Changhong Electric CH48400 User manual

CH48400 Battery Pack System
Product Manuel
Sichuan Changhong Battery Co., Ltd.
March,2019

Contents
1 Scope.......................................................................................................................................................1
1.1 Purpose.........................................................................................................................................1
1.2 Composition.................................................................................................................................1
1.3 Main technical parameters............................................................................................................1
2 Appearance..............................................................................................................................................2
3 System working principle and interface definition .................................................................................2
3.1 System working principle.............................................................................................................2
4 System usage..........................................................................................................................................3
4.1 System assemble ..........................................................................................................................3
4.2 System wiring...............................................................................................................................3
4.3 System charging parameters.........................................................................................................4
4.4 Power switch off...........................................................................................................................4
5 Threshold value of battery fault ..............................................................................................................4
6 Faulty and disposal methods...................................................................................................................6
7 Safety instruction .....................................................................................................................................8
8 Transportation.......................................................................................................................................9
9 Storage period........................................................................................................................................9
Annex..........................................................................................................................................................10

1
CH48400 Battery Pack System Product Manuel
1 Scope
1.1 Purpose
The CH48400 battery pack system (hereinafter referred to as the “system”) is a 48V system DC
chemical power source for backup applications produced by Sichuan Changhong Power Co., Ltd. The
power supply adopts lithium iron phosphate lithium-ion battery and comes with a battery management
system (BMS), which has the advantages of light weight, long cycle life, safe and reliable work.
1.2 Composition
The system is mainly composed of 16PCS IFP400 lithium ion cells, 1pcs battery management system,
power interface, LCD screen and battery container. The main block diagram is shown in Figure 1.
Figure 1. Main block diagram
1.3 Main technical parameters
Main technical parameters of the system are shown in table 1.
Table 1. Main technical parameters
No
Item
Technical parameters
1
System rated capacity
400AH
2
System nominal voltage
DC 51.2V
3
Battery core
3.2V/50Ah Lithium Iron Phosphate
4
System compound mode
8P, 16S
5
Battery pack voltage range
40～57.6V
6
Standard charge current
80A
7
Max charge current
150A
8
Standard discharge current
80A
9
Max discharge current
150A
10
Operation temperature in charge
0℃～+40℃
11
Operation temperature in discharge
-20℃～+40℃
12
Relative humidity
≤90%
CH48400 Battery Pack System
IFP400 Li-ion cells
BMS
Power interface
LCD
Container
IFP11200275 Punch cell
Cell container
Bus components
CMO
D
Working power module
Contactor
+ Interface
- Interface

2
No
Item
Technical parameters
14
Cabinet size L×W×H (mm)
441×900×432（See drawing 2）
15
Self-discharge rate
＜5%/month
Figure 2. System outline dimension drawing
2 Appearance
The system has no obvious deformation, no mechanical damage, no corrosion of interface contacts,
clear product identification, and clear identification of power interface
3 System working principle and interface definition
3.1 System working principle
System working principle see figure 3.

3
Figure3. System working principle
3.2 Power interface
The definition of power interface is shown in table 2
Table 2 Definition of power interface
No.
Interface
symbol
Interface definition
Fit wire
specification
Interface model
1
+
Output +
50mm2
REQ1-ZNT-A
2
-
Output -
50mm2
REQ1-ZFT-A
4 System usage
4.1 System assemble
System assembly method refer to annex CH48400 battery system assembly instructions.
4.2 System wiring
1）Make sure the system power switch is disconnected
2）Connect the positive and negative poles of the system with the electrical load or the charger.
3）The system can be charged and discharged after switch on and the fault free information of the
system is confirmed.
Electric switch
Prefill contactor control
Single cell voltage,
Temperature sampling
Hall current sensor
Prefill resistance
Charge contactor control
Discharge contactor control

