GSC 640V2520AH User manual

USER MANUAL
640V2520AH
HIGH-VOLTAGE LITHIUM IRON
PHOSPHATE BATTERY
Version 1.0
NEW ENERGY TECHNOLOGY -- LIFE CHANGING

CONTENTS
I. Installation instructions.............................................................................................1
1.1 To carry or move................................................................................................ 1
1.2 Open-box inspections........................................................................................1
1.3 Installation........................................................................................................... 1
II. Main control interface introduction......................................................................... 7
2.1 Main interface..................................................................................................... 7
2.2 Single information interface..............................................................................8
2.3 Single cluster information interface.............................................................. 10
2.4 Alarm Information Interface............................................................................10
2.5 Single cluster control interface...................................................................... 11
III.Instructions for lithium battery charge.................................................................12
3.1 Electrical performance index......................................................................... 13
3.2 Instructions for use.......................................................................................... 13
IV. Product profile....................................................................................................... 22
V.Systemic statements.............................................................................................. 23
5.1. System composition....................................................................................... 23
5.2. System parameters........................................................................................ 23
5.3. Technical features........................................................................................... 24
5.4. Product Graphics and Technical Parameters............................................25
VI.Maintenance and troubleshooting.......................................................................29
6.1. Routine maintenance..................................................................................... 29
6.2. Notes.................................................................................................................29
VII.Lithium battery management requirements..................................................... 29
VIII.Warranty................................................................................................................32

1
384V500AH
640V2520AH
I Installation instruction
1.1 To carry or move
Lithium batteries in the carrying or movement process, should avoid inverted handling or
side sleeping handling, should be handled with care and to avoid collision
1.2 Open-box inspection
Check the battery for damage during transportation. Check the packing list (to actual
supply prevail)
N0.
Annex Name
Color/material/ specification
Quantity
Unit
Remarks
1
Battery power cable
Black
168
Piece
2
Core acquisition cable
4 P through wall terminals
24
Piece
3
Communication between battery modules
RJ 45 connector (network cable)
184
Piece
4
Communication cable
CAN cable
1
Piece
5
Grounding mark
φ5
Several
Piece
6
Ground wire
Yellow green
Several
Piece
7
Grounding screws
Stainless Steel
Combination M 5*12
Several
Piece
8
Front shade panel
48
Piece
9
Front panel support
96
Piece
10
Front fixing screws
Several
Piece
11
Battery Module Fixer
Stainless Steel
Combination M 5*12
Several
Piece
12
Connector assembly (Orange)
184
Piece
13
Connector assembly (Black)
184
Piece
1.3 Installation
1.3.1 Confirm the installation environment and location
The battery needs to be installed in a ventilated and dry environment. Considering that
the battery adopts natural air cooling, the battery should not be too close to the source of
heat, so as to ensure the ambient temperature and maintenance space around the battery
It is forbidden to place batteries in any of the following environments.
High temperature Rainfall Source of fire Corrosion Slope

2
2
640V2520AH
3-3
1.3.2 Installation
Put the battery rack in the specified position and fix it (pay attention to the direction of
the battery rack), and put the battery module on the shelf according to the battery layout
diagram, as shown below:
Partial drawing (module with label)
--------------------------------------------------------------------------------------------------
Battery module layout and power wiring connection drawing

3
384V500AH
640V2520AH
Battery module layout and signal cable connection diagram
--------------------------------------------------------------------------------------------------
Overall

4
4
640V2520AH
Battery modules must be placed in the specified order.
Battery module is heavy, in order to reduce the risk of injury, please do a good
job of protective measures.
After the battery module is arranged as required, connect each battery module according
to the battery line connection diagram.
If the battery module is placed for too long time, check the appearance of each battery
module for damage and deformation before wiring for safe operation and compliance.
Without the above situation, the voltage value of each battery module is measured by
multimeter in turn. When the maximum and minimum voltage difference of the battery
module exceeds 0.5 V, it can not be connected directly. The battery module needs to charge
and discharge separately so that the voltage difference is within 0.5 V.
When the battery module is connected in series, use the battery connection we provide
to ensure that the terminal positive (+) on the adjacent battery module is connected to the
negative (-), negative (-) to the positive (+) and tighten the bolt.
All wiring must be done by professionals.
1. Please follow the following steps to implement battery connection：
After it is stuck on the connector base,
tighten the bolts with an M 6 hex wrench.
Use a multimeter to measure the B+ and
B- of each battery module and the B+
and B- of the high-voltage package to
see if the voltage of each module is
basically the same and if the pressure
normal
Remove orange and
black connectors from
battery module
Connect the signal
lines and power
lines of each cluster
of battery modules
according to the
CAD drawings
Insert the connector
into the connectors

