Pylontech Extra 2000 User manual

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

LEGAL NOTICES
Copyright of Pylon Technologies Co., Ltd. Enjoin from abstracted reproduced or translated
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Rights reserved.
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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

Pylon Technologies Co., Ltd. Confidential Proprietary 1
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.

Pylon Technologies Co., Ltd. Confidential Proprietary 2
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

Pylon Technologies Co., Ltd. Confidential Proprietary 4
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

Pylon Technologies Co., Ltd. Confidential Proprietary 1
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
Extra2000LithiumIronPhosphateBatteryBackupManual

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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.
Extra2000LithiumIronPhosphateBatteryBackupManual

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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".
Extra2000LithiumIronPhosphateBatteryBackupManual

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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
Extra2000LithiumIronPhosphateBatteryBackupManual