Rechargeable Li-Ion Battery: US5000 Series Operation Manual
Rechargeable Li-Ion Battery: US5000 Series Operation Manual
Rechargeable Li-Ion Battery: US5000 Series Operation Manual
1. Symbol 1
2. Safety Precautions 3
2.1 Before Connecting 4
2.2 In Using 4
3. Introduction 5
3.1 Features 5
3.2 Specification 7
3.3 Equipment interface instruction 8
Definition of RJ45 Port Pin 12
4. Safe handling of lithium batteries guide 14
4.1 Schematic diagram of solution 14
4.2 Danger label 14
4.3 Tools 15
4.4 Safety gear 15
5. Installation and operation 16
5.1 Package items 16
5.2 Installation location 18
5.3 Installation Direction 19
5.4 Grounding 20
5.5 Put into cabinet or rack 21
5.6 Put into bracket 22
5.7 Suitable disconnection device 23
5.8 Power on 24
5.9 Power off 25
5.10 Multi-group mode 26
6. Trouble shooting 28
7. Emergency Situations 31
8. Remarks 32
1. Symbol
Warning Fire.
Do not place near flammable material
Grounding.
Recycle label.
1
The certificate label for EMC/CE.
2
2. Safety Precautions
Reminding
3
2.1 Before Connecting
Warning
1) After unpacking, please check product and packing list first, if product is
damaged or lack of parts, please contact with the local retailer.
2) Before installation, be sure to cut off the grid power and make sure the
battery is in the turned-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 and AC power directly.
5) The embedded BMS in the battery is designed for 48VDC, please DO NOT
connect battery in series.
6) Battery must connect to ground and the resistance must be less than 0.1Ω.
7) Please ensured the electrical parameters of battery system are compatible
to related equipment.
8) Keep the battery away from water and fire.
2.2 In Using
1) If the battery system needs to be moved or repaired, the power must be cut
off and the battery is completely shut down.
2) It is prohibited to connect the battery with different type of battery.
3) It is prohibited to connect batteries with faulty or incompatible inverter
4) It is prohibited to disassemble the battery (QC tab removed or damaged).
5) In case of fire, dry powder fire extinguisher or vast amount of water can be
used.
6) Please do not open, repair or disassemble the battery except staffs from
Pylontech or authorized by Pylontech. We do not undertake any consequences
or related responsibility which because of violation of safety operation or
violating of design, production and equipment safety standards.
4
3. Introduction
US5000 lithium iron phosphate battery is the new energy storage products
developed and produced by Pylontech, it can be used to support reliable high
power for various types of equipment and systems.
3.1 Features
1) Build-in soft-start function able to reduce current strike when inverter need
to start from battery.
2) Dual active protection on BMS level.
3) Automatic address setting when connect in multi-group.
4) Support wakeup by 5~12V signal from RJ45 port.
5) Support upgrade battery module from upper controller via CAN or RS485
communication.
6) Enable 95% depth of discharge, available for the inverter which completely
follow Pylontech latest protocol to operate.
7) The module is non-toxic, non-pollution and environmentally friendly.
8) Cathode material is made from LiFePO4 with safety performance and long
cycle life.
9) Battery management system (BMS)has protection functions including
over-discharge, over-charge, over-current and high/low temperature.
10) The system can automatically manage charge and discharge state and
balance voltage of each cell.
11) Flexible configuration, multiple battery modules can be in parallel for
expanding capacity and power.
12) Adopted self-cooling mode rapidly reduced system entire noise.
13) The module has less self-discharge, up to 6 months without charging it on
shelf, no memory effect, excellent performance of shallow charge and
discharge.
5
14) Small size and light weight, standard of 19-inch embedded designed
module is comfortable for installation and maintenance.
15) Compatible with the 48V series battery of Pylontech.
*Mixture using master battery priority:
US5000>UP5000/US3000C/US2000C>U3000/US2000
For same type of module always use the latest production unit as master.