5
384V500AH
640V2520AH
2. Please follow the steps below to implement the power-on process:
Check the power lines between the battery packs and
whether the communication lines are properly
connected and fastened.
Set the multimeter to the DC voltage position, the red
test pen touches B+ of the battery cluster high voltage
control box, and the black test pen touches B- of the
battery cluster high voltage control box. Check whether
the voltage of each battery cluster tends to be the same
(the voltage difference is within 0.5V) and make sure it
is the positive voltage.
Close the battery breaker
BAT/SW of the fifth cluster,
power on the system with
weak current, and the display
screen on the system cabinet
starts to work, press the
ON/OFF button switch on the
system cabinet
Turn on the BAT/SW and
RUN buttons of the battery
circuit breakers of each
cluster in turn, then BAU will
check whether each BCU is
online normally, and the
system will self-check
The power lines P+ and P- of each cluster are connected to the system
cabinet according to the CAD drawings.
Set the multimeter to the
electric blocking position,
and the red and black test
leads respectively touch the
two poles of the debugging
CAN port (regardless of
positive and negative), and
confirm whether the
resistance value is about 60
Ω

6
6
640V2520AH
When connecting a longer battery connection cable, when one end terminal
is fixed, be sure to hold the other end of the battery connection to prevent
danger from falling off against the same pole of other battery modules.
3. List of tools required for installation:
No.
Annex Name
Color/material/specification
Quantity
Unit
Remarks
1
Insulation gloves
Several
pair
2
Protective gloves
Several
pair
3
Flat head screwdrive
φ3
1
pcs
4
Cross screwdriver
Routine
1
pcs
5
Inner hexagonal
wrench
M6
1
pcs
6
Multimeter
1
pcs
7
Insulation tape
Black
1
pcs
8
Banding
Black
1
Bag
The system self-check is correct, the high
voltage power on, the system is running
normally, the running indicator RUN on the
system cabinet is always on, the battery
information of each cluster is summarized
on the system cabinet display, the charge
and discharge relay is enabled, and the
charging on the display (Allow Charge)
The discharge (Allow Discharge) indicator
light is always on, the battery can be
charged and discharged normally, and the
battery is powered on.
It is better to use a temperature
measuring gun to test the
temperature on the connector
after powering on for a period of
time to prevent the temperature of
the wiring connection from rising
due to the bolts being not
tightened, which may cause
safety hazards

7
384V500AH
640V2520AH
II、Main control interface introduction
2.1 Main interface：
2.1.1 Key function：
The position of each button on the main interface is as shown in the figure below：
The specific function description of each serial number button：
(1)Restart the display control screen function, which can be used to solve the display
control screen display data stuck screen.
(2)Chinese and English bilingual switching function.
(3)Cut into the main interface function.
(4)Cut into the alarm interface function.
(5)Cut into the single cluster information interface function.
(6)Cut into the battery cell information interface function.
(7)Switch into the single-cluster strong control interface function. (Non-our engineers
please do not use)

8
8
640V2520AH
2.1.2 Status display：
The location of each display data on the main interface is as shown below：
Detailed description of each display data on the main interface：
(1)Overall general data: SOC, overall current, voltage, actual total capacity, dry contact
signal of charge and discharge (green light indicates permission).
(2)The three data from left to right indicate in turn: the actual number of high-voltage
access clusters, the actual number of clusters with normal communication, and the
total number of clusters with full configuration.
(3)The last piece of data specifically shows: a gray light indicates that the cluster is not
connected, a yellow light indicates that the cluster's CAN communication access is
normal, and a green light indicates that the cluster's high-voltage access is normal.
2.2 Single information interface：
2.2.1 Key function：
The position of each button on the unit information interface is as follows：

9
384V500AH
640V2520AH
Specific function description of each serial number button：
(1)Restart the display control screen function, which can be used to solve the display
control screen display data stuck screen.
(2)Selection of cluster serial number to be queried: Select to query the individual
information of the cluster, and enter the number selection by clicking the pop-up
keyboard.
(3)Switching interface function: See the main interface button function introduction for
details.
(4)Single information page turning function.
2.2.2 Data display：
The position of each display data in the unit information interface is as shown below：

