Pylontech Extra 2000 User manual

Extra 2000
Lithium-Iron Phosphate Battery Backup
Product Manual
Information Version: 1.2

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Copyright of Pylon Technologies Co., Ltd. Enjoin from abstracted reproduced or translated
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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 relevant national laws.
When appeared product updates or technical changes, you can send via 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: V1.2
Information Number: MKT-EXSC1-130410
Revise History
Revision NO. Revision Date Revision Reason
1.0 2010.9.10 First Release
1.1 2012.5.20 Product Updates
1.2 2013.4.10 Product Updates

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Introduction
Manual Explains
Extra 2000 (V1.2) lithium iron phosphate battery is external backup power module for
48V devices. Under normal mains power, the power supply provides energy for user
equipment and charging the battery; when the power supply interrupted, the battery
provides energy for equipment.
Extra 2000 Product Manual exposited the basic processes and methods of the device,
includes structure, parameters, installation and operation. The main contents of this
manual are follows:
Chapter Abstract
Chapter 1 Introduction Main application and features of Extra 2000
Chapter 2 Structure and
Parameters
External structure, panel description, management module
parameters and others of Extra 2000.
Chapter 3 Installation and
Collocation
Product installation, network usage and requires attention in
installation process of Extra 2000
Chapter 4 Maintenance and
Troubleshooting
Common operating status descriptions and Troubleshooting of
Extra 2000
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 result 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 Extra 2000
Note: If warning ignored, the product may malfunction.

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Catalogue
Extra 2000........................................................................................................................1
Lithium Iron Phosphate Battery Backup .................................................................1
1 Information .....................................................................................................................1
1.1 Information ----------------------------------------------------------------------------------------1
1.2 Product Features --------------------------------------------------------------------------------1
2 Structure and Parameter................................................................................................2
2.1 Equipment Structure----------------------------------------------------------------------------2
2.1.1 Equipment Model................................................................................................2
2.1.2 Equipment Front Interface Instruction.................................................................2
2.2 Battery Management System（BMS）----------------------------------------------------4
2.2.1 Voltage Protection Function................................................................................4
2.2.2 Current Protection Function................................................................................4
2.2.4 Other Protection Function...................................................................................5
2.3 Charge Parameters-----------------------------------------------------------------------------5
2.4 Discharge Parameters -------------------------------------------------------------------------6
3 Installation and Configuration ........................................................................................7
3.1 Installation Preparation-------------------------------------------------------------------------7
3.1.1 Environmental Requirements..............................................................................8
3.1.2 Tools and Information .........................................................................................8
3.1.3 Technical Preparation.........................................................................................9
3.1.4 Unpacking .........................................................................................................10
3.1.5 Project Coordination..........................................................................................10
3.2 Equiment Installation---------------------------------------------------------------------------- 10
3.2.1 Mechanical Installation......................................................................................11
3.2.2 Electrical Installation.........................................................................................11
4 Using, Maintenance and Troubleshooting ...................................................................16
4.1 Alarm Description and Processing-------------------------------------------------------- 16
4.1.1 The Alarm and Countermeasure Influence System Output..............................16
4.1.2 The Alarm and Countermeasure Do Not Influence System Output.................16
4.2 Common Fault Analysis and Solutions--------------------------------------------------- 17

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Catalogue of Diagrams
Figure 2-1 Extra 2000 Front Interface Diagram................................................................3
Figure 3-1 Schematic of Installation Process ...................................................................9
Figure 3-2 Schematic Device Fixed to the Cabinet........................................................13
Figure 3-3 Multiple Batteries in Parallel Power Line Connection Diagram.....................14
Figure 3-4 Connection Interface between Battery and Load Equipment of DC Backup15
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
Table 2-1 Extra 2000 Equipment Model............................................................................2
Table 2-2 Definition of RS232 Port Pin.............................................................................3
Table 2-3 ADD Switch.......................................................................................................4
Table 2-4 LED Indicators Instructions...............................................................................4
Table 2-5 Protection Function Parameters .......................................................................6
Table 2-6 Charging Parameters........................................................................................7
Table 2-7 Discharging Parameters....................................................................................7
Table 3-1 Tools and Meters.............................................................................................10
Table 3-2 Installation Steps.............................................................................................12
Table 4-1 Major Alarm and Protection.............................................................................18
Table 4-2 SecondaryAlarm.............................................................................................19
Table 4-3 Common Faults and Solutions........................................................................19