*Mixture using battery deployment option:
Master battery (1st) US5000
Slave 2nd ~8th US5000/UP5000/US3000C/US2000C/
US3000/US2000
Slave 9 ~16
th th
US5000/UP5000/US3000C/US2000C
6
3.2 Specification
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Basic Parameters US5000 US5000-B
Nominal Voltage (Vdc) 48
Nominal Capacity (Wh) 4800
Usable Capacity (Wh) 4560
Depth of discharge (%) 95
Dimension (mm) 442*420*161
Weight (Kg) 39.7 40
Discharge Voltage (Vdc) 43.5 ~ 53.5
Charge Voltage (Vdc) 52.5 ~ 53.5
Recommended
80*
Charge/Discharge Current (A)
Max. continuous
100*
Charge/Discharge Current (A)
101-120@15min
Peak Charge/Discharge Current (A)
121~200@15sec
Communication RS485, CAN
Configuration
16pcs
(max. in 1 battery group)
0°C ~50°C Charge
Working Temperature
-10°C ~50°C Discharge
Shelf Temperature -20°C ~60°C
Short current/duration time <2000A/1ms
Cooling type Natural
Breaker No Yes
Protective class I
IP rating of enclosure IP20
Humidity 5% ~ 95%(RH) No Condensation
Altitude(m) ≤4000
Certification TÜV / CE / UL / UN38.3
Design life 15+ Years (25°C /77℉)
Cycle Life >6,000 25°C
IEC62619, IEC63056,
Reference standards UL1973, UL9540A, IEC61000-6-2,
IEC61000-6-3, UN38.3
*: The recommended and max. continuous operation current is for a battery cell temperature
within 10~40°C to consider, out of such temp. range will cause a derating on operation current.
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3.3 Equipment interface instruction
9
Reminding
When breaker released for protection, check the root cause of current surge
and cable connection between battery and inverter first. Then try to connect
again.
Power Switch
ON: ready to turn on.
OFF: power off. For storage or shipping.
Start (SW)
Turn on: press more than 0.5s to start the battery.
Turn off: press more than 0.5s to turn off the battery.
RUN
Green LED flashing or lighting to show the battery running status.
Alarm (ALM)
Red LED flashing to show the battery has alarm; lighting to show the battery is
under protection.
SOC
LEDs to show the battery’s current capacity.
Dip Switch (ADD)Dip1: RS485 baud rate: 1: 9600; 0: 115200. After change,
please restart battery.
Dip2: CAN terminal resistance on BMS side. 1: NONE. 0: connected. After
change, no restart required. In single group mode, please keep dip2 at 0
position. For multi-groups, please refer to [5.10].
Dip3~4, reversed. (function reserved)
10
For instance:
The
Dip1 Dip2 Dip3 Dip4 corresponding Status
position of switch
RS485:115200
0 0 0 0 CAN terminal resistance:
connected
RS485:9600
1 0 0 0 CAN terminal resistance:
connected
RS485: 115200
0 1 0 0 CAN terminal resistance:
disconnected.
Console
For manufacturer or professional engineer to debug or service.
Pin3 232-TX
Pin4* +5~+12V for wake up
Pin5* GND for wake up
Pin6 232-RX
Pin8 232-GND
*Wake up signal shall ≥0.5Sec, current between 5~15mA. After send wake up signal, the
voltage shall disappear for normal operation.
Contact
Pin1
Input, passive signal. On: turn off battery. Off: normal.
Pin2
Pin3 +
Output1. On: stop charge.
Pin4 -
Pin5 +
Output2. On: stop discharge.
Pin6 -
Pin7 +
Output3. On: BMS error.
Pin8 -
Input terminals: BMS provide 5Vdc internally. External contactor control ON/OFF.
Output terminals: BMS control ON/OFF. External source request signal voltage ≤25V, current <0.3A.
11
CAN
500 Kbps. Recommended 120Ω. To inverter or upper battery.
RS485
9600 or 115200 bps. Recommended 120Ω. To inverter or slave battery.
Link Port 0, 1
For communication between multiple parallel batteries.
Power Terminals
Power cable terminals: there are two pair of terminals
with same function, one connects to equipment, the
other one paralleling to other battery module for
capacity expanding.
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LED Status Indicators
Condition RUN ALR 1 2 3 4 5 6
Power off - - - - - - - -
Power on ● ● ● ● ● ● ● ●
Idle/Normal ● - - - - - - -
Charge ● - Show soc; highest LED flash, on 0.5s, off 0.5s
Discharge ● Show soc
Alarm ALR:●; Other LEDs are same as above.
