feature, for more details
please check with Pylontech service team.
20
RS232 Communication Terminal: for manufacturer or professionals to debug or service.
PIN 1-10
RJ45
PIN 1-10
DB9
A. If you have RS232 debug tool (DB9 – USB – RJ45)
provided by PYLONTECH before, PIN8~10 here
PIN 8 PIN 3 (Green and white)
corresponds to PIN3, PIN6 and PIN8 of RJ45.
PIN 9
PIN10 PIN 8 (Brown)
PIN 6 (Green）
B. If you use a new RS232 debug tool (DB9 – USB),
the Pin 8~10 here corresponds to PIN 2,3,5 of DB9
terminal.
PIN 8 PIN2
PIN9 PIN3
PIN10 PIN5
21
For communication cables connection for PIN1~10 terminal station, please follow the steps below:
Press the button, insert
the cable terminal into the
corresponding hole. Then
release the button and the
1. Dismantle the two screws from the
communication protection cover.
4. Insert the communication cable into the hole.
2. Unscrew the plastic nut from the cover. 5. Follow the instructions of Pin 1~10 Assignment
Table, and insert the cable terminal into the
corresponding pin of the terminal plug.
*
* You can use a screwdriver as shown or your finger to
press the button.
3. Take out the rubber plug(s) from the
rubber pad.
cable is fixed in the hole.
NOTE,
After communication cables connection,
1. REMEMBER to install the rubber plugs back in the EMPTY holes of the rubber pad to
guarantee water resistance of the cover.
2. Screw the plastic nut back to the cover.
3. Install the two screws in the protection cover to fix it on the control module interface.
22
2.3 System Diagram
23
3. Installation
Wire Cutter
Crimping Modular Plier
Cable Ties
Screw Driver Set
Electric Screw Driver
Adjustable Wrench
Sleeve Piece
600VDC Multimeter
Insulated gloves
Safety goggles
Safety shoes
3.1 Tools
The following tools are required to install the battery pack:
NOTE
Use properly insulated tools to prevent accidental electric shock or short circuits.
If insulated tools are not available, cover the entire exposed metal surfaces with available
insulated alternatives, except their tips, with electrical tape.
3.2 Safety Gear
It is recommended to wear the following safety gear when dealing with the battery pack
24
3.3 System Working Environment Checking
3.3.1 Cleaning
Danger: Before installation and system power on, the dust and iron scurf must be
removed to keep a clean environment.
The system cannot be installed in desert area without an enclosure to prevent from sand.
Danger: Battery module has active DC power at terminals all the time. Be careful to
handle the modules.
3.3.2 Temperature
Force-H3 system working temperature range: -10℃~55℃; Optimum temperature: 18℃~28℃.
There are no mandatory ventilation requirements for battery module, but please avoid of
installation in confined area. The aeration shall avoid high salinity, humidity or temperature.
Caution: The IP rating of Force-H3 system is IP55. But please avoid frost or direct sunlight.
Out of the working temperature range will cause the battery system high / low
temperature alarm or protection which will further lead to the cycle life reduction.
According to the environment requirements, a cooling system or heating system should
be installed when necessary.
3.3.3 Fire-extinguisher System
Danger: Fire-extinguisher system must be equipped for safety purpose.
The fire system needs to be checked regularly to ensure a normal working status.
Regarding to the using and maintenance requirements, please follow local fire
equipment guidance.
3.3.4 Grounding System
Danger: Before the battery installation, make sure the grounding point of the basement
is stable and reliable. If the battery system is installed in an independent equipment
cabin (e.g. container), the grounding of the cabin must be stable and reliable.
The resistance of the grounding system must be ≤100mΩ
3.3.5 Clearance Minimum clearance to heat source shall be more than 2 meters. Minimum clearance between battery strings shall be more than 0.3 meters.
25
3.4 Handling and Placement
Warning: The battery pile’s power terminals has high DC voltage. It must be installed in
a restricted access area;
Warning: Force-H3 is a high voltage DC system, operated by qualified and authorized
personnel only.
