Lithium-Ion Phosphate Energy Storage System Force-L2 Operation Manual

Introduction

This manual introduces Force-L2 from Pylontech. Force-L2 is a 48V DC 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.

1. Safety Precautions

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 Person

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 the manual and other related documents;
• Knowledge of the local regulations and directives.

1.1 Symbol

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 the cables and terminals are touched.

Warning: Do not open or deform the battery module;

Warning: Whenever working on the battery, wear suitable personal protective equipment (PPE) such as rubber gloves, rubber boots and goggles.

Warning: Force-L2 system working temperature range: 0℃~50℃; Optimum temperature: 18℃~28℃. Out of the working temperature range may cause the battery reduces the cycle of life even cause the battery system over / low temperature alarm or protection. It will affect the warranty.

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 the premature aging of battery.

Reminding

1. It is very important and necessary to read the user manual carefully (in the accessories) before installing or using battery. Failure to do so or to follow any of the instructions or warnings in this document can result in electrical shock, serious injury, or 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. All the battery terminals must be disconnected for maintenance;
6. Please contact the supplier within 24 hours if there is something abnormal.
7. Do not use cleaning solvents to clean battery;
8. Do not expose battery to flammable or harsh chemicals or vapors;
9. Do not paint any part of battery, include any internal or external components;
10. Do not connect battery with PV solar wiring directly;
11. Do not open, repair or disassemble the battery except staffs from Pylontech or authorized by Pylontech. Pylontech does not undertake any consequences or related responsibility which because of violation of safety operation or violating of design, production and equipment safety standards.
12. The warranty claims are excluded for direct or indirect damage due to items above.
13. Any foreign object is prohibited to insert into any part of battery.

1.2 Before Connecting

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 system must be well ground and the resistance must be less than 100mΩ;
7. Please ensured the electrical parameters of battery system are compatible to related equipment;
8. Keep the battery away from water and fire.

1.3 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 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;

2. System Introduce

2.1 Product Introduce

Force-L2 is a 48VDC 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 equipment and systems. Force-L2 is especially suitable for those application scenes which required high power energy, limited installation space, restricted load-bearing and long cycle life.

2.2 Specifications

2.2.1 System parameter

2.2.2 Battery Module (FL4874M)

2.2.3 Control Module FC0048M-100S (internal power supply)

Control Module (FC0048M-100S) Display Panel:

LED Button:

• Short Press: Display the LED panel for 20sec.
• Long Press (more than 5sec): When status LED fast flashes blue, release the button, then it is 115200 baud rate of RS485. When status LED fast flashes orange, release the button, then it is 9600 baud rate of RS485.

Status Indicators:

Battery Module Status:

System Capacity: Indicate the system SOC.

Remark: Slow flashing: 1.5s ON/0.5s OFF. Flashing 0.5s ON/0.5s OFF. Fast flashing: 0.1s ON/0.1s OFF.

Control Module (FC0048M-100S) Cable Panel:

Power Switch:

• Switch A (1P): ON - the battery system's controller can turn on. OFF - whole system turns OFF.
• Switch B (2P): Main breaker.

Caution: When the breaker is tripped off because of over current or short circuit, must wait more than 30min then can turn on it again, otherwise may cause the breaker damage.

Start:

• Start function: press more than 5sec, to turn on controller.
• Black start function: when system turn on, and relay is OFF, press more than 10 sec, and relay will turn on for 3 min (depends on conditions).

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 Specifications:

• Maximum Transmitting power: 18dBm
• Wireless maximum output power: 20dBm
• Operating frequency: 2412-2472MHz
• Gain of antenna: Max 3dBi
• Modulation system: DBPSK/DQPSK/CCK(DSSS), BPSK/QPSK/16QAM/64QAM(OFDM)
• Modulating Repetition: 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)
• Channel spacing: 5MHZ
• Type of antenna: 2.4G IPEX-SMA Antenna

Power Terminal (+/-): Connect power cables of battery system with Inverter.

Communication Terminal (RS485 / CAN / RS232 / Link Port 0 / Link Port 1):

• RS485 Communication Terminal: (RJ45 port) follows RS485 protocol, for communication between battery system and inverter.
• CAN Communication Terminal: (RJ45 port) follows CAN protocol, for communication between battery system and inverter.
• Link port0/1: for communication between battery piles.
• RS232 Communication Terminal: (RJ45 port) for manufacturer or professional engineer to debug or service.

Definition of RJ45 Port Pin

Note: Other Pins must be NULL, otherwise it may influence the communication of the system.

2.3 System Diagram

[Diagram showing the system architecture with battery modules, control module, power switches, and communication connections.]

3. Installation

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
• Adjustable Wrench
• Sleeve Piece
• Multimeter

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

3.3 System Working Environments Checking

3.3.1 Cleaning

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.

3.3.2 Temperature

Force-L2 system working temperature range: 0℃~50℃; Optimum temperature: 18℃~28℃. Caution: Force-L2 system is out-door design. But please avoid frost or direct sunlight. 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. According to the environment, the cooling system or heating system should be installed if it is necessary.

