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Lithium-Ion Phosphate Energy Storage System
PowerCube-H1/H2 Operation Manual
Information Version: 2.1
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This manual introduces PowerCube-H1/H2 from Pylontech. PowerCube-H1/H2 is a high voltage
Lithium-Ion Phosphate Battery storage system. Please read this manual before you install the
battery and follow the instruction carefully during the installation process. Any confusion, please
contact Pylontech immediately for advice and clarification.
PowerCube-H1 and H2 are the same series of products. They are installed in the same way.
Contents
1. SAFETY................................................................................................................................................3
1.1 Symbol................................................................................................................................3
2. SYSTEM INTRODUCE ..........................................................................................................................5
2.1 Product Introduce.............................................................................................................5
The parameter of system..........................................................................................................5
2.2 System Diagram ................................................................................................................7
2.2.1 Multi battery string parallel connection by CAN communication between
MBMS and BMS diagram (battery string qty. İ6 set) ..........................................................7
2.2.2 Diagram between BMS and battery modules:..........................................................7
3. INSTALLATION ....................................................................................................................................8
3.1 Tools ....................................................................................................................................8
3.2 Safety Gear........................................................................................................................8
3.3 System Working Environments Checking.......................................................................9
3.3.1 Cleaning..........................................................................................................................9
3.3.2 Temperature ...................................................................................................................9
3.3.3 Cooling System...............................................................................................................9
3.3.4 Heating System...............................................................................................................9
3.3.5 Fire-extinguisher System.................................................................................................9
3.3.6 Grounding System..........................................................................................................9
3.4 Package Items ................................................................................................................10
Accessories...............................................................................................................................10
Unpacking and check the Packing List:...............................................................................10
3.5 Handling and placement ..............................................................................................11
3.5.1 Handling and placement of the battery module...................................................12
3.5.2 Handling and placement of the rack.......................................................................12
3.5.3 The fix and installation of the rack................................ .............................................12
3.5.4 Control Module (BMS) and all Battery Modules install into the Rack....................12
3.5.5 Install the MBMS into a 19’ standard rack [On the top of BMS, or use the
rack configured by user] ........................................................................................................13
3.6 Cables connection.........................................................................................................13
3.6.1 Pay attention terms:.....................................................................................................13
3.6.2 Cables Connection .....................................................................................................13
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CAN Communication Mode between MBMS and BMS (battery string qty. İ6 set)
(battery string qty. İ6 set).....................................................................................................13
CAN Communication Mode between MBMS and BMS Cable Diagram:.......................14
3.6.3 ADD Switch Setting (Address Assignment) ...............................................................14
Under CAN Communication Mode between MBMS and BMS (battery string qty .
İ6 set).......................................................................................................................................15
3.6.4 System turns on......................................................................................................... ....15
3.6.5 System turns off.............................................................................................................17
4. SYSTEM DEBUG ................................................................................................................................19
5. MAINTENANCE
................................................................................................................................20
5.1 Trouble Shooting:.............................................................................................................20
5.2 Replacement of main component ..............................................................................22
5.2.1 Replacement of Battery Module...............................................................................22
5.2.2 Replacement of Control Module (BMS)....................................................................23
5.2.3 Replacement of 3
rd
level Control Module (MBMS)..................................................23
5.3 Battery Maintenance .....................................................................................................24
6. STORAGE RECOMMENDATIONS.....................................................................................................26
7. SHIPMENT .........................................................................................................................................26
ANNEX 1: CABLE CONNEC TION DI AGR AM ............................................................................................27
ANNEX 2: INSTAL L ATION AN D SYSTEM TURN ON PROGRESS LIST
..........................................................28
ANNEX 3: SYSTEM TURN OFF PROGRESS LIST...........................................................................................30
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1.
Safety
The PowerCube-H1/H2 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 on with the system.
Incorrect operation or work may cause:
¾ injury or death to the operator or a third party;
¾ damage to the system hardware and other p roperties belonging to the operator or a t hird
party.
Skills of Qualified Personnel
Qualified personnel must have the following skills:
z training in the installation and commissioning of the electrical system, as well as the dealing
with hazards;
z knowledge of this manual and other related documents;
z knowledge of the local regulations and directives.