3.4.1 Handling and Placement of the Battery Module
Warning: Single battery module is 39kg. The battery module must be handled by more
than 2 personnel if there’re no handling tools.
3.4.2 Handling and Placement of the Base
The weight of the base is light, which a single person can handle with.
3.4.3 Requirements of Installation Site
A. Force-H3 system working temperature range: -10℃~55℃; Optimum temperature: 18℃~28℃.
DO NOT expose the battery system to direct sun light. It is suggested to build sunshade
equipment. In cold area a heating system is required.
B. Force-H3 system must not be immersed in water. The battery base cannot be exposed to rain
or other water sources. As a suggestion, the base’s height shall be >300mm above the ground.
C. The support surface should have sufficient load capacity to support the weight of whole
battery system (130~300kg).
D. Force-H3 system bust be installed on a fixed and flat support surface.
NOTE,
The above illustration is just for reference. The quantity of the battery modules is based on
your practical system.
26
3.4.4 Packing List
FC1000 Battery Controller
FH10050 Battery Module
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Description
FC1000 Battery Controller
Force-H3 basement (540*350*40, mm)
3M black external communication cable (RJ45)
1.5M black internal communication cable (RJ45)
3M DC+ red external power cable (8AWG)
3M DC- black external power cable (8AWG)
1M yellow-green grounding cable (10AWG)
M4 screws for fixing brackets
M8 bolts for fixing basement
M6 screws for fixing ground cable
Product Manual
Warranty card
Qualified Certificate Card
Communication protocol setup manual
571.5 mm left bracket
Set
1
1
2
1
1
1
1
18
6
1
1
1
1
1
1
For up to 3 battery modules installation
NOTE
16
17
18
19
20
21
: No additional kits are needed for Force-H3 installation.
571.5 mm right bracket
For up to 3 battery modules installation
706.6 mm bracket
For up to 4 battery modules installation
Anti-Toppling Bracket
M4 screws for fixing the battery module and control moduel
Dismantle tool
Moisture-proof desiccant
1
FH10050 battery module
2
Qualified Certificate Card
3
Moisture-proof desiccant
1
2
2
2
1
1
1
1
1
27
3.4.5 Mounting and Installation of the Battery Rack Basement
The base must be fixed securely on the support surface with 4pcs M8×60 expansion bolts.
Battery rack base holes’ (circled in red) bitmap (unit: mm)
Battery rack basement bitmap (unit: mm)
28
3.4.6 Installation of the Battery Module onto the Base
123
Warning: Single battery module is 39kg. The battery module must be handled by more
than 2 personnel if there’re no handling tools.
3.3.1.1 Lift the two handles on the battery module as blow, making sure the battery not tilting to one
side.
3.3.1.2 Adjust to keep the connector of the battery (circled in red) align with the connector of the
base (circled in red). Slowly put down the battery, fitting it properly onto the base.
3.3.1.3 Continue to install the left battery modules one by one onto the existing battery.
NOTE
: Max. 7 battery modules to be installed in one system.
29
3.4.7 Battery Modules and Control Module (BMS) Pile up
Danger: When battery is connected together with the base, the internal socket still has
high voltage DC power from serial connected battery modules.
1. After installation of the battery module, lift up the control module (BMS), adjusting to make its
connector align with the connector of the battery module.
2. Slowly place down the control module (BMS) on the installed battery module.
NOTE
: The above picture is just for reference. The quantity of the battery modules is based on
your practical system.
30
3.4.8 Installation of the Metal Brackets for the System
In control module’s package, there are 2pcs
short and 2pcs long metal brackets.
Fix these metal brackets at both back sides of
the battery modules (see the illustration on the
right).
Please follow the illustrations below to install the metal brackets for your practical system.
