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PowerWalker LiFe Battery System 102-37 User Manual

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LiFe Battery System
102-37
User Manual
Version: 01
Date: 2023-7-10

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Summary of Contents for PowerWalker LiFe Battery System 102-37

  • Page 1 LiFe Battery System 102-37 User Manual Version: 01 Date: 2023-7-10...
  • Page 2 ~ 1 ~...
  • Page 3 Thank you for purchasing the lithium battery — PowerWalker LiFe Battery System 102-37. Please read this manual before you install the battery and follow the instructions carefully during the installation process. Symbol Conventions This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
  • Page 4 Manual Intended Audience The operation in this document can only be performed by qualified personnel with the following skills: Personnel who plan to install or maintain battery equipment and inverter must receive ▪ thorough training, understand all necessary safety precautions, and be able to correctly perform all operations.

  • Page 5: Table Of Contents

    Table of Contents 1 Safety Messages and Precautions ....................6 Declaration ........................6 General Safety Requirements ................... 7 2 Product Introduction ......................... 10 Overview ........................10 Battery Capacity Description ..................10 Battery application on the Grid ..................11 Battery Pack System Description ................... 12 2.4.1 Battery Illustration ....................
  • Page 6 Battery pack specification ....................43 Modular guide ........................ 45 6 Troubleshooting ........................47 7 Acronyms and abbreviations ....................49 ~ 5 ~...

  • Page 7: Safety Messages And Precautions

    Safety Messages and Precautions 1.1 Declaration Please read this manual carefully before installation, operation, and maintenance. Inappropriate use may lead to injury or even death for the user or third parties. Material damage to the battery and other equipment can also occur. All operations should be performed by a qualified person. The manufacturer will not be liable for any consequences of the following circumstances: Operation beyond the conditions specified in this document.

  • Page 8: General Safety Requirements

    1.2 General Safety Requirements DANGER Ensure the housing of the battery packs is properly grounded before operation. • Do not dispose of batteries in a fire or hash chemicals. The batteries may explode. • The disassembly of batteries may generate internal short circuits, which may cause •...
  • Page 9 WARNING Wear suitable personal protective equipment for all work on the battery system. • Before installation, be sure to cut off the power grid and ensure that the battery is • in shutdown mode. For the equipment that needs to be grounded, install the protective earthing (PE) •...
  • Page 10 1.3 Disclaimer The manufacturer shall not be liable for equipment function abnormality, component damage, personal health or safety, property loss, or other damage caused by the following reasons: 1) The batteries are not charged as required during storage, resulting in capacity loss or irreversible damage to the batteries.

  • Page 11: Product Introduction

    Product Introduction 2.1 Overview The Lithium-Ion Battery Pack System is a high-power DC battery system for use with inverters. It contains two parts, one is the battery module, and the other is the control box. It can store and release electric energy based on the requirements of the inverter. It has a built-in intelligent battery management system (BMS), which can manage and monitor the battery voltage, temperature, current and other information.

  • Page 12: Battery Application On The Grid

    Figure 2 Battery in parallel for capacity expansion Note: Two batteries in parallel only support capacity expansion, power expansion is not suggested. The Module quantity of each string of battery should be the same. 2.3 Battery application on the Grid The battery can be used in the grid-tied systems of residential rooftop PV plants.

  • Page 13: Battery Pack System Description

    2.4 Battery Pack System Description 2.4.1 Battery Illustration This topic describes the battery's illustration. Figure 3 Battery Illustration (1) Logo and cold start switch (2) Control Box (3) Battery modules (4) Base ~ 12 ~...

  • Page 14: Control Box Description

    2.4.2 Control Box Description Figure 4 Control Box Front Panel Item Description Symbol Logo A power button with dual-color LEDs, for switching the battery on / off and displaying working status. For starting up and shutting down the battery pack: Pressing the button for 3 seconds to shut down the battery pack when it is in active status.
  • Page 15 Figure 5 Control Box Side Panel Item Description Four 8 pins RJ45 ports for communication. RS485 + I/O port： Communication port Every single pin of the two RJ45 ports is connected in parallel internally. Connect this port to another control box or system. CAN + 12V port：...
  • Page 16 This breaker controls the power supply for the battery pack. DC Breaker Left: OFF Right: ON To protect people from electric shocks in the Protective earthing port event of a fault “+” is battery power positive port. Battery power ports “-”...

  • Page 17: Battery Module Description

    2.4.3 Battery Module Description The standard capacity of a battery expansion module is 3.8 kWh. Figure 7 Battery Module Bottom Panel Item Description Module bottom connector that connects to Bottom Connector module top connector. Figure 8 Battery Module Top Panel Item Description Module top connector that connects to module...

  • Page 18: Base Introduction

    2.4.4 Base Introduction Figure 9 Base Top Panel Item Description The base top connector connects to the Top Connector module bottom connector. Table 4 Base description ~ 17 ~...