4
Note: Before turning on the power-on switch, confirm that there is no voltage outside the system.
Otherwise, the system will report fault F2 after the system is turned on, the discharge relay is not
connected, the charging relay is turned on, and the system has no output.
4.3 System charging parameters
Charging voltage limit is 57.6V±0.5V, current limit is less than150A.
4.4 Power switch off
Because the BMS system itself has power consumption, if the system is vented, it should be
replenished in time. If the system is not used for a long time, the system should be shut down. Otherwise,
the system will consume its own power if it is in standby for a long time. If the standby time is too long, it
will lead to System over discharge, then damage the system.
5 Threshold value of battery fault
System faulty definition and threshold value of battery fault see table 3
Table 3 System faulty definition
Faulty
Grade
number
Fault
value
Time
delay
Recover
value
Time
delay
Options
Low insulation
resistance
＜
100Ω/V
All relays are not connected.
The system has no output and
the display screen shows F0
Prefill failure
Charge relay is connected. The
system has no output and the
display screen shows F2
High charging
voltage
Grade 1
Grade 2
≥3.6V
0S
≤3.55V
6S
LCD displays message 04
Grade 3
≥3.65V
0S
≤3.38V
（Max
single cell）
or
SOC≤90%
6S
LCD displays message 03.SOC
is 100% and the charging relay
is disconnected.
High
discharging
voltage
Grade 1
Grade 2
≥3.7V
15S
≤3.65V
6S
LCD displays message 0B
Grade 3
Low charge
voltage
Grade 1
Grade 2
≤2.0V
15S
≥2.5V
6S
LCD displays message 0C
Grade 3
Low discharge
Grade 1

5
Faulty
Grade
number
Fault
value
Time
delay
Recover
value
Time
delay
Options
voltage
Grade 2
≤3.0V
5S
≥3.05V
6S
LCD displays message 02
Grade 3
≤2.5V
0S
Have charge
current
6S
LCD displays message 01,
disconnect discharging relay
Large charging
voltage
difference
Grade 1
Grade 2
≥0.6V
5S
≤0.5V
6S
LCD displays message 0D
Grade 3
Large discharge
voltage
difference
Grade 1
Grade 2
≥0.8V
5S
≤0.6V
6S
LCD displays message 0E
Grade 3
Overheat when
charging
Grade 1
Grade 2
≥55℃
3S
≤50℃
4S
LCD displays message 05
Grade 3
≥65℃
1S
Not release
Disconnect charging relay
Overheat when
discharging
Grade 1
Grade 2
≥55℃
3S
≤50℃
4S
LCD displays message 06
Grade 3
≥65℃
1S
Not release
Disconnect discharging relay
Too low
temperature
when charging
Grade 1
Grade 2
≤5℃
5S
≥7℃
6S
LCD displays message 08
Grade 3
≤0℃
5S
≥5℃or
discharge
current ≥
10A
6S
LCD displays message 07,
disconnect charging relay
Too low
temperature
when
discharging
Grade 1
Grade 2
≤-10℃
5S
≥0℃
6S
LCD displays message 0A
Grade 3
≤-20℃
5S
≥-10℃
6S
LCD displays message 09,
Disconnect discharging relay
Temperature
sense line
Grade 1
Grade 2
open
circuit
20S
Close
6S
LCD displays message 0F
Grade 3
Charging flow
Grade 1
Grade 2
≥160A
2S
≤150A
4S
LCD displays message 20
Grade 3
≥200A
2S
Not release
Disconnect charging relay
Discharge flow
Grade 1
Grade 2
≥160A
2S
≤150A
4S
LCD displays message 21
Grade 3
≥200A
2S
Not release
Disconnecting discharge relay
Note: failure does not release the need to re-power

6
6 Faulty and disposal methods
Faulty and disposal methods see table 4.
Table 4. Faulty and disposal methods
LCD
display
Reason
Relay response
Disposal methods
F0
Low insulation resistance
detected when the system is
powered up
All relays are not
connected
Disconnect the power switch and
check if there is a short circuit
between the negative pole of the
system and the container. If it is,
disconnect the short circuit
connection between the negative pole
and the container immediately, and do
insulation treatment.
F2
Pre-charge failure
connect the charge
relay only
Before switch on, confirm that the
system positive and negative output
terminals have no voltage
01
System power is empties and
in discharge low voltage
protection.
Disconnect the
discharge relay
Connect the charger to charge.
02
System power will be empty.
Voltage of discharge cell is
lower than 3.0V.
/
Stop discharging or connect the
charger to charge, so that the single
voltage is higher than 3.05v
03
System power is full and in
high voltage charging
protection
Disconnect the
charge relay
The system works normally logic,
need not dispose.
04
The system power will be
fully charged, and the single
charging voltage is higher
than 3.6v
/
The system works normally logic, no
need to deal with.
05
Charge temperature is higher
than 55℃.
/
Stop charging, recharge after
temperature recovery.
The charging temperature is
higher than 65℃, and in high
charge temperature
protection.
Disconnect the
charge relay
①Check if the battery itself is hot, if
it is, stop using it immediately.
②Check if the system is in a high
temperature environment and ensure
that the system ambient temperature is
below 40 °C;
③Switch on the power again.
06
Discharge temperature is
higher than 55℃.
/
Stop charging and discharge when the
temperature is restored.
The discharge temperature is
higher than 65℃, and in high
Disconnect the
discharge relay
①Check if the battery itself is hot, if
it is, stop using it immediately.