1.1 Symbol
Danger
Lethal voltage!
z Battery strings will produce high voltage DC power and can
cause a lethal voltage and an electric shock.
z Only qualified person can perform the w
iring of the battery
strings.
Warning
Risk of battery system damage or personal injury
z DO NOT pull out the connectors while the system is operating!
z De-energize from all multiple power sources and verify that
there is no voltage.
Caution Risk of battery system failure or life cycle reduction.
Read the product manual before operating the battery system!
Danger: Batteries deliver electric power, resulting in burns or a fire hazard when they are short
circuited, or wrongly installed.
Danger: Lethal volt ages are present in the batt ery terminals and cables. Severe injuries or death
may occur if touch the cables and terminals.
Warning: DO NOT open or deform the battery module, otherwise the product will be out of
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warranty scope
Warning: Whenever working on the batt ery, wear suitable personal protective equipment (PPE)
such as rubber gloves, rubber boots and goggles.
Warning: PowerCube-H1/H2 system working temperature range: 0 ć50 ć ; Optimum
temperature: 18ć28ć. Out of the working temperature range may cause the battery
system over / low temperature alarm or protection which further lead to the cycle life
reduction as well as. It will affect the warranty terms as well.
Caution: Improper settings or maintenance can permanently damage the battery.
Caution: Incorrect inverter parameters will lead to a further faulty/damage to battery.
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2. System Introduce
2.1 Product Introduce
PowerCube-H1/H2 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 support reliable power for various types of equipments and systems.
PowerCube-H1/H2 is especially suitable for those application scene which required high power
output, limited installation space, restricted load-bearing and long cycle life.
The parameter of system
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Product Type
POWERCUBE-H2
(576V74AH)
Cell Technology Li-ion(LFP)
Battery System Capacity(kWh) 42.624
Battery System Voltage(Vdc) 576
Battery System Capacity(AH) 74
Battery Controller Name SC1000-100
Battery Module Name H48074
Battery Module Quantity(pcs) 12
Battery Module Capacity(kWh) 3.552
Battery Module Voltage(Vdc) 48
Battery Module Capacity(AH) 74
Battery Module Cell Quantity(pcs) 15
Battery System Charge Upper-Voltage(Vdc) 648
Battery System Charge Current(Standard) 14.8
Battery System Charge Current(Normal) 37
Battery System Charge Current(Max.) 74
Battery System Discharge lower-Voltage(Vdc) 540
Battery System Discharge Current(Standard) 14.8
Battery System Discharge Current(Normal) 37
Battery System Discharge Current(Max.) 74
Efficiency 96%
Depth of Discharge 80%(10~90%)
Dimension(W*D*H,mm) 600*505*2130
Communication RS485\CAN
Protection Class IP20
Weight˄kg˅
460.5
Operation Life(Years) 10
Operation Cycle Life 3500
Operation Temperature(ć)
0~50
Storage Temperature(ć)
-20~60
Product Certificate TUV, CE
Transfer Certificate UN38.3
Other˖
1˅Battery Controller Dimensions(W*D*H)
2˅Battery Module Dimensions (W*D*H)
442*390*132
442*390*132
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2.2 System Diagram
2.2.1 Multiple battery string parallel connection via CAN communication between MBMS and
BMS diagram (battery string qty. İ
6sets)
2.2.2 Diagram between BMS and battery modules:
3.
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3. Installation
Please check every installation step in detail at <Annex 2: Installation and System Turn ON
Progress List> during the install.
3.1 Tools
The following tools are required to install the battery pack:
Wire Cutter Crimping Modular Plier Cable Ties
Screw Driver Set Electric Screw Driver Sleeve Piece
Adjustable Wrench
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
Insulated gloves Safety goggles
Safety shoes
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3.3 System Working Environments Checking
3.3.1 Cleaning
The battery system has high voltage connectors. The cleaning condition will affect the isolation
performance of the system.
Before installation an d system pow er on, the dust and iron scurf m ust be removed to keep a
clean environment. And the environment must have certain anti-dust ability.
Dust and humidity condition shall be regularly checked during the system continuous operation.
If it`s detected the above two elements are not in the working range, the system shall be stopped
for cleaning purpose.
Danger: the power cables and plugs will have high voltage DC power from serial connected
battery modules (battery module has active DC power at terminal all the time), must be
careful to handle the Power Plugs.