4
3
3
2
2
1
1
31
6
5
3
4
5
4
2
3
3
1
2
2
1
1
7
6
4
3
2
1
5
32
3.4.9 Installation of the Anti-Toppling Brackets for the System
Force H3 system is equipped with two anti-toppling brackets as follows.
Such brackets act as an alternative of ground mounting of the battery system. Customers can
choose either of the following methods for the system installation:
ground mounting with 4*M8 expansion bolt to the support surface (see section 3.4.5).
bracket mounting with 2*M8 expansion bolt to the wall (Battery system still needs to be
placed on the support surface for supporting the overall weight.)
As long as the installation area meets the requirement of the installation site (see section 3.4.3),
in either case the installation stability is guaranteed.
The detailed installation process with such brackets are as follows:
1. Put the base along the wall and reserve 40mm distance between back of the base and the
wall.
33
2. Follow the steps described above correctly to install all the battery modules, BMS and
Unlocked
Unlocked
Unlocked
M4 Screw
brackets.
IMPORTANT
: When installing the metal brackets at the back side, ALWAYS remain the two
connecting points between brackets and BMS unlocked shown as below.
3. Follow the illustrations below, firstly fit the anti-toppling brackets on back sides of the BMS,
then use M4 screws to fix.
REMEMBER to fit the brackets on both sides of BMS, same with following steps：
34
4. Mark the central points of the slotted holes at both sides on the wall.
Central point
5. Dismantle the brackets on both sides. Aligning the central points, drill two holes (≥60mm
depth) in the wall with a drilling tool, and clean the holes.
35
6. Embed the two M8 expansion bolts into the holes respectively.
M8 Expansion
bolt
7. Fit the brackets across the M8 expansion bolts on both sides, then fix the brackets on the BMS
with M4 screws.
36
8. Fix the M8 nut (a) across the 8mm flat gasket (c) and spring washer (b), with 12~13N.m torque.
c
b
a
Repeat this step for the other bracket.
37
3.5 Cables Connection
Danger: The battery system is high voltage DC system. Make sure the grounding is fixed
and reliable.
Danger: No short circuit or reverse connection of the battery system’s positive and
negative ports.
Caution: Wrong communication cables connection will cause the battery system failure.
3.5.1 Grounding
Warning: The Force-H3 modules has 3 grounding points a follows.
Grounding cable must be≥10AWG. The cable shall be copper with yellow-green color.
38
3.5.2 Cables
Caution: Power cables use water-proofed connectors.
To disconnect, it is required to use a special tool (in the
accessory bag), shown as the picture. Do not pull out the
cables directly.
NOTE
: Communication cable uses RJ45 connector and water-proof cover(M19-RJ45) matched
with controller connection port.
1000
39
3.5.3 Multi-strings’ Battery Wiring Diagram
3.5.3.1 Electrical Wiring
A. Wiring diagram of 3 strings` system (String qty.≤3)
It`s suggested to use P-Combiner-HV-3-V2 for up to 3 strings, max. 50Amps continuous
operation.
IMPORTANT
: DO NOT use P-Combiner-HV-3/V2 or similar concept of multi-strings
connection method in case the multiple battery strings need to be operated independently.
NOTE
: Make sure to have the D+ & D- plugs into the combiner box properly.
40
B. Wiring diagram of multi strings’ system (3<String qty.≤6)
It`s suggested to use P-Combiner-HV-6-V2 for up to 6 strings, max.100Amps continuous
operation.
IMPORTANT
: DO NOT use P-Combiner-HV-6-V2 or similar concept of multi-strings
connection method in case the multiple battery strings need to be operated independently.
NOTE
: Make sure to have the D+ & D- plugs into the combiner box properly.
41
3.5.3.2 Communication Cables Connection of Master and Slave Battery Strings
The communication for master/slave string connection shall use a 8pin pin-pin RJ45 cable,
connecting from the first BMS Link 1 to second BMS Link 0, then from second BMS Link 1 to third
BMS link 0(if has), all the way to the last BMS Link 0. The BMS with Link Port 0 EMPTY is defined
as the Master string. Select either CAN or RS485 on the master string for further connection with
the inverter or upper controller.