  • Page 19: Battery Pack System Installation

    Battery Pack System Installation 3.1 Inspection of package When unpacking the package, please check the appearance ahead of installation. If the main body of the product is damaged, please consult the dealer, and do not install the product. After unpacking the battery, check that the deliverables are intact and complete, and free from any obvious damage.
  • Page 20 Connection 4/6/8/10 mounting pieces Dimensions (W x D x H): 81 mm x 50 mm x 2.0 mm Control Box Dimensions (W x D x H) : 625 mm x 250 mm x 150 mm Weight: Approx 12.5Kg Control box package Wall mounting piece...
  • Page 21 Expansion bolt M10x60mm Connector Plug Connector Plug, Orange Mate with 6AWG wire Connector Plug Connector Plug, Black Mate with 6AWG wire Communication cable RJ45 wire, Length 2000mm, Black Terminal PE Terminal PE Terminal Mate with 10AWG wire, Yellow/Green Table 5 Delivery list ~ 20 ~...

  • Page 22: Required Tools (Not Included)

    3.3 Required Tools (not included) Tools are not delivered with the battery. They are not standard accessories. Category Tools Torque socket wrench Hammer drill (with a Torque wrench the drill bit of 13 mm) Wire strippers Crimping tool Cable cutter Installation Cord end terminal Hydraulic pliers...
  • Page 23 Heat-shrink tubing Heat gun Level （Diameter Ø7MM） Personal protective equipment (PPE) Safety gloves Safety shoes Safety goggles Table 6 Tool list for installation ~ 22 ~...

  • Page 24: Installation Environment

    3.4 Installation environment Choose a dry, clean, neat well-ventilated, and convenient location for installation, and use environment • must meet relevant international, national, and local standards for lithium batteries, and are in accordance with the local laws and regulations. Installation ambient temperature: 0 ℃ ~ 40 ℃, Relative humidity: 5 - 95 % (non-condensing) •...

  • Page 25: Determination Of The Location And Position

    3.5 Determination of the Location and Position 3.5.1 Installation Angle Requirement The battery can be floor-mounted and wall-mounted. The installation angles requirement is as follows: Do not install the battery at forward-tilted, back-tilted, side-tilted, horizontal, or upside-down positions. • 3.5.2 Installation Position Requirements Install the battery on a solid concrete structure or concrete wall or floor.

  • Page 26: Installation Process

    3.6 Installation Process 3.6.1 Installation Precautions Step 1: Use the steel measuring tape to determine the drilling hole positions on the wall for securing the power control module and mark the positions using a marker. Figure 12 Dimensions of mounting holes for the system on the wall Step 2: Use a Hammer drill to drill a Ø13mm hole in the wall and insert the M10 expansion bolt into the hole.
  • Page 27 DANGER When drilling holes, avoid the water pipes and power cables buried in the wall. NOTICE To prevent dust inhalation or contact with the eyes, wear safety goggles and a dust mask when drilling holes. Wipe away any dust in or around the holes and measure the hole distances. If the •...

  • Page 28: Installation Of Battery Modules And Control Box

    3.6.2 Installation of battery modules and control box Step 1: Use Level to make sure the floor is flat. If not, please make it flat before installation. Figure 15 Use level to check the floor Step 2: Place the base on the floor next to the wall. Figure 16 Install the base on the floor.
  • Page 29 Step 3: Install the 1st battery module on the base as follow. Figure 17 Install the 1st battery module. CAUTION For safety, the battery module needs to be moved by 2-3 persons Step 4: Install the 2nd battery module as follow and fix it with the connection mounting pieces Figure 18 Install the 2nd battery module Figure 19 Fix connection mounting piece ~ 28 ~...
  • Page 30 Step 5: Install the 3rd battery module and fix it with the connection mounting pieces, then repeat the operation until all battery modules have been installed. Figure 20 Install the rest battery modules. ~ 29 ~...
  • Page 31 Step 6: Remove the side cover from the control box. Figure 21 Remove the side cover from the control box CAUTION For safety, please make sure the DC breaker on the control box is OFF before installing the control box. Figure 22 DC Breaker on the control box ~ 30 ~...
  • Page 32 Step 7: Install the control box on the top as follows, then fix it with the connection mounting piece as well. Figure 23 Install the control box Step 8: Install the wall mounting pieces to the top of the control box, and lock it to the wall with an expansion bolt.

  • Page 33: Crimping The Cables

    3.6.3 Crimping the cables Insert the positive and negative battery connectors into the corresponding DC input terminals (“+” and “–”) Step 1: Crimping the wire for the connector plugs. Figure 25 Crimping the DC wire NOTICE It is advised to use 6AWG wire for the DC connector. •...
  • Page 34 Step 2: Installing wire to RJ45 Crystal Head as signal cable if the original communication cable doesn’t fit. Figure 26 Crimping the signal cable Step 3: Crimping the PE wire. (A) Core wire (B) Insulation layer (C) Heat shrink tubing (D) Heat gun (E) Hydraulic pliers Figure 27 Crimping the PE wire.