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1Introduction
1.1 Introduction
Extra 2000 lithium iron phosphate battery backup is new energy storage battery
products developed and produced by Pylontech according to market demand, it
can be used to provide reliable backup power for various types of communication
operators of 48V power supply equipments. Extra2000 is especially suitable for
operating environment of high temperature, limited installation space, light
load-bearing and long cycle life applications.
Extra 2000 has built-in BMS battery management system. Under normal
circumstances, the main power provides energy for user equipment and charging
battery; when the power supply interrupted, the battery provides energy for user
equipment. Multiple batteries can be connected for larger capacity in parallel for
longer duration backup requirements.
1.2 Product Features
Extra 2000 product from Pylontech is using lithium iron phosphate as cathode
material, with BMS for effective management of cells. The system has the following
characteristics:
The battery 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 status of
over-discharge, over-charge, over-current and high temperature;
The system can automatically manage charge and discharge status and balance
current and voltage of each single cell;
The centralized monitoring module is intelligent designed with three remote
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functions of test, signal and control;
Flexible configuration achieved that several battery modules can be in parallel to
expand capacity and extend 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 55 ℃, with excellent discharge
performance and cycle life in high temperature;
Small size and light weight, standard of 19-inch embedded design, comfortable
installation and maintenance;
2Structure and Parameter
2.1 Equipment Structure
2.1.1 Equipment Model
Table2-1 Extra 2000 Equipment Model
Product
Series Model Rated Voltage
Rated
CapacitySize Weight
Extra
Series Extra 2000 48V 50Ah 436×370×132mm 30kg
2.1.2 Equipment Front Interface Instruction
This section details the front panel of the interface functions.
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Figure 2-1 Sketch of Extra 2000 Product Front Interface
123456
ON
OFF
87
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)
RS485 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."
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
devices from ZTE.
Table 2-2: Definition of RS232 Port Pin
RS232 Pin Definition Description
1 Land
2 Veneer Reception, Computer sends
Interface Protocol Standard: YD/T 1363.3-2005 " Part 3: Front intelligent devic
e
protocol of Communications Authority (Station) Power Supply, Air-conditioning an
d
Environment Centralized Monitoring and Management Systems".
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3 Veneer Sends, Computer Receives
4 Land
ADD Switch (5)
ADD Switch: 4 ADD switches, to definite different address code for each
battery module when network cascade multiple battery, up to 8 addresses.
The coding and description see "Table 2-3 ADD Switch."
Table 2-3 ADD Switch
Coded Bit Address Pack Description
1 2 3 4
ON OFF OFF OFF (1) Pack1 Master Pack, Corresponding with
RS232
OFF ON OFF OFF (2) Pack2 Slave Pack1
ON ON OFF OFF (3) Pack3 Slave Pack2
OFF OFF ON OFF (4) Pack4 Slave Pack3
Note: The coded bits 1 to 4 in table separately represent ADD keys from left to right. (set up for
the "ON", down to "OFF"). The address of each device in accordance with the binary
coded bits, 1 is low, 4 is high, Table 2-3 Example 1-4 address coding, 5-8 address and
so on. If several Extra products cascading multiple network devices, the address
encoding 1 is the main battery, others are assistants.
LED Status Indicators (6,7,8)
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 / RUN ALM Capacity LED Description s
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Normal ●●● ● ● ●
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 Flash3
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 light 1 - 0.25s / off 3.75 seconds; flash 2 - 0.5s light / 0.5s
off; flash 3 - 0.5s light / 1.5s off
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.
Protection parameters see entry 1 of "Table 2-5 Protection Parameters".
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.
Protection parameters see entry 2,3 of "Table 2-5 Protection Parameters".
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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.
Protection parameters please see entry 4 of "Table 2-5 Protection function
parameters".
Over-current Protection in Discharge:
When the discharge current is greater than the protection value, discharge
stopped. Protection removed after the system delay time.
Protection parameters see entry 5 of "Table 2-5 Protection function
parameters".
Charging Current Limit:
To ensure the load equipment working, Extra 2000 product sets the maximum
charge current limit value; see "Table 2-6 Charging Parameters."
Discharging Current Limit
To protect the load equipment working, Extra 2000 sets the maximum
discharge current limit; see "Table 2-7 discharge parameters." In products