The slave strings` CAN/RS485 Port is ineffective in this case.
42
4. Operation
Status: Orange , solid
SOC: Blue, Solid
Status LED
Status LED
4.1 System Power On
4.1.1 Single String System Power On
Warning: Double check all the power cables and communication cables. Make sure the
voltage of the inverter/PCS matches the voltage of the battery system. Check to make
sure all the power switches are OFF.
System Power On Procedure:
1. Check the grounding is connected.
2. Check all the cables are connected correctly.
3. If necessary, turn on the switch for battery on the inverter or the switch between inverter
and battery system. If possible, turn on AC or PV power source to wake up the inverter.
4. Open the protection cover of Power Switch on the control module (BMS). And turn on
Power Switch.
5. Press Start Button for at least 5 seconds or until buzzer rings. Battery takes 10-30s for selfchecking.
If the inverter is powered by AC or PV source, most types inverters can set up communication
with BMS automatically, in this case, the BMS will close relay and system is ready for work.
If after 30sec self-checking the LED becomes as follows, this means the inverter needs to be
powered on by the battery energy:
In this case, press the Start Button for at least 10 secs, till the Status LED lighting Blue and fast
flashing. Then the battery will perform black start to support the inverter. After the inverter is
started and communication is set, the BMS is ready for work.
If the battery has been configured to a different communication protocol, please follow LED
Long Press 2 guidance in section 2.2.3.2. Make sure to select the correct protocol and restart
BMS to enable the communication with inverter.
Caution: If the breaker is tripped off due to over current or short circuit, be sure to wait
more than 30mins, then it can be turned on again; otherwise it may cause damage to
the breaker.
System
LED Button
System
Capacity
Battery Module
Status Light
43
Warning: If there is any failure during the self-check process, be sure to debug the failure
prior to next step. If the “STATUS” LED shows orange from the beginning, it means there is
failure in the battery string. In this case, the Power Relays in BMS will open, and debugging
must be done first.
NOTE
: The LED lamp will be off in 20secs without any operation.
Caution: During the first time starting, the system requires full charge process for SOC
calibration purpose.
Caution: After long time storage without charging, it is suggested to fully charge the
whole Battery Energy Storage System (BESS) prior to installation. Depending on the SOC
level, regularly every 6 months’ full charge is requested during continuous operation as
well. it will be handled automatically by the communication between BESS and external
device.
44
4.1.2 Multi-strings System Power On
Communication Structure
Start-up Sequence
Status: Orange , solid
SOC: Blue, Solid
Warning: Double check all the power cables and communication cables. Make sure the
voltage of the inverter/PCS matches the voltage of the battery system. Check to make sure
all the power switches are OFF.
System Power on Procedure:
1. Check grounding is connected.
2. Check all cables are connected correctly, especially the Link 1 / Link 0 between master and
slave strings.
3. If necessary, turn on the switch for battery on the inverter or the switch between inverter
and battery system. If possible, turn on AC or PV power source to wake up the inverter.
4. Open protect cover of Power switch. And turn on power switch on the control module
(BMS)of all the strings.
5. From the last string, press start button for at least 5 seconds or until buzzer rings for startup. Then further turn on each string one by one follow below table, the start-up interval
between each strings shall less than 30secs:
Master string Last Start-up
Slave string 1 5th Start-up
Slave string 2 4th Start-up (if has)
Slave string 3 3rd Start-up (if has)
Slave string 4 2nd Start-up (if has)
Slave string 5 1st Start-up (if has)
6. After all strings start-up, the battery system takes 30sec for self-checking.
If the inverter is powered by AC or PV source, most types inverters can set up communication
with BMS automatically. In this case, the BMS will close relay and system is ready for work.
