Pylon Technologies BP Series User manual

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BP Series
Lithium-Iron Phosphate Battery Backup
Product Manual
Information Version: 1.0
Pylon Technologies Co., Ltd.
No. 73, Lane 887, Zu Chongzhi Road, Zhangjiang Hi-Tech Park
Pudong, Shanghai 201203, China
Zip Code: 201203
Phone: [phone]
Fax: [phone]
URL: http://www.pylontech.com.cn
E-mail: [e-mail].

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LEGAL NOTICES
Copyright of Pylon Technologies Co., Ltd. Enjoin from abstracted reproduced or translated
by any unit or individual in any way without the written permission.
Rights Reserved.
The trademarks of Pylon Technologies Co., Ltd are
and . The names and logos of products from Pylontech are exclusive
belongs to Pylon Technologies Co., Ltd, proprietary marks or registered trademarks. Other
products or company names mentioned in this manual may be belonging to trademarks of
their respective owners or tradenames. Without the prior written consent of the Pylontech
or third party trademarks or owners of tradenames, this manual does not confer the
license or right by the reader to use any mark appeared on this manual in any way.
This product accord with the design requirements of environmental protection and
personal security, product storage, using and disposal should be in accordance with
product manuals, relevant contract and national laws.
When required product updates or technical changes, you can visit website of Pylontech
for the latest information, URL: http://www.pylontech.com.cn, without notice if the product
improvements or technical change in other way.
Information Version: V1.0
Information Number: MKT-BPSC1-201201

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Introduction
Manual Explains
BP series (V1.3) lithium iron phosphate battery is power module for backup system and
energy storage system. In backup power system, the main power provides energy for
equipment and charging the battery; when power off, battery provides energy. While in
energy storage system, battery charging or discharging can be managed by system,
users can choose energy from solar panel, main power or battery, it saves energy cost.
BP series Product Manual exposited the basic processes and methods of the device,
includes structure, parameters, installation and operation. The main content following:
Chapter
Abstract
Chapter 1 Introduction
Main application and features of BP48100
Chapter 2 Structure and
Parameters
External structure, panel description, management module
parameters and others
Chapter 3 Installation and
Collocation
Product installation, network usage and requires attention in
installation process of BP48100
Chapter 4 Maintenance and
Troubleshooting
Common operating state descriptions and Troubleshooting of
BP48100
Safety Instructions
This device only be installed, operated and maintained by people who professional trained
and qualified. In the process of installation, operation and maintenance, local safety
regulations and related procedures must be complied, or it may cause injury or equipment
damage. Safety precautions mentioned in manual only as a supplement for local safety
regulations. Pylontech does not assume any responsibility for breaching common security
operation or equipment safety standards.
Symbols
The following format described some contents need attention for BP series
Note: If warning ignored, the product may malfunction.

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Catalogue
1 INTRODUCTION...............................................................................................................................1
1.1 Introduction.......................................................................................................................... 1
1.2 Product Features................................................................................................................ 1
2 STRUCTURE AND PARAMETER................................................................................................. 3
2.1 Equipment Structure.......................................................................................................... 3
2.1.1 Equipment Model............................................................................................................... 3
2.1.2 Equipment Front Interface Instruction............................................................................ 4
2.2 Battery Management System（BMS）.......................................................................... 7
2.2.1 Voltage Protection.............................................................................................................. 7
2.2.2 Current Protection.............................................................................................................. 7
2.2.3 Additional Protection Features.........................................................................................7
2.3 Charge Parameters............................................................................................................8
2.4 Discharge Parameters....................................................................................................... 8
3 INSTALLATION AND CONFIGURATION....................................................................................9
3.1 Installation Preparation......................................................................................................9
3.1.1 Environmental Requirements........................................................................................ 10
3.1.2 Tools and Information...................................................................................................... 11
3.1.3 Technical Preparation...................................................................................................... 11
3.1.4 Unpacking......................................................................................................................... 12
3.1.5 Project Coordination........................................................................................................12
3.2 Equipment Installation..................................................................................................... 13
3.2.1 Mechanical Installation....................................................................................................13
3.2.2 Electrical Installation........................................................................................................14
4 USING, MAINTENANCE AND TROUBLESHOOTING............................................................19
4.1 Alarm Description and Processing................................................................................ 19
4.1.1 The Alarm and Countermeasure Influence System Output..................................19
4.1.2 The Alarm and Countermeasure do not Influence System Output..................... 19
4.2 Common Fault Analysis and Solutions.........................................................................20

