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Summary of Contents for KStar BC197DE
- Page 1 BC197DE User Manual BC197DE User Manual of Industrial and Commercial Battery Cabinet...
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Page 2: Target Readers
BC197DE User Manual Overview This manual introduces the main characteristics, performance indicators, system principle and outline structure of BC197DE industrial and commercial battery cabinet, as well as installation, use and operation instructions, maintenance management and other contents. Target Readers This document is intended for the following engineers:... -
Page 3: Revision History
BC197DE User Manual Revision History Version Revised on Revision Content Internal Document No. 2024/08/30 First draft Add Charge and discharge power curve 、 External protection device current、Maximum 2024/11/23 short current and duration、Noise grade，edit Installation of Cabinet... -
Page 4: Table Of Contents
BC197DE User Manual Table of Contents 1 General Safety Precautions ......................1 1.1 General Safety ........................1 1.2 Personnel Requirements ....................... 5 1.3 Electrical Safety ........................6 1.4 Requirements for Installation Environment ................. 9 1.5 Mechanical Safety ......................10 1.6 Battery Safety ........................13 1.7. - Page 5 BC197DE User Manual 3.5.1 AC Input Connection ....................42 3.6 Description of Communication Wiring ................44 3.7 Schematic Diagram of EMS Wiring ...................45 3.8 Schematic Diagram of Single Pack ..................46 4 Operation Guideline ........................47 4.1 Inspection after Installation ....................47 4.2 Operating Environment Inspection ..................
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Page 6: General Safety Precautions
The "Caution", "Warning", and "Danger" signs in this manual do not encompass all safety precautions to be followed but act as a supplement to the safety precautions. Kstar New Energy is not responsible for any breach of general safety operation requirements or equipment design, production and operation safety standards. -
Page 7: General Requirements
BC197DE User Manual Damage caused by storage conditions that do not meet the requirements of product documentation. General Requirements It is strictly prohibited to install, use and operate outdoor equipment and cables in severe weather such as thunder and lightning, rain, snow and strong wind of Grade VI... - Page 8 BC197DE User Manual Installation, operation and maintenance must be carried out according to the steps in this manual. Before touching any conductor surface or terminal, the voltage at the contact point shall be measured to confirm that there is no risk of electric shock.
- Page 9 BC197DE User Manual The handle of the tool used needs to be insulated for protection, or an insulating tool is required, as shown in the figure below. Seal all cabling holes with fireproof mud. Use the cover that comes with the cabinet to ...
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Page 10: Personnel Requirements
Do not power on the equipment before it is installed or confirmed by professionals. 1.2 Personnel Requirements The personnel responsible for the installation and maintenance of KSTAR equipment must first receive strict training, understand various safety precautions and master correct operation methods. -
Page 11: Electrical Safety
BC197DE User Manual have the necessary experience, can be aware of the dangers that may be brought to them during an operation, and can take measures to minimize the risks to themselves or other personnel. Operators: operators who may come into contact with the equipment, except for trained ... -
Page 12: Wiring Requirements
BC197DE User Manual to the human body. The power switch must be turned off before installing and removing the power cord. Ensure that the power cord's label is correct before connecting it. If the equipment has multiple inputs, disconnect all inputs and operate the equipment ... -
Page 13: Anti-Static Requirements
BC197DE User Manual regulations and codes. Anti-static Requirements Static electricity generated by the human body will damage the electrostatic-sensitive components on boards, such as the large-scale integrated circuit (IC), etc. Static electricity generated by the human body will damage the electrostatic-sensitive ... -
Page 14: Requirements For Installation Environment
BC197DE User Manual 1.4 Requirements for Installation Environment Do not block the vent or heat dissipation system when the equipment is running, so as to prevent high-temperature fire. The equipment shall be installed in an area away from liquids. It is forbidden to install it ... -
Page 15: Mechanical Safety
BC197DE User Manual work at heights shall be rejected. Carry out safety protection, wear safety helmets, safety belts or waist ropes, and tie them to firm and solid structural members. It is strictly prohibited to hang them on movable objects that are not firm or metal with sharp edges and corners, so as to prevent falling accidents caused by hook slippage. - Page 16 BC197DE User Manual take up their posts after passing the examination. Hoisting tools shall be inspected and used only when the tools are complete. Before hoisting, ensure that the hoisting tool is firmly fixed to a load-bearing fixture or ...
- Page 17 The entry of metal chips generated by drilling into the equipment will cause a short circuit of the circuit board. The tripartite agreement between the Client, Contractor and KSTAR shall be obtained ...
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Page 18: Battery Safety
BC197DE User Manual Safety in Handling Heavy Objects When pulling the equipment out of the cabinet, be aware of other equipment that may not be securely installed in the cabinet to avoid being crushed or injured. When handling heavy objects, make preparations for load bearing to avoid being ... - Page 19 In order to ensure the safety of battery use and the accuracy of the battery management function, please use the batteries configured by KSTAR with a PCS host. KSTAR is not responsible for battery-related faults if batteries other than those supplied by KSTAR are used.