3.3.2 Temperature
PowerCube-H1/H2 system working temperature range: 0ć50ć; Optimum temperature: 18
ć
28ć.
Caution: Out of the working temperature range will cause the battery system over / low
temperature alarm or protection which further lead to the cycle life reduction.
3.3.3 Cooling System
It is essential to equip a cooling system to keep the battery system in a relevant temperature
range.
Caution: Out of the working temperature range will cause the battery system over / low
temperature alarm or protection which further lead to the cycle life reduc
tion.
3.3.4 Heating System
It is essential to equip a heating system to keep the battery system in a relevant temperature
range. If the environment is lower than 0ć, the system may be shut down for protection purpose.
It is necessary to open the heating system at first.
Caution: Out of the working temperature range will cause the battery system over / low
temperature alarm or protection which further lead to the cycle life reduction.
3.3.5 F
ire-extinguisher System
The room must be equipped with fire-extinguisher system for safety purpose.
The fire system needs to be regularly checked to be in normal condition. Refer to the using and
maintenance requirements please follow local fire equipment guidance.
3.3.6 Grounding System
Before the battery installation must make sure the grounding point of the basement is stable and
reliable. If the battery system is installed in an independent equ
ipment cabin (e.g. container),
must make sure the grounding of the cabin is stable and reliable.
The resistance of the grounding system must İ
100m¡
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3.4 Package Items
Accessories
The type and quantity of the accessories are subject to the battery
packing list.
NOTE
Power cable uses water-proofed connectors. It must keep pressing this
Lock Button during pulling out the power plug.
Unpacking and check the Packing List:
Power Cable + (Battery Module
and Main Controller Serial
Connection)
Orange/0.16m/4AWG/2 Ora ng e
Surlok Terminal
pcs 1
Power Cable - (PH Main Control
Module Battery)
Black/2m/4AWG/2 Black Surlok
Terminal
pcs 1
Power Cable (Battery Module
Upper and Lower Serial
Connection)
Orange/0.18m/4AW G/1 Orang e &
1 Black Surlok Terminal
pcs 14
Battery Cascade
Communication Cable (0.18m)
Black/0.18m/8 Core Super 5th
Class Twisted-pair Wire/RJ45
pcs 15
160
2000
180
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External Battery CAN
Communication Cable (direct)
Black/3.5m/Super 5th Class
Twisted-pair Wire/2 RJ45 terminal
pcs 1
External Power Cable +
Orange/2m/4AWG/SURLOK
Terminal/25-8 Terminal
pcs 1
External Power Cable -
Black/2m/4AWG/SURLOK
Terminal/25-8 Terminal
pcs 1
For external power supply control module there is an additional AC power cable:
AC Power Cable (Australia
Standard)
Black/2.5m/3*0.75mm2/Australia
Standard
pcs 1
3.5 Handling and placement
Warning: The battery rack is IP00. It must be installed in a restricted access area;
Warning: PowerCube-H1/H2 is a high voltage DC system, operated by qualified and authorized
personnel only.
2000
2000
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3.5.1 Handling and placement of the battery module
Sigel battery module is 24kg. If without handling tools must have more than 1 manto handling
with it.
3.5.2 Handling and placement of the rack
If without handling tools must have more than 4 men to handling with it.
3.5.3 The fix and installation of the rack
The rack must be fixed installed on the basement or carriage on the wall with M10 screws.
Battery rack basement holes bitmap (unit: mm):
Battery ra
ck wall fixed holes bitmap (unit:
mm):
3.5.4 Control Module (BMS) and all Battery Modules install into the Rack
z Install the buckle nuts. The position of nuts must meet the position of the control module (BMS)
and all battery modules.
z Install the control module (BMS) and all battery modules in. Each module uses 4 screws to fix.
Refer to chapter 3.5.1
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3.5.5 Install the MBMS into a 19’ standard rack [On the top of BMS, or use the rack configured by
user]
z Install the buckle nuts. The position of nuts must meet the position of the MBMS.
z Install the MBMS in. Uses 4 screws to fix.
3.6 Cables connection
3.6.1 Attention:
Danger: The battery system is high voltage DC system. Must make sure t he groun din g of t he rack
is stable and reliable.