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Catalogue of Diagrams
Figure 2-1 Sketch of BP series Product Front Interface................................................. 4
Figure 3-1 Schematic of Installation Process:.............................................................. 10
Figure 3-2: Schematic of Device Fixed to the Cabinet................................................14
Figure 3-3 Multiple Batteries in Parallel Power Line Connection Diagram:.............15
Figure 3-4 Connection Diagram Interface between Battery and Load Equipment of
DC Backup Power..............................................................................................................16
Figure 3-5 Battery and Switch Power Connection Diagram.......................................16
Figure 3-6 Cascading of Multiple Batteries in Parallel Network Schematic.............17

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Catalogue of Table
Table2-1 BP series Equipment Model............................................................................3
Table 2-2 Definition of RS232 Port Pin.........................................................................5
Table 2-3 ADD Switch......................................................................................................5
Table 2-4 LED Indicators Instructions...........................................................................6
Table 2-5 Charging Parameters.....................................................................................8
Table 2-6 Discharging Parameters................................................................................8
Table 3-1 Tools and Meters.......................................................................................... 11
Table 3-2 Installation Steps.......................................................................................... 13
Table 4-1 Major Alarm and Protection........................................................................ 19
Table 4-2 Secondary Alarm.......................................................................................... 20
Table 4-3 Common Faults and Solutions...................................................................20

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1Introduction
1.1 Introduction
BP series lithium iron phosphate battery are new energy storage products
developed and produced by Pylontech according to market demand, it can be used
to provide reliable power for various types of equipment and solar systems. BP
series are especially suitable for application scene of high temperature, limited
installation space, light load-bearing and long cycle life.
BP series has built-in BMS battery management system, which can manage and
monitor cell information including voltage, current and capacity. What’s more, BMS
can balance cells charging and discharging and extend cycle life. Multiple batteries
can be connected for larger capacity in parallel for longer duration backup
requirements.
1.2 Product Features
BP series product from Pylontech is using lithium iron phosphate as cathode
material, with BMS for effective management of cells. The module has following
characteristics:
New: Updated the MCU and AFE chips, has stronger anti short circuit and
reversed connection function. It will lower the fuse or MOSFET failure;
New: 1 group can maximum 16 batteries connected in;
New: More memory capacity, now it is 12288 records (before was only 4096
records).
The whole module is non-toxic, non-polluting and environmentally friendly;
Cathode material is made from LiFePO4 which has safety performance and long
cycle life;
Battery management system (BMS) has protection function for over-discharge,

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over-charge, over-current and high/low temperature;
The system can automatically manage charge and discharge state and balance
current and voltage of each cell;
The centralized monitoring module is intelligent designed with three remote
functions of test, signal and control;
Flexible configuration achieved that several battery modules can be in parallel for
expanding capacity and backup duration;
Adopted self-cooling mode rapidly reduced system entire noise;
Battery has less self-discharge, without charge up to 10 months; no memory effect,
can be floating charge and discharge;
Working temperature range is from -10 ℃to 50 ℃, with excellent discharge
performance and cycle life in high temperature;
Small size and light weight, standard of 19-inch embedded designed module is
comfortable for installation and maintenance;

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2Structure and Parameter
2.1 Equipment Structure
2.1.1 Equipment Model
BP4850
BP48100

