Pylontech UP2500 Rechargeable Lithium-Ion Battery Product Manual

1. Safety Precautions

Reminding: 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, or death, or can damage the battery, potentially rendering it inoperable.

• If the battery is stored for a long time, it is required to charge it every six months, and the State of Charge (SOC) should be no less than 90%.
• Battery needs to be recharged within 12 hours after fully discharged.
• Do not expose cables externally.
• All battery terminals must be disconnected for maintenance.
• Please contact the supplier within 24 hours if there is something abnormal.
• Do not use cleaning solvents to clean the battery.
• Do not expose the battery to flammable or harsh chemicals or vapors.
• Do not paint any part of the battery, including any internal or external components.
• Do not connect the battery with PV solar wiring directly.
• Warranty claims are excluded for direct or indirect damage due to the above items.
• Any foreign object is prohibited from insertion into any part of the battery.

Warning:

1.1 Before Connecting

• After unpacking, please check the product and packing list first. If the product is damaged or lacks parts, please contact the local retailer.
• Before installation, be sure to cut off the grid power and ensure the battery is in the turned-off mode.
• Wiring must be correct. Do not mistake the positive and negative cables, and ensure no short circuit with the external device.
• It is prohibited to connect the battery and AC power directly.
• The embedded Battery Management System (BMS) in the battery is designed for 24VDC. Please DO NOT connect batteries in series.
• The battery system must be well-grounded, and the resistance must be less than 1Ω.
• Please ensure the electrical parameters of the battery system are compatible with related equipment.
• Keep the battery away from water and fire.

1.2 In Using

• If the battery system needs to be moved or repaired, the power must be cut off, and the battery must be completely shut down.
• It is prohibited to connect the battery with a different type of battery.
• It is prohibited to use batteries with a faulty or incompatible inverter.
• It is prohibited to disassemble the battery (QC tab removed or damaged).
• In case of fire, only dry powder fire extinguishers can be used; liquid fire extinguishers are prohibited.
• Please do not open, repair, or disassemble the battery except by Pylontech staff or authorized personnel. Pylontech does not undertake any consequences or related responsibility due to violations of safety operations or design, production, and equipment safety standards.

2. Introduction

The UP2500 lithium iron phosphate battery is a new energy storage product developed and produced by Pylontech. It can support reliable power for various types of equipment and systems. The UP2500 is especially suitable for application scenarios requiring high power, limited installation space, restricted load-bearing, and long cycle life.

The UP2500 has a built-in BMS that can manage and monitor cell information, including voltage, current, and temperature. The BMS can also balance cell charging and discharging to extend cycle life.

Multiple batteries can be connected in parallel to expand capacity and power, allowing for longer duration requirements.

2.1 Features:

• The whole module is non-toxic, non-polluting, and environmentally friendly.
• Cathode material is made from LiFePO4, ensuring safety performance and long cycle life.
• The BMS has protection functions including over-discharge, over-charge, over-current, and high/low temperature.
• The system can automatically manage charge and discharge states and balance the current and voltage of each cell.
• Flexible configuration allows multiple battery modules to be connected in parallel for expanding capacity and power.
• Adopted self-cooling mode rapidly reduces system noise.
• The module has low self-discharge, can be stored for up to 6 months without charging, has no memory effect, and offers excellent performance in shallow charge and discharge.
• The working temperature range is from -10°C to 55°C (Charging 0°C~55°C; Discharging -10°C~55°C), with excellent discharge performance and cycle life.
• Small size and light weight, with a standard 19-inch embedded design, making it comfortable for installation and maintenance.

2.2 Specifications

A diagram shows the dimensions and connections of the UP2500 module.

2.3 Equipment Interface Instruction

This section details the front panel interface functions of the UP2500.

UP2500 Product Front Interface: A diagram shows the front panel with ports and indicators.

Power Switch: To turn ON/OFF. ON: the battery is in standby mode with no power output.

SOC (State of Charge): 4 green LEDs indicate the battery's current capacity.

Alarm: A YELLOW LED flashing or lighting indicates an alarm. It combines with SOC LEDs to show the type of alarm. Refer to the 'LED Instructions' table.