Danger: All the plugs and sockets of the power cables must be fro
m orange to orange and black
to black. Otherwise it will cause personal injury.
Danger: N o short circuit or reserved connection of the battery syst em’s positive and n egative
port.
Caution: Wrong communication cables connection will cause the battery system failure.
Grounding
The PowerCube-H1/H2 modules’ grounding is based on metal directly touch
between the module’s surface and rack’s surface. So it don`t need grounding
cables at all. If uses normal rack, it should remove the paint at the corresponding
grounding point.
3.6.2 Cables Connection
Note: Power cable uses water-proofed connectors. It must keep pressing this
Lock Button during pulling out the power plug.
If there are more than 1 rack of
PowerCube-H1/H2, there will require a MBMS on the top
which aggregate information from all the BMS and communicate with inverter/PCS.
CAN Communication Mode between MBMS and BMS (battery string qty.İ
6 sets)
When system configured PowerCube-H1/H2 İ
6 sets. The communication between
PowerCube-H1/H2s uses CAN cascade communication mode. The communication between the
MBMS and the BMS of 1
st
PowerCube-H1/H2 uses CAN communication mode.
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V
CAN Communication Mode between MBMS and BMS Cable Diagram:
Note: The 1
st
PowerCube-H1/H2 should be installed nearest to the MBMS.
3.6.3 ADD Switch Setting (Address Assignment)
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ADD Switch is a 6 bit dial switches to manually distribute the communication address of the
battery system. Nether position is OFF, means “0”. Upper position is ON, means “1”. For BMS, 1
st
bit
to 5
th
bit is for address allocation, and the 6thbit dial switch support a 120¡ resistance (Terminal
Resistance).
Under CAN Communication Mode between MBMS and BMS (battery string qty. İ
6 set)
The MBMS’s ADD Switch shall set as “1000X
1X0
”with 1stbit at ‘1’ always. The last 2 bits are terminal
resistances.;
X
1
address should correspond with CAN1 port connection, X0address should correspond with
CAN0 port connection.
When the external communication is via CANBUS, and if this equipment requires terminal
resistance, then X
0/X1
should be set to “1”. If t his equipment not require terminal resistance, then
X
0/X1
should be set to “0”; If there are multiple external devices communicate with MBMS via
CANBUS, then the X
0/X1
shall follow varying external device requirement.
The BMS’s first five bits must set in below <BMS’s Address Configure
Table>. The last (farthest posit ion) BMS’s terminal resistance must set in
“1” (X=1), and other BMS’s terminal resistance must set in “0”.
The address is configured follow ASCII code: (“X” is terminal
resistance).
BMS’s Address Configure Table:
Note: The abo
ve setting is following normal standard. But some PCS or Inverter’s address is
changeless, can’t be set. In this case the address setting must follow such equipment’s guidance.
If the address setting is failed, please contact the distributor or Pylontech.
3.6.4 System turns on
Double check all the power cables and communication cables. Make sure the voltage of the
PCS is same level with the battery system. Check all the power switch of every
battery system is
Battery
String
Address Bit
Battery
String
Addres s Bi t
Battery
String
Addres s Bit
Battery
String
Addres s Bi t
1 10000X 9 10010X 17 10001X 25 10011X
2 01000X 10 01010X 18 01001X 26 01011X
3 11000X 11 11010X 19 11001X 27 11011X
4 00100X 12 00110X 20 00101X 28 00111X
5 10100X 13 10110X 21 10101X 29 10111X
6 01100X 14 01110X 22 01101X 30 01111X
7 11100X 15 11110X 23 11101X 31 11111X
8 00010X 16 00001X 24 00011X 32 00000X
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OFF.
Warning: MBMS must be turned on after all battery strings self-check finish.
(1) Check the UPS is turned on and suppling power if configured.
(2) Switch the external power or PCS on, to make sure all the power equipments can work
normally.
(3) Turn on the 1
st
BMS (Battery Control Modules) of battery string:
The second BMS must be operated after the first battery string’s self-check is successful.
From 1st BMS to the last BMS Then turn on the
battery strings on one by one.
z Turn on the “POWERRELAY SWITCH”:
Warning: This Power Relay Switch must be sure turned ON. Otherwise it will affect
automatic checking process and causes danger.
z Turn on the “POWER SWITCH”:
Caution: When the breaker is tripped off because ULover current or short circuit, must
wait after 30min to turn on it again, otherwise may cause the breaker damage.
z The battery string’s system will check itself, if work n
ormal the battery string system will go
to self-check mode.