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Table2-1 BP Series Equipment Model
Product
Series
Model
Rated
Voltage
Rated
Capacity
Size
Weight
BP Series
BP4850
48V
50Ah
442×380×88.5mm
24kg
BP Series
BP48100
48V
100Ah
442×385×176mm
45kg
2.1.2 Equipment Front Interface Instruction
This section details the front panel of the interface functions.
Figure 2-1 Sketch of BP series Product Front Interface
Power Port (1)
Power cord connection: the same function of two power interface in parallel.
Each interface from top to bottom is anode and cathode. For each single cell,
any interface can achieve charging and discharging function.
Reset (2)
Shut down button: When the battery is in storage, transportation and other
non-using state, press the button to shutdown. If there is no external load or
external power supply for 10 hours, it will automatically shutdown.
Communication Interface (3, 4, 5, 6)
Dry Contact (DO).
RS232 port (No. 4, Figure 2-1): The interface is for the local network
management, but can also be the docking tube interface of network with ONU
equipment from ZTE.

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RS485 A/B port (No. 3, Figure 2-1): when using multiple batteries in parallel,
cascade each RS485 interface, information of other packs can be checked
from the main pack. The definition of main battery and others please check
“ADD Switch Table 2-3."
ADD Switch (7)
ADD Switch: 4 ADD switches, to definite different address code for each
battery module when network cascade multiple batteries, up to 16 addresses.
The coding and description see "Table 2-3 ADD Switch."
Table 2-3 ADD Switch
ADD No.
Switch 1
Switch 2
Switch 3
Switch 4
1
OFF
OFF
OFF
OFF
2
OFF
OFF
OFF
ON
3
OFF
OFF
ON
OFF
4
OFF
OFF
ON
ON
5
OFF
ON
OFF
OFF
6
OFF
ON
OFF
ON
7
OFF
ON
ON
OFF
8
OFF
ON
ON
ON
9
ON
OFF
OFF
OFF
10
ON
OFF
OFF
ON
11
ON
OFF
ON
OFF
12
ON
OFF
ON
ON
13
ON
ON
OFF
OFF
14
ON
ON
OFF
ON
15
ON
ON
ON
OFF
16
ON
ON
ON
ON
Note: Recommend is 1111 (ADD No. 16).

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LED Status Indicators (8)
RUN Lamp (No.6 Figure 2-1): green, long lighting when charging and flash
when discharging;
ALM Lamp (No. 7 Figure 2-1 7): red, flashes when alarm and long bright if
equipment failure or protected;
Battery capacity indicator (No. 8 Figure 2-1): 4 green lamps, each light
represent 25% of capacity. The four lights lit when capacity is 100%, if 75%,
the first left a lamp off, and the right three lights; if 50%, the left two lights out,
the right two lights; if 25 %, the left three lights off, the right one lights.
Table 2-4 LED Indicators Instructions
Battery
Statues
Protection
/ Alarm /
Normal
RUN
ALM
Capacity LED
Descriptions
●
●
●
●
●
●
Shut Down
Off
Off
Off
Off
Off
Off
All off
Standby
Normal
Flash1
Off
Off
Off
Off
Off
Indicates Standby
Alarm
Off
Flash3
Off
Off
Off
Off
PACK Low Voltage
Directive
Charge
Normal
Light
Off
Based on capacity
the right side
indicator LED
flashes (flash 2),
others lighting
Alarm
Light
Flash3
Protection
Off
Light
Off
Off
Off
Off
Stop charging, ALM
lighting
Discharge
Normal
Flash3
Off
Based on capacity
Alarm
Flash3
Flash3
Indicate based on
capacity
Protection
Off
Light
Off
Off
Off
Off
Stop discharging,
ALM lighting
Note: The flashing instructions, flash 1 - light 0.25s / off 3.75 seconds; flash 2 - 0.5s light / 0.5s
off; flash 3 - 0.5s light / 1.5s off