  • Page 35: Installing The Cables To The Control Box

    3.6.4 Installing the cables to the control box Step 1: Install the positive wire and the negative wire to the control box. Figure 28 Install the positive wire and the negative wire. Step 2: Install the PE wire to the control box. Figure 29 Install the PE wire.
  • Page 36 Step 3: Install the signal cable to the control box. Figure 30 Install the Signal cable. ~ 35 ~...
  • Page 37 Definition of RS485 + I/O port and CAN + 12V port PIN1: RS485_A1: Noninverting Driver Output/Receiver Input. PIN2: RS485_B1: Inverting Driver Output/Receiver Input. RS485 + I/O port： PIN3: GND of RS-485 PIN4: Inactive pin of Dry contact signal. PIN5: Active pin of Dry contact signal. PIN6: Common pin of dry contact PIN7: RS485_A2: Noninverting Driver Output/Receiver Input.

  • Page 38: Installing The Side Cover To The Battery Module And The Control Box

    3.6.5 Installing the side cover to the battery module and the control Step 1: Open the breaker cover and turn the breaker from OFF to ON. Figure 31 Breaker Step 2: Install the side covers of the battery modules. The side cover must be installed from the bottom battery modules until all battery modules have been installed.
  • Page 39 Figure 32 Install the side cover of the battery module. ~ 38 ~...
  • Page 40 Step 3: Install the side covers to the control box. Figure 33 Install the side cover of the control box ~ 39 ~...

  • Page 41: Connecting Battery Packs In Parallel

    3.7 Connecting battery packs in parallel The battery pack supports a maximum of eight parallel strings. The connection among all paralleled battery packs can refer to the below diagram. Figure 34 Battery parallel connection block diagram ~ 40 ~...

  • Page 42: Powering The System

    Powering the System 4.1 Preparation before running: 1) Confirm the battery system is securely installed. 2) The location should have good ventilation. 3) No external objects or parts are placed on top of the battery system. 4) Cables are properly distributed, tight, and well-protected from mechanical damage. 5) Ensure that all terminals are properly and securely connected, and that the battery cabinet is properly grounded.

  • Page 43: Powering Off The Battery System

    4.3 Powering off the battery system If the battery is not in use or needs maintenance, please follow the below steps to let the battery pack power off. Step 1: Set the inverter to stop charging and discharging the battery packs. Step 2: Turn off the switch between the inverter and battery packs.

  • Page 44: Battery Pack Parameters

    Battery Pack Parameters 5.1 Battery pack specification Items Standard Remarks Nominal Voltage 102.4V*N N is the Battery module quantity Standard Charge 112V*N N is the Battery module quantity Voltage Max charge voltage 115.2V*N N is the Battery module quantity Standard Charge Current Maximum Charge Current...
  • Page 45 Discharge Current 112V *N, 25A CC (constant current) charge to 112V*N, Standard Charge then CV 112V*N charge till N is the Battery module quantity Method charge current decline to 1.8A. Control box: ≤20mΩ AC Internal Between positive and negative Resistance poles of the output port at 1kHz Battery module: ≤50mΩ...

  • Page 46: Modular Guide

    5.2 Modular guide Module Quantity 3 Modules 4 Modules 5 Modules Modules System Battery System 11.4 15.2 Capacity(kWh) Usable Capacity 11.4 15.2 (kWh) Number of Battery Modules Rated Battery 204.8 307.2 409.6 Voltage (V) Operating Battery 160~230 240~345 320~460 400~576 Voltage Range (V) Rated Power (kW) 12.5...
  • Page 47 Battery Module 625 x 315 x 250 mm (W x H x D) Dimensions Battery Control Box LiFe Battery System 102-37 Control Box Rated Voltage (V) 307.2 (with 3 modules in string) Control Box 625 x 150 x 250 mm (W x H x D)

  • Page 48: Troubleshooting

    Troubleshooting According to the severity of the fault, the fault status of the battery pack is defined as a major fault or minor fault. In general, minor faults can recover automatically after the fault condition is resolved, while major fault needs to contact the supplier for service.
  • Page 49 button is blinking Check the battery pack temperature via the inverter’s APP. Protection against over- If the battery pack temperature is temperature or under-temperature higher than 55°C, wait for the (cell temperature is lower than temperature to drop to 50°C. 0 °C or higher than 55 °C).

  • Page 50: Acronyms And Abbreviations

    Acronyms and abbreviations Battery system Rechargeable Lithium-Ion Battery Pack Direct current power supply Battery Management System CC-CV Constant current to constant voltage Application End of life Table 11 Acronyms and abbreviations ~ 49 ~...

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