If the BMS and all battery modules are working normally, every status LED will lighting
green, that’s mean self-check are pass. Self-check will be finish within 10sec.
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If the BMS can’t receive communication from upper equipment because of the
communication is off, the “STATUS” lamp will light red after 30sec. That doesn’t means
failure existed, it means this battery string is ok while the external communication is off.
Warning: If has failure during the self-check, must debug the failure then can start next
step.
If the “STATUS” lamp shows red from beginning, it means there has some failure in the
battery string, the Power Relays in BMS will open, must debug at first.
(4) Switch the MBMS onafter all the BMS turn on successful:
And check whether MBMS is working. The “STATUS” lamp will light green.
When the voltage difference between strings is smaller than the parameter, the battery
string will do the parallel operation. Then the power relays in BMS will switch ON after 30
seconds. The “STATUS” la mp of the BMS will light green;
When the voltage difference be
tween strings is bigger than the parameter, the battery
string will NOT do the parallel operation, the “STATUS” lamp of the BMS will light red, but it
is normal; such battery string will be paralleled in during charging stage automatically.
Note: If the MBMS can’t build communication with other equipment, the system can’t
work normally. External device should communicate with battery system through LAN,
CAN or RS485. Otherwise maybe cause
battery system work abnormal.
Caution: During first time power on, the system will require to do fully charge progress for SOC
calibration purpose.
Caution: The whole Battery Energy Storage Syste m (BESS) after installation or restart the system
when long time not in using should charge it to full at first. There will be a regularly (3
month) fully charge requesting during continuous operation as well, it will be handled
automaticall
y by the communication between BESS and external device.
3.6.5 System turns off
When failure or before service, must turn
the batterystoragesystem off:
(1)
Soft-off the PCS through PCS’s
control panel.
(2) Turn off the switch between PCS
and battery string
(PowerCube-H1/H2), or turn off the
power switchof PCS,to make sure no current transmission through battery string and PCS.
(3) Turn off t he “P ower Sw it ch” of the
BMS.
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Danger: DO NOT turn off the “Power Relay Switch” during normal running condition, only in
emergency case it could be turned off directly. Otherwise will cause this battery string current
surge by another battery strings.
(4) Turn off the “Power Switch” of the MBMS. If the ESS configures only single battery without
MBMS, then ignore this operation step.
(5) Turn off the UPS if configured.
The UPS can turn on if have equipment must keep running
can’t turn off. Otherwise must turn
off the UPS to save its power.
Caution: Before change the battery module for servic e, must charge/discharge the replaced
battery same voltage to the other in system battery modules. Otherwise the system need long
time to do the balance for this replaced battery module.
NOTE
After installation, DO NOT forget to register online for full warranty:
www.pylontech.com.cn/service/support
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4. System Debug
This system debug is for BESS syste m (Battery Energy Storage System). B ESS system can’t do the
debug itself. It must operation with configured UPS, PCS and EMS system together.
Debug Step Content
Prepare of debug. Turn on the BESS system , refer to chapter 3. Before turn on the whole
BESS system turn on the load is not allowed!
Remark: Except the BESS, if other equipmen ts hav e its own system t urn
on step, must follow its own system operation manual.
System function test. Each component system debug:
Power supply Check if the External Power Supply (e.g. UPS) is working
normally.
Communication Test: Check the communication between the BESS
system and communicated devices normal or not, has alarm or not.
Power Conversion System Test: Before conjoint test must test the
Inverter System turn on progress at first. And check the parameters
meet BESS requirement or not.
BESS Test: Charge/Discharge test ;
Test stop charging , st op disc ha rging,
current limiting functions, etc.
Caution: Before turn on the BESS system m ust setup all the paramet ers
of the PCS and EMS at first.
Monitor function test.
(If configured.)
Check whether the data of the BESS system is showing on the monitor
system normally.
EMS conjoint test
(If configured.)
If the EMS system has running monitor requirements, check if the BESS
system is following EMS instructions.
Trial operation test. After the system debugged, run the system a period as test (testing
with low load), to test the high voltage DC system is fit for the contract.