If after 30sec self-checking the LED becomes as follows, this means the inverter needs to be
powered on by the battery energy:
In this case, press and hold the Start button for at least 10s, till the Status LED lighting Blue
and fast flashing. Then battery will perform black start to support inverter. After the inverter is
started and communication is established, the BMS is ready for work.
45
4.2 System Power Off
Danger: When any failure occurs or there is a need for service, the battery storage system
must be powered off at first.
System Power Off Procedure:
1. Turn off inverter or power supply on DC side.
2. Turn off the switch between PCS and battery system.
3. Turn off the “Power Switch” of the all BMSs.
Caution: Before replace the battery module for service, make sure to charge/discharge
the existing battery module voltage similar to the replaced one. Otherwise the system
needs long time to do balance for this replaced battery module.
Caution: When restart is required for any troubleshooting steps, make sure to restart the
entire system (every BMS within the system). Please do not only restart partially of the
BMS within the system, which will further lead to error.
NOTE
After installation, DO NOT forget to register online for full warranty:
www.pylontech.com.cn/service/support
46
5. System Debug
Debug Step
Instructions
NOT ALLOWED
This system debug is for BESS
(Battery Energy Storage System). BESS debug can’t be performed alone. It must be operated with
configured inverter, UPS, PCS and EMS system together.
Turn on the BESS, referring to Section 4. It is
load before turning on the whole BESS.
Preparations for debug.
Working together with
inverter
Remark: Except the BESS, if other equipment has its own system power on
procedure, be sure to follow its specific operation manual.
(1) Check the communication cable connection and make sure the cable
(2) Check the baud rate of inverter. The default value of battery CAN is
(3) Check the terminal resistance CAN 120 Ω, 485 120 Ω
(4) If necessary, check the setting on inverter or control box has right
to turn on the
order on battery and inverter side are matched. All undefined pins are
suggested to be empty.
500kbps, MODBUS 485 is 9600bps. If necessary, change the baud rate
of RS485.
parameters and brand of battery. And check the information of BESS
shown on inverter is correct.
47
6. Maintenance
No
Problem
Possible Reason
Solution
6.1 Trouble Shooting
Danger: The Force-H3 is a high voltage DC system, operated by qualified and
authorized personnel only.
Danger: Before checking the failure, be sure to check all the cables connection and
check if the BESS can be turned on normally.
Check the environment first
No power
1
output, no LED
on.
After turning
on, Status LED
slow flashing
2
orange. Others
off.
Too short time for pressing Start
button.
The button battery in controller is
missing or has failure.
The power supply in control module
(BMS) has failure.
The battery voltage is too low.
The connector of base has failure or
the base is not connected.
Self-checking failure.
DC side has a voltage, but voltage
difference with the battery system is
higher than 20V.
BMS internal failure.
Press and hold at least 5s to turn on.
Press and hold at least 10s for black
start.
Change the control module.
Make sure there are at least 2 battery
modules.
Make sure the base in connected
properly and change base if
necessary.
Make sure no DC voltage or set
correct DC voltage before pressing
Start button.
Follow power on process to turn on.
Use debug tool/Wi-Fi monitoring to
further analysis or change the control
module.
Status LED fast
flashing
3
orange, others
off.
Buzzer ring
4
continues
The time interval after latest black start
is too short.
The battery system under error
condition such as: temperature or
current protection or other errors, thus
no response to black start.
Relay adhesion or failure.
48
Wait more than 5 minutes and try
black start again.
Make sure no other protection
factors. Or use debug tool for further
analysis.
Completely disconnect battery
system with any DC source then
make a restart. If problem still exists,
then replace the controller.
Status LED
solid orange.
Battery
5
module LED
blue solid.
Status LED
solid orange.
Battery
6
module exists
LED in orange
solid
All LED blue
7
but no output.
8 Other failure
Check the communication cable PIN
Communication lost with inverter
Over current protection.
Control module failure.
Over/ under temperature protection.
Over voltage protection.
Under voltage protection.
Battery module BMS failure
Fuse fusing Change the control module
Cell failure or electrical board failure.