working, the maximum operating current of electrical load should be less than
the maximum battery discharge current.
2.2.4 Additional Protection Features
Short Circuit Protection:
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
The protection parameters of Extra 2000 see "Table 2-5 Protection Function
Parameters."。
Table 2-5 Protection Function Parameters
Order
Number Type Protective Function Parameter to Protection
Parameter to Remove
Protection
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1Low-voltage in
Discharging for Cell 2.7V 3.25V
2Over-voltage in Charging
for Cell 3.75V 3. 5V
3Over-voltage in Charging
for Pack 57V 54V
4
Current
Over-current in Charging 28A 15 Seconds Delay
5Over-current in
Discharging 53A 15 Seconds Delay
2.3 Charge Parameters
When the device working, reasonable charge voltage you should set,
recommended charge voltage range shown in Table 2-6. The Extra 2000
product sets the maximum charge current to protect the power supply and load
equipments.
Table 2-6 Charging Parameters
Model Voltage Range in Charging Current Limit in Charging
Min Max Max
Extra 2000 54V 57V 10A
2.4 Discharge Parameters
To protect the load equipment, Extra 2000 products limited the maximum
discharge current shown in Table 2-7.
Table 2-7 Discharging Parameters
Model
Voltage Range in
Discharging
Current Limit in
Discharging
Min Max Max
Extra 2000 42V 56.5V 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
Figure 3-1 Schematic of Installation Process:
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3.1.1 Environmental Requirements
Ambient Temperature: -10℃~+55℃
Relative Humidity:5%〜93% RH
Altitude: Under 4000m
Working environment: No conductive dust and corrosive gas
3.1.2 Tools and Information
Hardware
Tools and instruments are shown in Table 3-1:
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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 2000 lithium iron phosphate Standby
Power User's Manual" and "installation and inspection reports".
3.1.3 Technical Preparation
Electrical Interface Checking
Connected directly to the battery device could be user equipments, switching
power supply or other power equipments. There are two typical interface device of
power line:
1. DC Backup Power Interfaces
If the battery directly connects to the user device, please check:
To check the user whether the device with DC backup power interface and
whether the output voltage electrical equipment meets the requirements in
voltage range of Table 2-6.
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 2-6; 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
mentioned in Table 2-7.
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 2-6; and also recognizing the maximum
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operating current of the battery-powered load devices must be less than the
maximum discharge current related products in Table 2-7.
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 can not 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 equipments 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 equipments 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:
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.
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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. Connect the Load
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 (disconnect the battery power cord and
press the Reset button), to ensure there is no electrification.
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
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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
cable is available.
Anode and cathode: after power cord connected, the battery positive and
negative should be connected respectively positive and negative of
equipment.
Cables connection order:
1 Ground Cable
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Connect one side of the cable to the copper rafts to ground, and the other side
connect to the hole placed on right interface back of battery chassis with 4mm2
line connection, make sure connections are tight and well grounded.
2 Batteries in Parallel
Please kip this step and go to Step 3 when using a single battery.
When using multiple batteries in parallel, firstly parallel each station batteries with
the power cord. Extra 2000 product has 2 power interfaces on left front panel
device, power connector from top to bottom are negative and positive. The 2
interfaces have same function, when multiple batteries in parallel, using parallel
power cable to connect each battery. After parallel, any free battery power
interface can connect load.
Figure 3-3 Multiple Batteries in Parallel Power Line Connection Diagram:
3 Load Connected
When connect load, connect the user equipment side power line interface first,
and then the battery power supply interface.
(1) Connection of battery and the load device in DC backup power interface
If the load device has a DC backup power interface, this installation can be used.
Single load equipment: the power cord directly connected to the load equipment
Extra2000LithiumIronPhosphateBatteryBackupManual