10
10
640V2520AH
Detailed description of each display data：
(1)Display the cell voltage information of the cluster.
(2)Display the collected temperature information of each temperature sensor of the
cluster.
2.3 Single cluster information interface：
2.3.1 Key function：
For the location and function of each button on the single cluster information interface,
see the description of the buttons on the single information interface
2.3.2 Data display：
The position of each display data in the unit information interface is as shown below：
Detailed description of each display data：
(1)Display the general information of the cluster: SOC, total voltage and current of the
cluster.
(2)Display the highest and lowest voltage and location of the cluster, and display the
highest and lowest temperature and location of the cluster.
2.4 Alarm Information Interface：
2.4.1 Key function：
For the location and function of each button on the alarm interface, see the description of
the buttons on the single information interface

11
384V500AH
640V2520AH
2.4.2 Data display：
The position of each data displayed on the alarm interface is as shown in the figure
below：
This interface mainly displays the fault information of the cluster：
Indicate normal
Indicate first-level fault
Indicate secondary-level fault
Indicate three-level fault
The severity of the fault level is: 3> 2> 1.
2.5 Single cluster control interface：
Click the strong control button on the main interface and enter the corresponding
password in the pop-up keyboard interface (the initial password is 8888) to enter the strong
control interface.
This interface can force a designated single cluster to connect to high
voltage and control its dry contact for charging and discharging. Please use
it with caution while ensuring safety.

12
12
640V2520AH
2.5.1 Key function：
The position of each button on the strong control interface is as shown in the figure
below：
Specific function description of each serial number button：
(1)Restart the display control screen function, which can be used to solve the display
control screen display data stuck screen.
(2)Forced control buttons, from left to right, are: cluster number to be strongly controlled,
forced switch control button, charge dry contact enable, discharge dry contact
enable, power-on self-test minimum allowable number of communications options.
(3)The specific steps for strong control are: select the cluster number to be controlled ->
click the strong control switch button to turn it on, and if it succeeds, the
corresponding cluster indicator in the lower display box will light up green -> click
the dry contact of charge and discharge control charging and discharging——>Click
the strong control switch button again after completion to turn off the strong control
function. At this time, the BAU needs to be restarted and powered on for normal
control.
(4)Switching interface function: see the main interface button function introduction for
details.
III. Instructions for lithium battery charger (Optional)
This product is a non-standard customized product, specially designed for the charging
of our company's lithium battery pack. It has a dedicated detection network port
communication to prevent damage to the lithium battery from excessive charging voltage,

13
384V500AH
640V2520AH
and is equipped with a display that can intuitively display the output voltage, current and
protection functions , The detailed description is as follows:
3.1 Electrical performance index
Product model: APSP-LI-80V50A
Input power: three-phase 380Vac 45--65HZ
Input current: 10A
Input power: 5KVA
Output voltage range: 30--100V
Output current range: 5--50A
Rated power: 4KW
Product size: 560*430*600 (mm)
Weight: 50KG
Production date: December 2020
3.2 Instructions for use
3.2.1 Wiring and switch instructions
Open the side panel of the machine
As shown in the figure, connect to the communication lines separately
485 communication
line
cable

14
14
640V2520AH
Connect the positive and negative poles of the battery here
Open the rear panel of the host
After connecting the three-phase input line, fix the switch on the rear panel to complete
the wiring
A. The input terminal (yellow, green and red) is connected to three-phase power,
B. The output terminal (red and black) is connected to the lithium battery pack,
C. The communication signals (network cable and RS485) are respectively connected to the
panel of the lithium battery pack
Three-phase
input line

15
384V500AH
640V2520AH
As shown in the figure:
3.2.2 Display description
A. After booting, the panel will display the following
The main interface will display the basic information of the machine and fault information

16
16
640V2520AH
B. On the main screen, click the upper left corner to enter the maintenance options as
Follows
Maintenance options include:
parameter settings

17
384V500AH
640V2520AH
Enter the management password 123456 and enter the settings
Then enter the password setting, you can modify the password to ensure safety

18
18
640V2520AH
Or enter the module settings
You can set the system minimum voltage, maximum current, maximum voltage, and BMS
voltage into the protection settings, which can limit the output over-voltage, output under-voltage,
and output over-current settings of the machine