Protection: A RED LED indicates the battery is under BMS protection. It combines with SOC LEDs to show the type of protection. Refer to the 'LED Instructions' table.

LED Status Indicators

It is important to check the detailed alarm/protection definitions in the table below for troubleshooting and maintenance.

Start

Start Button: Press more than 2 seconds to Start/Off the battery module.

ADD Switch

ADD Switch: 4 ADD switches (DIP switches) are used to define the different baud rates. 'OXXX' setup the bond rate to 115200, and '1XXX' setup the baud rate to 9600. The setting will be active only after restarting the battery. Every battery module needs to have its DIP switch set to configure the RS485 baud rate. In a group, all battery settings should be the same.

Console

Console Communication Terminal: (RJ11 port) follows RS232 protocol, for manufacturer or professional engineers to debug or service.

L 0/1 / RS485

Link Port 0/1 or RS485 Communication port: Follows RS485 protocol for communication between the master battery and host equipment. It connects all batteries as a group.

Definition of RJ45 Port Pin

When connecting to host equipment, pins 1-5 should be NULL.

A diagram shows the RJ45 port and plug.

Definition of RJ11 Port Pin

A diagram shows the RJ11 port and plug.

Power Terminals +/-

Power cable terminals: There are two pairs of terminals with the same function. One connects to the equipment, and the other parallels to other battery modules for capacity expansion. For each module, each terminal can achieve charging and discharging functions.

For power cables, water-proofed connectors are used. Please keep pressing the Lock Button [?] during pulling out the power plug.

BMS function:

3. Safe Handling of Lithium Batteries Guide

3.1 Schematic Diagram of Solution

A diagram illustrates a typical system setup including PV Array, Inverter, Battery Module, Local Load, and Public Grid.

3.2 Explanation of Symbol

DANGER: LOW DC VOLTAGE INSIDE, DANGER ARC FLASH & SHOCK HAZARD

• Do not disconnect or disassemble by non-professional personnel.
• Do not drop, deform, impact, cut, or spear with a sharp object.
• Do not place in areas accessible to children or pets.
• Do not place near open flames or flammable materials.
• Do not cover or wrap the product case.
• Do not sit on or place heavy objects on the battery.
• Do not touch leaking liquid.
• Avoid direct sunlight.
• Avoid moisture or liquid.
• The product's Ingress Protection (IP) class is IP20.
• Ensure the grounding connection is set correctly before operation.
• Follow the product manual for wiring connections.
• If leaking, on fire, wet, or damaged, switch off the breaker on the DC side and stay away from the battery.
• Contact your supplier within 24 hours if any failure occurs.

3.3 Tools

The following tools are required to install the battery pack:

• Wire cutter [✂️]
• Crimping Modular Plier [?]
• Screw Driver [?]

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.

3.4 Safety Gear

It is recommended to wear the following safety gear when handling the battery pack:

• Insulated gloves [?]
• Safety goggles [?]
• Safety shoes [?]

4. Installation

4.1 Package Items

Unpacking and check the Packing List

1) For battery module package:

Two power cables and one communication cable for each battery package.

A diagram shows the power cables (180mm and 210mm) and communication cable.

Grounding cable:

A diagram shows the grounding cable (1000mm).

Grounding cables use 10AWG yellow-green cables.

UP2500 modules' grounding is achieved by direct metal contact between the module's surface and the rack's surface. If using a standard rack, ensure the paint at the connection point is removed, or install a grounding cable to the grounding point of the modules.

A diagram shows the power switch and grounding point on the module.

2) For battery system connects to inverter:

Two long power cables (current capacity 120A) and one communication cable for each energy storage system.

A diagram shows longer power cables (2000mm) and a communication cable (3500mm).

NOTE: These three long cables are NOT included in the battery package; they are in a separate small cable box. If anything is missing, please contact the dealer.

4.2 Installation Location

Make sure that the installation location meets the following conditions:

• The area is completely waterproof.
• The floor is flat and level.
• There are no flammable or explosive materials.
• The ambient temperature is within the range of 0°C to 50°C.
• The temperature and humidity are maintained at a constant level.
• There is minimal dust and dirt in the area.