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5. Maintenance
5.1 Trouble Shooting:
Danger: The PowerCube-H1/H2 is a high voltage DC system, operated by qualified and
authorized person only.
Danger: Before check the failure, must check all the cables connection and setting of ADD
Switches are right or not (refer to chapter 3), and the BESS system can turn on normally or
not.
No Problem Possible Reason Solution
1 Turn on the BMS. All battery
modules’ status LED is not
working.
z The DC/DC power
board or control board
is failure.
z The communication
cable from BMS to the
first battery module is
broken
z Power cable is broken;
z Change the control
module (BMS module)..
z Change the broken
communication cable;
z Check all the power
cables and
connections are fine or
not;
2 Turn on the BMS. The Status
LED for BMS is not working.
But all battery modules’
status LED is lighting green.
z The control board is
failure.
z Change the control
module (BMS module).
3 Turn on the BMS. The Status
LED is lighting red. But all
battery modules’ status LED
is lighting green.
z
This battery string is
under protection. It is
possible Over Current
Protection or Failure
Protection.
z Communication cables
failure;
z Battery String is reversed
connection.
z Through the monitor or
maintenance software
check the battery cell,
battery module has
alarm or not.
z Check the
Communication Cables;
z Reversed connection is
s
erious danger!
4
The BMS’s Status LED is
lighting red and some the
battery module’s status
LED is lighting green but
some is lighting red.
z This battery string is
under protection. It is
possible Over Current,
Over Voltage, Low
Voltage, Over
Temperature, Low
z Use the monitor or
maintenance software
to check the battery
cell, battery module has
protection and failure or
not.
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Temperature or Failure
Protection.
5 Cannot close the power
Switch.
z DC Output breaker is
fault.
Check the DC output
breaker is fault or not. If it is
fault, change the control
module (BMS module).
5 Open the Power Relay
Switch, but the relay can’t
be open.
z The main control board
is failure.
z The wire of the output
relay, or the wire of the
power relay switch in
the BMS is broken
z Change the control
module (BMS module).
z Check the wire got
loose or broken? Fix it.
O
r the control module
(BMS module).
5 Turn on the BMS. The Status
LED is flashing red.
Self-check can’t pass. If something is wrong,
please contact with seller or
sells agent.
6 Turn on the BMS. The Status
LED is lighting red. And the
buzzer is noising.
z Output relay is
non-separable
switching,.
z The buzzer is failure᧷
z Output relay False alarm;
z Check th e outp ut relay . If
fault find out the short
circuit reason. Change
the relay or the control
module (BMS module).
z Change the control
module (BMS module).
7 Turn on the BMS. The Status
LED shows normal. But the
output relay can’t be
actuation.
z The wire of the output
relay or the wire of the
power relay switch in
the BMS is broken.
z Power Relay Switch is
open;
z Check the wire got
loose or broken? Fix it.
Or change the control
module (BMS module).
z Close the Power Relay
Switch.
8 Turn on the BMS. The one
and the following of the
battery module’s Status LED
lighting red or not lighting.
z This battery module has
failure;
z Its communication cable
failure;
z Its Address Distribution
failure.
z Change this battery
module;
z Check the
communication cable;
z Check by professional
stuff.
9 Single Cell is over voltage/
low voltage.
(Check through the monitor
or maintenance software.)
z Cell voltage sampling
failure.
z Cell failure;
z Check the wires of cell
sampling module;
z Change this battery
module.
10 Battery module shows the
temperature is -40ć.
(Check through the monitor
or maintenance software.)
The wires of temperature
sampling failure.
Check the wires of
temperature sampling
module. Or change this
battery module.
11 Another failure Cell failure or electrical Can’t find out failure point
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board failure. or can’t check. Please
contact with distributor or
Pylontech.
5.2 Replacement of main component
Danger: The PowerCube-H1/H2 is a high voltage DC system, operated by qualified and
authorized person only.
Danger: Before replace the main component must shut off the maintenance battery string’s
power. Must confirm the D+ and D- terminal are without power. The turn off progress
refer to chapter 3.6.5.