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2.2 Battery Management System（BMS）
2.2.1 Voltage Protection
Low Voltage Protection in Discharge:
When discharging, the protection starts if any one of the single cells has lower
voltage than the setting value and the power supply stop. When voltages of all
single cells return to the normal, protection removed.
High Voltage Protection in Charge
When charging, the system stops charging when the total voltage of the
battery or any one cell over the voltage value. When total voltage and cell
voltage are restored to the normal, protection removed.
2.2.2 Current Protection
Over-current Protection in Charge:
If the charging current is larger than the guard value, the system stops
charging. Protection removed after the system delay time.
Over-current Protection in Discharge:
When the discharge current is greater than the protection value, discharge
stopped. Protection removed after the system delay time.
Charging Current Limit:
To ensure the load equipment working, Extra series product sets the
maximum charge current limit value; see "Table 2-5 Charging Parameters."
Discharging Current Limit
To protect the load equipment working, Extra series sets the maximum
discharge current limit please see "Table 2-6 discharge parameters." In
products working, the maximum operating current of electrical load should be
less than the maximum battery discharge current.
2.2.3 Additional Protection Features
Short Circuit Protection:

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If short circuit occurs, the system starts short circuit protection and lasts 30
seconds.
Automatic Shutdown:
The system will shutdown automatically after 10 hours without power supply
2.3 Charge Parameters
When the device working, reasonable charge voltage you should set,
recommended charge voltage range shown in Table 2-5. The BP product sets
the maximum charge current to protect the power supply and load equipments.
Table 2-5 Charging Parameters
Model
Voltage Range in Charging
Min
Max
BP 4850
52.5V
53.5V
BP 48100
52.5V
53.5V
2.4 Discharge Parameters
To protect the load equipment, Extra series products limited the maximum discharge
current shown in Table 2-6.
Table 2-6 Discharging Parameters
Model
Voltage Range in
Discharging
Current Limit in
Discharging
Min
Max
Max
BP 4850
43.5V
53.5
50A
BP 48100
43.5V
53.5
50A
Note: the maximum discharge current of pack should be greater than maximum
operating current of electrical load.

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3Installation and Configuration
3.1 Installation Preparation
Safety Requirements
Only those who have finished training and knowledge and fully grasp the power
system personnel may install the system. During installation process, one must
always observe the safety requirements listed below and local safety regulations.
All the circuit under 48V connected to the external power supply system must
meet following criteria defined in IEC60950 SELV Requirements.
If operation of the power system is in cabinet, it must ensure that the power
system is not energized first, at the same time battery device must be turned
off.
Distribution cabling must be reasonable and protective measured to prevent
operation of power equipment from touching these cables. Equipment
installation preparation process shown in Figure 3-1

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Figure 3-1 Schematic of Installation Process
Operation Environment
Checking
Environment
Rectify and
Reform
Passed or
Not
Environmental
Checking Report
Unpacking Report
Technical Preparation
Unpacking
Project Coordination
Ending
Tools and Materials
3.1.1 Environmental Requirements
Ambient Temperature: -10℃~+50℃
Relative Humidity:5%～93% RH
Altitude: Under 4000m
Working environment: No conductive dust and corrosive gas

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3.1.2 Tools and Information
Hardware
Tools and instruments are shown in Table 3-1:
Table 3-1 Tools and Meters
Name
Screwdriver (Slotted, Phillips)
Multimeter
Wrench
Clip-on Ammeter
Diagonal Pliers
Insulating Tape
Pliers
Thermometer
Clip Pliers
Antistatic Wrist Ring
Strippers
Ties
Technical Information
"Project Exploration Station Report", "Extra series lithium iron phosphate Standby Power
User's Manual" and "installation and inspection reports".
3.1.3 Technical Preparation
Electrical Terminal Checking
The battery module also can be connected directly to user equipments, switching
power supply or other power equipments. There are two typical interface devices
with power cable:
1. Devices with DC Backup Power Interfaces (such as ZTE9806H, Huawei
MA5616)
If the battery directly connects to the user device, following check is necessary:
To check the user whether the equipment with DC backup power interface
and whether the output voltage electrical equipment meets the requirements
in voltage range of Table 2-5.
To confirm the maximum discharge current capability of user interface to the
device DC backup power, must be greater than the maximum discharge
current products in Table 2-5; if not, the limiting function is required.
To confirm the maximum operating current by battery-powered user
equipment must be less than the maximum discharge current products