7
LCD
display
Reason
Relay response
Disposal methods
discharge temperature
protection.
②Check if the system is in a high
temperature environment and ensure
that the system ambient temperature is
below 40 °C;
③Switch on the power again.
07
Charge temperature is lower
than 0℃, and in charge low
temperature protection.
Disconnect the
charge relay
①Check if the system is in a low
temperature environment and ensure
that the charging environment of the
system is higher than 0 °C
②Increase the temperature so that the
temperature is higher than 5 °C, or
connect the load discharge, the
discharge current is greater than 10A
08
The charge temperature is
lower than 5℃
/
Raise the temperature above 7℃.
09
The discharge temperature is
lower than -20 °C, and the
discharge is in low
temperature protection.
Disconnect the
discharge relay
①Check if the system is in a low
temperature environment and ensure
that the charging environment of the
system is higher than-20℃.
②Increase the temperature so that the
temperature is higher than-10℃.
0A
The discharge temperature is
lower than -10 °C
/
Raise the temperature above 0℃.
0B
The discharge voltage is
higher than 3.7V.
/
Continue to discharge until the
monomer voltage is lower than 3.65V
0C
The discharge voltage is
higher than 2.0V.
/
Continue charging until the single
voltage is higher than 2.5V
0D
Voltage difference of
charging unit is greater than
0.6V.
/
①Check that the battery screws are
tightened
②Check if the voltage difference of
the battery itself is too large. If it is .
Replace the cell caused by the
capacity
0E
Voltage difference of
discharging unit is greater
than 0. 8V
/
①Check that the battery screws are
tightened
②Check if the voltage difference of
the battery itself is too large. If it is .
Replace the cell caused by the
capacity
0F
Temperature sampling is on
open circuit.
/
Check whether the temperature sensor
is damaged (infinite resistance). If so,

8
LCD
display
Reason
Relay response
Disposal methods
replace the temperature sensor
20
Charge current is more than
160A.
/
Reduce the charger current so that the
current is less than 150A
Charge current is more than
200A.Charge current is in
protection.
Disconnect the
charge relay
Reduce the charger current so that the
current is less than 150A. Switch on
the power again.
21
Discharge current is more
than 160A
/
Reduce the load current so that the
current is less than 150A.
Charge current is more than
200A.Discharge current is in
protection.
Disconnect the
discharge relay
Reduce the load current, ensure that
the current is less than 150A. Switch
on the power again.
7 Safety instruction
In order to make sure battery's safety, and prevent it from any danger, please comply with the
following rules:
Avoid short circuit between positive terminal and negative terminal by wire and other metal object,
and avoid short circuit by wire object dropping into the system
Avoid any wet or water into the system.
Do not put the system into fire or heat the system. Do not use the system in an extremely hot
environment. Otherwise, the system will overheat, affecting performance and shortening the service
life.
Avoid any heavy vibrations during transportation and handling
Do not pierce the system with nails or other sharp objects. Prohibit hammering or pedaling systems
Do not place the system in a microwave oven or pressure vessel
It is inhibit to take the battery apart. The disassembly of battery could result in short circuit in battery,
or chemical decomposition and leakage, battery useless, even cause fire and explosion
If the system emits abnormal odor, heat, deformation, abnormal sound, discoloration or any other
abnormal phenomena, it shall not be used. If the system is in use or charging, it shall be taken out of
the appliance or charger immediately and stop using. Please send it to the manufacturer's authorized
unit for disposal or the relevant institution for proper handling.
If the system leaks or emits an odor, remove it immediately from the open flame.
Do not use organic solvents to clean the system enclosure.