5.2.1 Replacement of Battery Module
5.2.1.1 Use a charger to charge the new battery module and existing mo
dule to full (SOC 100%)
5.2.1.2 Turn off the whole battery string’s power. Must confirm the D+ and D- terminal are without
power. The turn off progress refer to chapter 3.6.5.
5.2.1.3Pull out the Plug of Power Cable +/-. Pull out the plug of
communication cable.
Danger: the power cables and plugs still have high voltage DC power from serial connected
battery modules (battery module can’t be turned off), must be careful to handle the Power plugs
w
ith insulated tools.
5.2.1.4 Dismantle the 4 screws of the battery module’s front face.
5.2.1.5 Handle the battery module out of the rack, and put it to the appoint place.
Warning: Single battery module is 24kg. If without handling tools must more than 1 personnel to
handling with it. If install in high place of the rack it must more than 2 personnel.
5.2.1.6Install the new battery module (see before 5.2.1.1). And connect the cables. Refer to
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chapter 3.5.
5.2.1.7 Turn on this battery string. Refer to chapter 3.6.
5.2.2 Replacement of Control Module (BMS)
5.2.1.1 Turn off the whole battery string’s power. Must confirm the D+ and D- terminal are without
power. The turn off progress refer to chapter 3.6.5.
5.2.2.2 Pull out the plugs of Power Cables and the communica tion plugs.
Danger: the power cables still have high voltage DC power from another battery modules, must
be careful to handle the Power plugs.
5.2.2.3 Dismantle the 4 screws of the battery module’s front face.
5.2.2.4 Install the new control module (BMS). And reconnect all the cables. Refer to chapter 3.5.
5.2.2.5 Turn on this battery string. Refer to chapter 3.6.
Caution: Before pull out the communication cables must mark the cable number, to avoid cable
wrong sequence.
5.2.3 Replacement of 3
rd
level Control Module (MBMS)
5.2.3.1 Turn off the Power Switch. Refer to chapter 3.6.5.
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Caution: Turn off this MBMS will stop the power output of belonging whole Battery Energy Storage
System.
5.2.3.2 Dismantle the 4 screws.
5.2.3.3 Install the new MBMS inside. And reconnect the cables. Refer to chapter 3.5.
5.2.3.4 Turn on this MBMS. Refer to chapter 3.6.
Caution: Before pull out the communication cables must mark the cable number, to avoid cable
wrong sequence.
5.3 Battery Maintenance
Danger: The maintenance of battery must done by qu
alified and authorized personnel only.
Danger: Some maintenance items must turn off at first.
5.3.1 Voltage Inspection:
[Periodical Maintenance] Check the voltage of battery system through the monitor system.
Check the system abnormal voltage or not. For example: Single cell’s voltage is abnormal high or
low.
5.3.2 SOC Inspection:
[Periodical Maintenance] Check the SOC of battery system through the monitor system. Check
the battery string abnormal SOC or not.
5.3.3 Cables Inspection:
[Periodical Maintenance] Visual inspect all the cables of battery system. Check the cables has
broken, aging, getting loose or not.
5.3.4 Balancing:
[Periodical Maintenance] The battery strings will become unbalance if long time not be full
charged. Solution: every 3 month should do the balancing maintenance (charge to full),
normally it will been done automatically by the communication between system and external
device.
5.3.5 Output Relay Inspe ction:
[Periodical Maintenance] Under low load condition (low current), control the output relay OFF
and ON to hear the relay has click voice, that’s mean this relay can off and on normally.
5.3.6 History Inspection:
[Periodical Maintenance] Analysis the history record to check has accident (alarm and
protection) or not, and analysis its reason.
5.3.7 Shutdown and Maintenance:
[Periodical Maintenance]
Some system function must be maintenance during the EMS restart, it is recommended to
maintenance the system every 6 months.
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6. Storage Recommendations
b) For long-term storage (more than 3 months), the battery cells should be stored in the
temperature range of 5~45ć, relative humidity <65% and contains no corrosive gas environment.
The battery module should shelfed in range of 5~45ć, dry, clean and well ventilated
environment. Before storage the battery should be charged to 50~55% SoC;
It is recommended to active the chemical (discharge and charge) of the battery ev
ery 3 months,
and the longest discharge and charge interval shall not exceed 6 months.
Caution: If not follow the above instructions for long term store the battery, The cycle life will have
relative heavily reduction.