Or debug tool is needed for further
analysis.
and wiring is correct.
Check the inverter communication
settings
Check DC side. And wait until BMS
release protection.
Use debug tool for further analysis or
change the control module.
Check environment temperature.
And wait BMS release.
Check DC charge voltage setting or
wait BMS release.
Perform black start function, and
then charge the system.
Use debug tool for further analysis or
change the battery module.
If you still can’t debug the failure,
please contact with distributor or
Pylontech.
Once a certain failure is detected following the trouble shooting procedure, turn off the battery
string first before replacement so as to avoid further over discharge to the system due to the selfconsumption.
49
6.2 Replacement of Main Components
Danger: The Force-H3 is a high voltage DC system, operated by qualified and authorized
personnel only.
Danger: Before replacing the main components, turn off the maintenance battery
string’s power first. Make sure the
4.2 for turning off process.
6.2.1 Replacement of Battery Module
1. Charge existing module to full (SOC 100%). Make sure new battery module is 100% SOC as
well.
2. Turn off the whole battery string’s power. Make sure to confirm the D+ and D- terminals are
without power. Refer to section 4.2 for turning off process.
3. Dismantle D+ and D- Power cables, Communication cable and Grounding cable.
4. Dismantle the control Module’s fix screws on the left and right.
D+ and D- terminals are without power. Refer to section
5. Dismantle the fix metal brackets as follows.
50
6. Remove the control module and each battery module one by one.
Internal
Socket
Danger: When battery is connected together with the base the internal socket still has
high voltage DC power from serial connected battery modules.
Warning: Single battery module is 39kg. If there are no handling tools, at least more than
2 people are needed to handle with it.
7. Pile up the new battery module. And install back the battery modules and control module.
8. Fix back the two screws on the control Module’s. And Install back the fix metal brackets.
9. Install back Grounding cable, Communication cable and the D+ and D- Power Cables.
10. Turn on this battery string. Refer to section 4.1.
6.2.2 Replacement of Control Module (BMS)
1. Turn off the whole battery string’s power. Make sure to confirm the D+ and D- terminals are
without power. Refer to section 4.2 for Power Off process.
2. Dismantle D+ and D- Power cables, Communication cable and Grounding cable.
3. Dismantle the control Module’s fix screws on the left and right (same as 5.2.1).
4. Dismantle the fix metal brackets (same as 5.2.1).
5. Remove the control module.
Danger: When battery is connected together with the base the internal socket still has
high voltage DC power from serial connected battery modules. Beware of electric shock.
6. Pile up the new control module.
7. Fix back the two screws on the control Module’s. And Install back the fix metal brackets.
8. Install back Grounding cable, Communication cable and the D+ and D- Power Cables.
9. Turn on this battery string. Refer to section 4.1 for Power on process.
51
6.3 Battery Maintenance
Danger: Battery maintenance can ONLY be done by qualified and authorized personnel.
Danger: Some maintenance items must be turned off at first.
6.3.1 Voltage Check
[Periodical Maintenance] Check the voltage of battery system through the monitor system.
Check if the system voltage is abnormal. For example: Single cell’s voltage is abnormally high or
low.
6.3.2 SOC Check
[Periodical Maintenance] Check the SOC of the battery system through the monitor system.
Check if the battery string SOC is abnormal.
6.3.3 Cables Inspection
[Periodical Maintenance] Visually inspect all the cables of the battery system. Check if the
cables are broken, aging or loose.
6.3.4 Balancing
[Periodical Maintenance] The battery strings will become unbalanced if not being fully charged
for a long time. Proposal: every 3 months do the balancing maintenance (charge to full),
normally
it will be done automatically through communication between system and external device.
6.3.5 Output Relay Inspection
[Periodical Maintenance] Under low load condition (low current), switch the output relay to OFF
and ON to hear the clicking sound, which means this relay can be turned off and on normally.