9
Do not use carbon dioxide fire extinguishing when in fire. It can use carbon tetrachloride and other
fire extinguishing equipment or sand fire to put out the fire.
Smoking and ignition are strictly prohibited in the charging area of the system to avoid
explosion.
Do not disassemble the system. Disassembling the battery may cause internal short circuit, causing
decomposition of internal materials, fire, explosion, etc.; disassembly of the battery may cause
leakage of the battery electrolyte; if the electrolyte enters the eye after the battery leaks, do not wipe
it, immediately rinse with water, seek medical attention immediately; or your eyes will be hurt; the
battery that leaks electrolyte should stay away from fire and avoid exploding.
When the system is in use, do not connect the positive and negative poles in reverse.
System maintenance areas should be kept clean, dry, bright and ventilated.
When the battery power is insufficient, it should be charged in time, which will be beneficial to
extend the life of the system. If the system is not charged in time, it will affect the service life of the
system. If the system needs to be shelved for a long time, it is best to make the system in a
semi-electric state
Avoid closing to fire and flammable materials when charging the system.
8 Transportation
When the system is transported, Battery and container (including the BMS) are packed in ply
wooden boxes separately when transportation. In the process of transportation, it shall not be exposed to
the sun or rain by violent mechanical impact, and it shall not be inverted.
9 Storage period
The system should be stored in a dry, ventilated and clean warehouse.Avoid contact with corrosive
substances and away from fire and heat sources; The storage temperature should be in 5 °C ~ 40 °C, The
relative humidity should be less than 75% and the storage period should be within 1 year; Battery should
be in a half-charge state of about 50% to 60% when in storage process. To prevent over-discharge of the
battery, charge the system to 55V with the current of 80Aevery 3 months.

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10
Annex
CH48400 Battery pack system assembly instructions
1 Preparatory work
1.1 Material list
Annex1. CH48400 system battery pack Material list
No
Materiel and pictures
Qty
Note
1
Container and BMS
1set
2
IFP400 Li-ion cells
16pcs
3
Connector 1
14pcs

附件：CH48400 蓄电池组系统装配说明
11
4
Connector 2
1pcs
5
Output terminal
2pcs
6
M12 screw bolt group
2套
1.2 Tool preparation
Need to prepare cross-cutting knife, wrench, scissors, insulating tape and harness strap.
2 Split container and management system
2.1 Open the container cover
1）Remove the screws around the top of the container (16pcs screws in total, see the figure
below) and open the cover.

附件：CH48400 蓄电池组系统装配说明
12
2）The internal state after opening the cover is as shown below
2.2 Disconnect the BMS from the container
1）Remove the J1, J2, J3, and J4 sockets, disconnect the positive line from the fuse, and cut
off the white straps shown in the figure below.
r2BMS
Baffle
e
LCD

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13
2）Disconnect the power-on switch and the plug connector (INPUT+, INPUT-) on the
harness.
2.3 Take out the BMS and baffle
Remove the screws on both sides of the container (18pcs screws in total), take out the
management system and the baffle
White straps

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14
3 Battery module connection
3.1 The battery is loaded into the container
Remove the insulation board on IFP400 Li-ion battery, install 16pcs batteries into the
container as shown below, and fix the battery with the baffle.
3.2 Batteries in series
Connect 16pcs batteries in series with connector 1 and connector 2 as shown in the figure
below, and install the output terminals at the positive and negative terminals.
Sampling
cable

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15
3.3 Sampling row line installation
Install the J3 and J4 sampling line on the series battery module. The installation position is as
follows:
3.4 Insulation cover installation
Reinstall the battery insulation board removed in step 3.1 on the battery
J3
B1-
B1+
B2+
B3+
T1
B4+
B5+
B6+
B7+
T2
B8+
J4
B16+
B15+
T2
B14+
B13+
B12+
T1
B11+
B10+
B9-
B9+
Connector1
connecto
Output terminal

附件：CH48400 蓄电池组系统装配说明
16
4 System assembly
4.1 Fixed BMS
Put BMS into the container and fixed it with screws.
4.2 Insert row line
Insert the J1, J2, J3, and J4 cables into the corresponding positions on the BMS.

附件：CH48400 蓄电池组系统装配说明
17
4.3 Connect LCD
1）First remove the display and insert the display cable into the corresponding interface.
2）Reinstall the display and connect the EARTH line to the position shown below
4.4 Connect the total positive and total negative lines

附件：CH48400 蓄电池组系统装配说明
18
1）Connect the total negative line and BAT- line to the total negative output terminal with the M12
bolt assembly, and connect the total positive line and BAT+ line to the total positive output
terminal.
2）Connect the positive output line to the fuse
4.5 Connect the power switch
Plug the power on switch into the corresponding INPUT+ INPUT- plug on the wiring harness
4.6 Collate wiring harness
Collate the harness with a strap