CAUTION: If the ambient temperature is outside the operating range, the battery pack stops operating to protect itself. The optimal temperature range for the battery pack to operate is 0°C to 50°C. Frequent exposure to harsh temperatures may deteriorate the performance and life of the battery pack.

Installation

A. Put battery modules into cabinet and connect the cables:

A diagram shows multiple UP2500 Lithium Battery Modules installed in a cabinet.

A diagram illustrates the connection of multiple battery modules within a cabinet, showing power cables and grounding cables. It indicates connections to the inverter and screw points.

Instructions:

1. Put the battery into the cabinet.
2. Drive the 4 screws.
3. Connect the cables between battery modules. If used.
4. Connect the cables to the inverter.

Note: The power cables' current capacity is 120A. If the battery string's current exceeds this limit, configure 2 pairs of external power cables to reach 240A.

B. Power On

Double-check all power and communication cables.

(1) Switch power on:

Switch on all the battery modules.

A diagram shows the front panel of a UP2500 module with the power switch in the ON position.

(2) The module with an empty 'LO' port is the Master Battery Module. Others are slaves (1 master battery can configure with a maximum of 19 slave batteries). Connect the Master Battery Module's RS485 to the inverter.

Diagrams show the connection from the Master Battery Module's RS485 port to the inverter.

(3) Press the Start Button (red button) of the master battery to power on. All battery LED lights will turn on one by one, starting from the Master battery.

A sequence of diagrams shows the LED lights turning on progressively across multiple battery modules.

If all the battery LED lights turn on and then off, it means the battery system is good and working.

5. Trouble Shooting Steps

Please always check the 'LED Indicators Instructions' table for detailed fault definitions before performing any troubleshooting steps.

5.1 Problem determination based on:

1. Whether the battery can be turned on or not.
2. If the battery is turned on, check if the red and yellow lights are off, flashing, or lit.
3. If the red light is off, check whether the battery can be charged/discharged or not.

5.2 Preliminary determination steps:

1. Battery cannot turn on, all lights are off or flashing: If the battery external switch is ON and the external power supply voltage is 26V or more, but the battery still fails to turn on, please contact the distributor.
2. The battery can be turned on, but the red light is lit, and it cannot charge or discharge: If the red light is lit, it indicates a system abnormality. Please check the following values:
   • a) Temperature: Above 55°C or below -10°C, the battery cannot work. Solution: Move the battery to the normal operating temperature range between -10°C and 55°C.
   • b) Current: If the current is greater than 100A, battery protection will activate. Solution: Check if the current is too high; if so, adjust the settings on the power supply side.
   • c) High Voltage: If the charging voltage is above 28.5V, battery protection will activate. Solution: Check if the voltage is too high; if so, adjust the settings on the power supply side.
   • d) Low Voltage: When the battery discharges to 23.2V or less, battery protection will activate. Solution: Charge the battery for some time; the red light should turn off.
   If the fault cannot be located after checking the above four points, turn off the battery's power switch and seek repair.

5.3 The battery cannot be charged or discharged

1. Cannot be charged: Disconnect the power cables, measure the voltage on the power side. If the voltage is 28.2~28.5V, restart the battery, reconnect the power cable, and try again. If it still does not work, turn off the battery and contact the distributor.
2. Unable to discharge: Disconnect the power cables and measure the voltage on the battery side. If it is <23.2V, please charge the battery. If the voltage is above 25V and it still cannot discharge, turn off the battery and contact the distributor.

6. Emergency Situations

1) Leaking Batteries

If the battery pack leaks electrolyte, avoid contact with the leaking liquid or gas. If exposed to the leaked substance, immediately perform the actions described below:

• Inhalation: Evacuate the contaminated area and seek medical attention.
• Contact with eyes: Rinse eyes with flowing water for 15 minutes and seek medical attention.
• 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

NO WATER! Only dry powder fire extinguishers can be used. If possible, move the battery pack to a safe area before it catches fire.

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.

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 appears to be damaged, pack it in its original container and return it to Pylontech or an authorized dealer.

NOTE: Damaged batteries may leak electrolyte or produce flammable gas. If such damage occurs, please contact Pylontech: service@pylontech.com.cn