3.3.3 Fire-extinguisher System

It will be better 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.

3.3.4 Grounding System

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), make sure the grounding of the cabin is stable and reliable. The resistance of the grounding system must ≤100mΩ.

3.4 Handling and placement

Single battery module is 35kg. If without handling tools, more than 2 men are required for handling.

3.4.1 Handling and placement of the base

The base is light; a single person can handle it.

3.4.2 Selection of installation sites

A. Force-L2 system working temperature range: 0℃~50℃; Optimum temperature: 18℃~28℃. Do not place the battery system in direct sunlight. It is suggested to build sunshade equipment. In cold areas, a heating system is required.

B. Force-L2 system must not be immersed in water. Cannot be placed the battery base in rain or other water sources. As a suggestion, the base's height should be >300mm above the ground.

C. The base's weight capacity should support the weight of the whole battery system (119~260kg).

3.4.4 Mounting and installation of the base

The base must be fixed installed on the basement with 4pcs M8×80 foundation bolts. [Diagram showing the battery rack basement holes bitmap with dimensions.]

3.4.5 Battery Modules and Control Module (BMS) pile up

[Diagram showing how to stack battery modules and the control module.]

Handle above the red marked edgings of the both sides of these battery modules and control module (BMS).

Caution: If hands are placed under this red marked side, hands will get hurt.

3.4.6 Installation of the fixed metal bracket for the system

In the control module's package, there are 2pcs Controller-2-modules-bracket, and 2pcs Base-2-modules-bracket. Fix these metal brackets at the both back side corners.

3.4.7 Locking of control module's fix screw of left and right side

Dismantle the Protection Cover of the Power Terminals.

3.5 Cables connection

Connect the power Terminal +/- to the inverter or the DC switches.

Danger: All the plugs and sockets of the power cables must not be reverse connected.

Danger: Do not short circuit or reverse connect the battery system's positive and negative port.

Caution: Wrong communication cables connection will cause the battery system failure.

Connect the communication cables between battery stacks: one by one from Stack last to Stack 1 (from LinkPort0 to Linkport1).

Connect the communication cable between the master battery stack (Stack 1) to the inverter.

The length of communication cable between stacks must be ≤2m.

It is recommended to use cables provided by Pylon; if not, a compatible water-proofed connector (M19-RJ45) is necessary.

[Diagram illustrating CAN and RS485 communication cable connections between stacks and to the inverter.]

3.5.1 Grounding

Connect the Force-L2 modules' grounding cable to the Cable Panel's grounding point.

Or use the M6 grounding bolt on the frame base.

Grounding cable must be ≥6AWG. The cable shall be copper with yellow-green color.

3.5.2 Cables

Note: Power cable uses water-proofed connectors. Communication cable uses RJ45 connector and water-proofed cover matched with the controller connection port.

For inverters following the same pin definition, the communication cable can be used directly. For inverters with different pin definitions or not using RJ45 ports, when changing the connector, please check the pin order and ensure undefined pins are not connected to each other or to the inverter.

[Diagrams showing cable specifications and connectors.]

3.5.3 System turns on

Warning: Double check all the power cables and communication cables. Make sure the voltage of the inverter is the same level as the battery system before connection. Check that all power switches of every battery system are OFF.

System turns on step:

1. Check all cables are connected correctly. Check grounding is connected.
2. Open the protective cover of the breaker and turn on the Power Switch first, then turn on the BMS Switch.
3. If the DC side has voltage higher than 48V, then the BMS will wake up by the inverter.
4. If the DC side does not have voltage, then press the start button for more than 5 seconds, and then wait.

It takes 10-30 seconds for BMS self-checking and waking up battery modules. Then the system is ready. You can touch the LED button and observe the LED flash.

Caution: When the breaker is tripped off because of over current or short circuit, please wait 30min before turning it on again, otherwise it may cause breaker damage.

Warning: If there is a failure during self-check, debug the failure before proceeding to the next step. If the "STATUS" lamp shows solid orange from the beginning, it means there is a failure in the battery string, and the Power Relays in the BMS will open. Debug must be performed first.

Note: The LED lamp will turn off in 20 seconds without any operation.

Caution: It is suggested to fully charge the entire Battery Energy Storage System (BESS) first after installation or after long-term storage without charging. Depending on the SOC level, there will be a regular (every 3 months) full charge request during continuous operation, which will be handled automatically by the communication between BESS and the external device.

After debugging, install the Protection Cover of the Power Terminals back.

3.5.4 System turns off

When there is a failure or before service, turn the battery storage system off:

1. Turn off inverter or power supply on the DC side.
2. Turn off BMS switch.
3. Turn off power switch.
4. Turn off switch between battery and inverter.

Under emergency conditions, it is suggested to turn off the switch between the battery system and the inverter first.

NOTE: After installation, DO NOT forget to register online for full warranty: www.pylontech.com.cn/service/support

4. System Debug

This system debug is for BESS system (Battery Energy Storage System). The BESS system cannot perform debug by itself. It must operate with a configured inverter, UPS, and EMS system together.