7. Shipment
Battery module will pre-charged to 50%SOC or according to customer requirement before
shipment. The remaining capacity of battery cell, after shipment and before charge, is
determined by the storage time and condition.
1. The battery modules meet the UN38.3 certificate standard.
2. In particular, special rules for the carriage of goods on the road and the current dangerous
goods law, specifically ADR (European Convention on the International Carriage of Dangerous
Goods by Road), as amended, must be observed.
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Annex 1: Cable connection diagram
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Annex 2: Installation and System Turn ON Progress List
Tick after
completion
No. Item Remark
ჱ
1
The environment is meeting all technical requirements.
3.3.1 Cleaning
3.3.2 Temperature
3.3.3 Radiating System
3.3.4 Heating System
3.3.5 Fire-extinguisher System
3.3.6 Grounding System
Refer to chapter
3.3
ჱ
2
Battery rack is installed follow the technical
requirements.
Refer to chapter
3.5.3.
ჱ
3
Control Module (BMS) and Battery Module are installed
well.
Refer to chapter
3.5.4.
ჱ
4 The MBMS are installed well. (If configured.)
Refer to chapter
3.5.5.
ჱ
5
Connect External Power Cable +/- between each BM S
to the PCS or confluence cabinet.
Refer to chapter
3.6.2.
ჱ
6 Connect power cables of each battery string.
Refer to chapter
3.6.2.
ჱ
7 Connect communication cables of each battery string.
Refer to chapter
3.6.2.
ჱ
8
Set up ADD switch of every BMS and the MBMS (Address
Assignment).
Refer to chapter
3.6.3.
ჱ
9
Connect external communication cables from BMS to
BMS, MBMS, inverter, PCS or another.
Refer to chapter
3.6.2.
ჱ
10
Connect the communication cable from MBMS to the
PCS.
Refer to chapter
3.6.2.
ჱ
11
Double check every power cables, communication
cables installed well. And ADD Switches are setting
right.
Refer to chapter
3.6.2 and 3.6.3.
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ჱ
12
Check the UPS is turned on. And the UPS is power
supplying. (If configured)
Refer to chapter
3.6.4.
ჱ
13
Switch the external power or PCS on, to sure all the
power equipments can work normally.
Refer to chapter
3.6.4.
ჱ
14
Turn the BMS (Battery Control Modules) of each battery
string on (from 1
st
BMS to the last, one by one)
z Turn on the “POWER RELAY SWITCH”:
z Turn on the “Power Switch”:
z The battery string’s system will check itself, if
work normal the battery string system will
goes into
self-check mode.
If has failure during the self-check, must debug
the failure then can start next step.
Refer to chapter
3.6.4.
ჱ
15
If every battery string are working normally.
Then switch the M BMS on . The MBMS will self-check and
check each battery string one by one.
Refer to chapter
3.6.4.
ჱ
16
The first installation should do full charging progress.
After MBMS has communicated with each BMS, it will
run parallel operation. It will begin from lowest voltage
battery string to do the parallel operation during the
charging.
If the status LED of BMS turns to green, it means this
battery string is in parallel operation.
The first
installation should
do full charging
progress.
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Annex 3: System Turn OFF Progress List
Tick after
completion
No. Item Remark
ჱ
1 Soft-off the PCS through PCS’s control panel.
Refer to chapter
3.6.5.
ჱ
2
Turn off the switch between PCS and this battery string
(PowerCube-H1/H2), or turn off the power switch of
PCS, to make sure no current through this battery string.
Refer to chapter
3.6.5.
ჱ
3 Turn off all the “Power Switch” of the BMS.
Refer to chapter
3.6.5.
ჱ
4 Turn off the “Power Switch” of the MBMS.
Refer to chapter
3.6.5.
ჱ
5
Turn off the UPS. (If configured.)
z The UPS can turn on to check the equipments (PCS
or battery system etc.). Otherwise must turn off the
UPS to save its power.
Refer to chapter
3.6.5.
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Pylon Technologies Co., Ltd.
No. 73, Lane 887, ZuChongzhi Road, Zhangjiang Hi-Tech Park
Pudong, Shanghai 201203, China
T+86-21-51317697 | F +86-21-51317698
Eservice@pylontech.com.cn
Wwww.pylontech.com.cn
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