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mentioned in Table 2-6.
2. Switching Power Supply
If the battery is connected to switching power supply, it must be confirmed the
positive and negative switching power connector, and measure whether the output
voltage meets the requirements in Table 2-5; and also recognizing the maximum
operating current of the battery-powered load devices must be less than the
maximum discharge current related products in Table 2-6.
Landing Checking
The collocation of landing line in engine room should be furnished ground
radiation or flat, it requiring three separate parts: DC power distribution systems
protection, power system working and lightning protection.
If the area cannot provide three kinds of ground because space is limited,
the three kinds can be merging and grounding resistance must be less than 1Ω.
Security Checking
Fire-fighting equipments must be available near the device such as powder fire
extinguishers. For more case of requirement, it should be equipped with automatic
fire extinguishing system. No flammable, explosive and other dangerous items
placed next to battery.
3.1.4 Unpacking
When products arrive at the installation site, before unpacking, check
whether the box appearance is intact or not, and calculate total number
according to freight highlighted list. Avoiding sunshine and rain, installation
and disassembly must follow regulatory requirements and handling;
To open box slightly to protect the object surface coating;
Reading technical documents and verifying the list firstly before open the
box, to ensure object is complete and intact according to the configuration
tables and packing slips inventory, if the internal packaging is damaged
please scrutinize and record.
3.1.5 Project Coordination
Attention of Previous Work:

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Specifications of Power Cord.
Power cord should meet the requirements of maximum discharge current of
each product;
Installation Space and Load-bearing
To ensure there is enough space for installation, and sufficient load-bearing
capacity for battery cabinet and brackets.
Wiring
Ensure the power cord and ground wiring is reasonable. No short circuit,
water and corrosion.
3.2 Equipment Installation
Table 3-2 Installation Steps
Step 1
system
powered down
Step 2
Mechanical
Installation
1. Tab Installation
2. Equipment Installation
Step 3
Electrical
Installation
1. Connecting
Grounding Cable.
2. Electrical Installation
3. Load Connection
4. Communication
Interface Cascade
5. Communication
Interface Collection
6. Power Supply
3.2.1 Mechanical Installation
Before installation, disconnect the entire device's power directly contact, and
recognizing that the battery is turned off (disconnects the battery power cord and
press the Reset button), to ensure there is no electrification.

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1 Tab Installation
There are tabs and mounting accessories equipment box. Before the equipment
fixed, install tabs on both sides of the device, and confirm screws are tightly
connected.
2 Equipment Installation
Extra 2000 products using 19-inch rack-mountable, it can be installed in the
chassis designed with battery, and also be installed in the cabinet. Put device in
parallel on the pallet rack, push it into the cabinet to make a very tight against
between tab and the mounting bracket, tighten with screws and floating nuts, it
must be ensure that all devices are secure. The position is flexible according to the
actual for arrangements device in a cabinet.
Figure 3-2 Schematic of Device Fixed to the Cabinet
3.2.2 Electrical Installation
Before connecting power and landing, using multimeter to measure cable
continuity, short circuit, and confirmed anode and cathode, and make the cable
labels.
Measuring methods:
Cable continuity: Select buzz file of multimeter with a probe touch the ends
of the same color cable, if buzzer means cable is available.
Short circuit: Select resistance profile of multimeter, with a probe measuring
the same anode and cathode, if the resistance displayed infinite, means