5. Maintenance

5.1 Trouble Shooting:

Check the environment first.

Once a certain failure is detected following the troubleshooting steps, shut down the battery string first before replacement to avoid further over-discharge to the system due to self-consumption.

5.2 Replacement of main component

Caution: Before replacing the main component, shut down the maintenance battery string's power. The shutdown progress refers to chapter 3.6.5.

5.2.1 Replacement of Battery Module

1. Use a charger (53.5Vdc, ≤ 10Amps) to charge the new battery module and existing module to full (SOC 100%).
2. Turn off the power of the entire battery string. Must confirm the D+ and D- terminals are without power. The turn-off progress refers to chapter 3.6.5. Dismantle the Protection Cover of the Power Terminals.
3. Dismantle D+ and D- Power Cable, Communication Cable, and Grounding Cable if necessary.
4. Dismantle the control Module's fix screws on the left and right sides. And dismantle the fix metal brackets.
5. Move the control module and each battery module one by one.

Handle above the red marked edgings of the both sides of these battery modules and control module (BMS).

Caution: If hands are placed under this red marked side, hands will get hurt.

Warning: Single battery module is 35kg. If without handling tools, more than 2 men are required for handling.

Caution: Before replacing the battery module for service, charge/discharge the replaced battery to the same voltage as other battery modules in the system. Otherwise, the system needs a long time to balance this new battery module.

6. Pile up the new battery module. Pile up the battery modules and control module again.
7. Install back the control Module's fix screws on the left and right sides. Install back the fixed metal brackets.
8. Install back Grounding Cable, Communication Cable, and the D+ and D- Power Cables.
9. Turn on this battery string. Refer to chapter 3.6.
10. After debugging, install the Protection Cover of the Power Terminals back.

5.2.2 Replacement of Control Module (BMS)

1. Turn off the whole battery string's power. Must confirm the D+ and D- terminals are without power. The turn-off progress refers to chapter 3.6.5.
2. Dismantle the Protection Cover of the Power Terminals. Dismantle D+ and D- Power Cable, Communication Cable, and Grounding Cable.
3. Dismantle the control Module's fix screws on the left and right sides. And dismantle the fixed metal brackets.
4. Remove the control module.
5. Pile up the new control module.
6. Install back the control Module's fix screws on the left and right sides. And install back the fixed metal brackets.
7. Install back Grounding Cable, Communication Cable, and the D+ and D- Power Cable.
8. Turn on this battery string. Refer to chapter 3.6.
9. After debugging, install the Protection Cover of the Power Terminals back.

5.3 Battery Maintenance

5.3.1 Voltage Inspection:

[Periodical Maintenance] Check the voltage of the battery system through the monitor system. Check if the system voltage is abnormal. For example: Single cell's voltage is abnormally high or low.

5.3.2 SOC Inspection:

[Periodical Maintenance] Check the SOC of the battery system through the monitor system. Check if the battery string's SOC is abnormal.

5.3.3 Cables Inspection:

[Periodical Maintenance] Visually inspect all the cables of the battery system. Check if the cables are broken, aging, or getting loose.

5.3.4 Balancing:

[Periodical Maintenance] The battery strings may become unbalanced if not fully charged for a long time. Solution: Every 3 months, perform balancing maintenance (charge to full). This is normally done automatically via communication between the system and the external device.

5.3.5 Output Relay Inspection:

[Periodical Maintenance] Under low load conditions (low current), control the output relay OFF and ON to hear the relay click. This indicates the relay can switch on and off normally.

5.3.6 History Inspection:

[Periodical Maintenance] Analyze the history record to check for accidents (alarms and protections) and analyze their reasons.

5.3.7 Shutdown and Maintenance:

[Periodical Maintenance] Some system functions require maintenance during the EMS restart. It is recommended to maintain the system every 6 months.

5.3.8 Recycle

NOTE: Damaged batteries may leak electrolyte or produce flammable gas. In case a damaged battery needs recycling, it shall follow the local recycling regulation (e.g., Regulation (EC) N° 1013/2006 among European Union) to process, and use the best available techniques to achieve relevant recycling efficiency.

6. Storage Recommendations

b) For long-term storage (more than 3 months), the battery cells should be stored in the temperature range of 5~45℃, relative humidity <65%, and in an environment free from corrosive gases. The battery module should be shelved in a dry, clean, and well-ventilated environment within the range of 5~45℃. Before storage, the battery should be charged to 50~55% SoC.

It is recommended to activate the chemical properties (discharge and charge) of the battery every 3 months, and the longest discharge and charge interval shall not exceed 6 months.

Caution: If the above instructions for long-term storage are not followed, the cycle life will be significantly reduced.

7. Shipment

Battery modules will be pre-charged to 60~70% SOC or according to customer requirements before shipment. The remaining capacity of the 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.

Any further questions, please contact Pylontech: service@pylontech.com.cn