System - -
- ● - - -
error/Protect
●/● ON
● flash, on: 0.3s; off: 3.7s
●/● flash, on:0.5s; off: 1.5s
SOC level (%) 91-100 70-90 51-70 31-50 11-30 0~10
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4. Safe handling of lithium batteries guide
4.2 Label
14
4.3 Tools
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 of
the available tools, except their tips, with electrical tape.
It is recommended to wear the following safety gear when dealing with the
battery.
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5. Installation and operation
16
2) For External cable kits:
NOTE: Power and communication cables connect to inverter belongs to an
External Cable Kit, NOT include in battery carton box . They are in another
extra small cable box. If there is anything missed, please contact dealer.
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5.2 Installation location
Make sure that the installation location meets the following conditions:
1) The area is completely waterproof.
2) The floor is flat and level.
3) There are no flammable or explosive materials.
4) The ambient temperature is within the range from 0°C to 50°C.
5) The temperature and humidity are maintained at a constant level.
6) There is minimal dust and dirt in the area.
7) The distance from heat source is more than 2 meters.
8) The distance from air outlet of inverter is more than 0.5 meters.
9) The installation areas shall avoid of direct sunlight.
10) The Minimum clearance to battery module(rack) is more than 0.5 mm.
11) There is no mandatory ventilation requirements for battery module, but
please avoid of installation in confined area. The aeration shall avoid of
high salinity, humidity or temperature.
Caution
If the ambient temperature is out of the operating range, the battery stops
operating to protect itself. The optimal temperature range for the battery pack
to operate is 10°C to 40°C. Frequent exposure to harsh temperatures may
deteriorate the performance and life of the battery.
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5.3 Installation Direction
NOT allowed:
Upside down Sidelong Sidelong
Recommended:
Note
Caution:
Do not stack
A modules together
directly.
Caution:
Make sure there is holder for
more than 40kg weight at bottom
of each module.
B
Installed only rely on two handles
is NOT allowed.
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5.4 Grounding
20
5.5 Put into cabinet or rack
21
5.6 Put into bracket
2) Use 4 location holes, stack the batteries together. And connect the 4 locker
together.
3) Maximum 3 in stack.
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NOTE
After installation, do not forget to register online for full warranty:
http://www.pylontech.com.cn/service/support
Caution
23
5.8 Power on
Double check all the power cable and communication cable between batteries
and between battery and inverter. Switch ON the disconnection device
between battery and inverter if available.
For US5000-B:
Switch ON all modules` breaker first.
2) The one with empty Link Port 0 is the Master Battery Module, others are
slaves (1 master battery configure with maximum 15 slave batteries):
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3) Press the red SW button of master battery to power on, all the battery LED
light will be on one by one from the Master battery:
Note:
1) After the battery module powered on, the soft-start function takes 3sec to
active. After soft-starts battery ready to output high power.
2) During capacity expansion or replacement, when parallel different
SOC/voltage of module together, it is recommended to maintain the system
in idle for ≥15mins or till the SOC LEDs becomes similar (≤1dot difference)
before normal operation.
1) Shut down external power source (inverter) and switch off disconnection device
between battery system and inverter (if available)
2) Press red SW switch of master battery. Then all batteries will off.
3) Switch Power switch OFF.
4) Switch Breaker OFF (for US5000-B).
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5.10 Multi-group mode
Connect power cable first:
1) each pair of cable hold max 100A constant current Connect enough pairs of
cable based on calculation of system current.
2) For Australian market, an overcurrent and disconnection device that isolates
all live conductors (positive and negative) is required between the battery system
and the inverter
3) Then turn ON the batteries. After all batteries running and buzzer of master
battery in group1 rings 3 times. Means all groups are online.
For inverter or EMS, The interruption of each RS485 command shall at
least≥1s.
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By CAN:
1) connect power cable of LV-HUB.
2) Connect communication cable follow the picture.
the cable from master battery to LV-HUB, is recommended to use:
WI0SCAN30RJ1 or cable with pin 1~3 empty.
3) Make sure all dipswitch of master batteries is 0000, then turn ON batteries.
4) After all batteries running and buzzer of master battery in group1 rings 3
times. Means all groups are online.
5) Change the dip switch of master battery in group1 to 0100. Then connect
communication cable between LV-HUB and master battery in group 1.
6) Then turn ON LV-HUB.
Detailed information please refer to manual of LV-HUB.
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6. Trouble shooting
Possible conditions:
1) RS485: baud rate. Check the dip switch1, set to correct one, and restart. All
master battery shall be the same.