6.3.6 History Inspection
[Periodical Maintenance] Analyze the history records to check if there is an accident (alarm and
protection) or not, and analyze the reasons.
6.3.7 Shutdown and Maintenance
[Periodical Maintenance]
Some battery function must be restarted before the EMS maintenance. ESS maintenance shall be
done at least once every 6 months.
6.3.8 Recycle
NOTE
Damaged batteries may leak electrolyte or produce flammable gas.
In case a damaged battery needs recycling, follow the local recycling regulations (i.e. Regulation
(EC) Nº 1013/2006 among European Union) to process, and use the best available techniques to
achieve recycling efficiency.
52
7. Remarks
7.1 Storage
For long-term storage, e.g. if it needs to be stored for a long time (more than 6 months), the
battery modules are highly suggested to be stored in the temperature range of 5~45°C, relative
humidity <65% and corrosive-gas-freed environment. Before storage the battery should be
charged to 50~55% SOC.
It is recommended to discharge and charge the battery every 6 months, charge to full and
discharge to 50%. The longest discharge and charge interval shall not exceed 12 months.
Caution: If you don’t follow the above instructions for long term storage, the battery cycle
life will decrease heavily.
7.2 Capacity Expansion
A new battery module can be added onto the existing system at any time. Please make sure the
existing system is being fully charged before adding a new module. In a serial connection
system, the new module, even has a higher SOH, shall follow the system’s worst SOH condition
module to perform.
53
8. Shipment
Before shipment, single battery module will be pre-charged to 100%SOC or according to
customer requirements. After delivered on-site, the remaining battery capacity is determined by
the storage time and condition.
The battery modules meet the UN38.3 certificate standard.
In particular, local rules and policies (e.g. ADR: European Agreement concerning the
International Carriage of Dangerous Goods by Road) for the product transportation shall be
complied with. For more details, please contact Pylontech: service@pylontech.com.cn
54
Annex 1: Installation and System Power On Process List
Tick after
completion
No
.
Item
Remark
☐
☐
D+
D-
power cables
communication cables, grounding cable
☐
The first installation should do full charging
The environment is meets all technical
requirements.
3.3.1 Cleaning
1
☐
☐
3.3.2 Temperature
3.3.3 Fire-extinguisher System
3.3.4 Grounding System
3.3.5 Clearance
Selection of installation sites.
2
Battery base is installed follow the technical
3
requirements.
Refer to section 3.3
Refer to section 3.4.3.
Refer to section
3.4.5.
☐
☐
☐
☐
☐
☐
Battery modules installation.
4
Battery system are fixed.
5
Control Module (BMS) and Battery Module are
6
installed well.
Connect
7
inverter/PCS or confluence cabinet.
Connect the grounding cable.
8
Double check all the
9
and
between BMS to the
,
are
installed well.
Refer to section
3.4.6.
Refer to section 3.4.7.
Refer to section
3.4.7.
Refer to section
3.5.3.1.
Refer to section
3.5.1.
Refer to section
3.5.1,3.5.2 and 3.5.3.
Switch the external power or inverter/PCS on,
ensure all the power equipment can work
10
Refer to section 4.1.
normally.
11
progress automatically.
If the status LED of BMS turns to blue, it means
this battery string is in operation.
55
Annex 2: System Power Off Process List
Tick after
completion
No.
Item
Remark
no current
☐
Soft-off the inverter through inverter’s control
☐
☐
1
panel.
Turn off the switch between inverter and this
battery string (Force-H3), or turn off the power
2
switch of inverter, to make sure
through this battery string.
Refer to section 4.2.
Refer to section 4.2.
3 Turn off the “Power Switch” of the BMS. Refer to section 4.2.
56
Pylon Technologies Co., Ltd.
5/F, No.71-72, Lane 887, ZuChongzhi Road, China (Shanghai) Pilot Free Trade Zone
Pudong, Shanghai 201203, China
T+86-21-51317699 | F +86-21-51317698
E service@pylontech.com.cn
W www.pylontech.com
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