2) CAN: terminal resistance. Check the dip switch2, set to 0 and retry.
3) CAN: pin. Try connects the CAN-H, L, GND only and do not connect other
pins to inverter. Using the correct cable.
Possible conditions:
1) Battery cannot turn on, switch ON and press the red SW the lights are all no
lighting or flashing.
a) Capacity too low, or module over discharged.
solution: use a charge or inverter to provide 48-53.5V voltage. If battery can
start, then keep charge the module and use monitor tools to check the
battery log.
If battery terminal voltage is ≤45Vdc, please use ≤0.05C to slowly charge
the module to avoid affect to SOH. If battery terminal voltage is >45Vdc, it
can use ≤0.5C to charge.
If battery cannot start, turn off battery and repair.
2) The battery can turn on, but red light is lighting, and cannot charge or
discharge. If the red light is lighting, that means system is abnormal, please
check values as following
b) Temperature: Above 60°C or under -10°C, the battery could not work.
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Solution: to move battery to the normal operating temperature range
between 0°C and 50°C.
c) Current: If current exceeds 90A, battery protection will turn on.
Solution: Check whether current is too large or not, if it is, change the
settings on power supply side.
d) High Voltage: If charging voltage above 54V, battery protection will turn on.
Solution: Check whether voltage is too high or not, if it is, to change the
settings on power supply side. And discharge the module.
e) Low Voltage: When the battery discharges to 44.5V or less, battery
protection will turn on.
Solution: Charge the battery till the red light turns off.
f) Cell voltage high. The module voltage is lower than 54V, SOC LED does not
all on. When discharge the module protection disappear.
Solution: keep charge the module by 53-54V or keep the system cycle. The
BMS can balance the cell during cycling.
3) Unable to charge and discharge with red LED on. The temperature is 0~50
degree. Use charger to charge, not possible. Use load to discharge, not
possible.
g) Under permanent protection. The single cell voltage has been higher than
4.2 or lower than 1.5 or temperature higher than 80 degree. Solution:
Switch off the module and contact your local distributor for repair.
4) Unable to charge and discharge without red LED on. The temperature is
0~50 degree. Use charger to charge, not possible. Use load to discharge,
not possible.
h) Fuse broken.
Solution: Switch off the module and contact your local distributor for repair.
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Check the communication between battery system and inverter whether
established or not; Check the ADD switch on battery module whether is set
correctly or not;
Under this condition, the BMS remains functional without damage. Just
leave the module switched OFF and wait for the battery voltage drop down
naturally(15mins) then restart. If then no alarm comes out, this means the
module is ready for work.
Excluding the points above, if the faulty still cannot be located, turn off
battery and contact your local distributor.
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7. Emergency Situations
1) Leaking Batteries
If the battery pack leaks electrolyte, avoid contact with the leaking liquid or
gas. If one is exposed to the leaked substance, immediately perform the
actions described below.
a) Inhalation: Evacuate the contaminated area and seek medical attention.
b) Contact with eyes: Rinse eyes with flowing water for 15 minutes and
seek medical attention as soon as possible.
c) Contact with skin: Wash the affected area thoroughly with soap and
water and seek medical attention.
Ingestion: Induce vomiting and seek medical attention.
2) Fire
If detect the battery cell is catching fire, firstly cut off the external power
source. Then use vast of water for suppression. After fire suppressed,
soaking battery within water and contact Pylontech or an authorized dealer.
If detect the cabling or other components (not battery cell) is catching fire.
Firstly, cut off the external power source. Then use dry powder fire or
carbon dioxide extinguisher for suppression.
3) Wet Batteries
If the battery pack is wet or submerged in water, do not let people access it,
and then contact Pylontech or an authorized dealer for technical support.
Cut off all power switch on inverter side.
4) Damaged Batteries
Damaged batteries are dangerous and must be handled with the utmost
care. They are not fit for use and may pose a danger to people or property.
If the battery pack seems to be damaged, pack it in its original container,
and then return it to Pylontech or an authorized dealer.
Caution
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8. Remarks
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Pylon Technologies Co., Ltd.
No. 73, Lane 887, ZuChongzhi Road, Zhangjiang Hi-Tech Park
Pudong, Shanghai 201203, China
T+86-21-51317699 | F +86-21-51317698
E [email protected]
W www.pylontech.com.cn