- Page 20 BC197DE User Manual To ensure safety, the following basic precautions shall be observed before the installation and operation of batteries: The battery shall be installed in a ventilated, dry and cool environment, away from heat sources, flammable and damp environments with a large amount of infrared radiation, organic solvents and corrosive gases, etc., and fire prevention measures shall be taken.
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Page 21: Others
Improper use of the battery may cause overheating damage to the battery. Kstar New Energy will not assume any responsibility for any accident caused by non-compliance with the specifications. In order to ensure the safe use and disposal of the battery, please read the... -
Page 22: Overview
BC197DE User Manual 2 Overview 2.1 Product Introduction The industrial and commercial battery cabinet contains an HV box, battery module, EMS, SBMU, BMU and other modules, which can store and release electric energy according to the requirements of the ESS energy management system. The input and output ports of the industrial and commercial battery cabinet are all HVDC. -
Page 23: Product Appearance
BC197DE User Manual 2.1.1 Product Appearance Front View of Battery Cabinet... - Page 24 BC197DE User Manual Side View of Battery Cabinet Fig. 2-1 Battery Cabinet The main battery cabinet has the following functions: managing the battery cluster, communicating with PCS, displaying and saving all system data, EMS management, modifying system parameters, etc. The main battery cabinet has an EMS display on the front door of the...
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Page 25: Product Structure
BC197DE User Manual 2.1.2 Product Structure Fig. 2-2 Product Structure 2.1.2.1 HV box The HV box contains the protection components of the whole system, such as relays, circuit breakers, fuses and DC lightning arresters. Fig. 2-3 HV Box... -
Page 26: Battery Module
BC197DE User Manual Function The HV box is used to collect information such as total battery voltage, current, temperature and external digital input signals, and cooperate with BMS to implement the system operation strategy. The dimensions of the HV box are as follows: Fig. - Page 27 BC197DE User Manual Function The battery module contains a battery pack composed of cells, which is the power source of the whole system. The BMU configured for the battery module is used to collect information such as the voltage and temperature of lithium batteries and upload the information to the SBMU control unit.
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Page 28: Product Model And Naming Rules
BC197DE User Manual 2.1.3 Product Model and Naming Rules 2.1.3.1 Naming rules for battery cabinet models: Field 1 Field 2 Field 3 Field 4 Field 1 Field 2 Field 3 Field 4 Battery Energy D: outdoor E: With the EMS... -
Page 29: Battery Module Parameters
BC197DE User Manual Maximum continuous charging 0.5C current Recommended charging current ≤0.5C Maximum continuous discharging 0.5C current Recommended discharging current ≤0.5C 2.2.2 Battery Module Parameters Item Features Series/parallel connection 20S1P Rated voltage Rated capacity 280AH Rated energy 17.92KWH Rated charging voltage... -
Page 30: Parameters Of Battery Cabinet
BC197DE User Manual Rated charging voltage 792V Maximum charging/discharging 140A current 2.2.4 Parameters of Battery Cabinet Item Features Total energy 197.12KWh Rated voltage 704VDC Recommended depth of discharge Operating voltage range 627VDC–792VDC Number of battery clusters/cabinet Maximum charging current 140A (0.5C) Maximum discharging current 140A (0.5C) -
Page 31: Interface Of Hv Box
BC197DE User Manual 2.2.5 Interface of HV Box Fig. 2-7 Panel of HV Box Definition of panel elements: Port Port description DC output anode DC output cathode Positive pole of the series-connected battery Negative pole of the series-connected battery DC START... -
Page 32: Front Cabinet Door Panel
BC197DE User Manual FIRE_FB+ Fire protection feedback input SMOKE_FB+ Reserved feedback DOOR_FB+ Door state detection IMM+ Immersion test One GND for each FB+ signal and 24V RJ45 description RJ45 port Port description COM1 CAN input line of the combined cabinet (the... -
Page 33: Charge And Discharge Power Curve
BC197DE User Manual EPO: EPO is an emergency stop button. After it is pressed, the battery cabinet will cut off high voltage and AC power supply, resulting in power failure of the battery cabinet. Below the EPO button is EMS, and you can see the screen by opening the protective cover with a key. - Page 34 BC197DE User Manual 2、Discharge power curve: -20℃-45℃ discharge current limit 140A; When the discharge current exceeds 45 ° C, it needs to be derated. When the discharge current reaches 55 ° C, it is limited to 0. More intuitive, the following discharge curve.
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Page 35: Installation
BC197DE User Manual 3 Installation 3.1 Site Planning 3.1.1 Dimensions of Battery Cabinet Fig. 3-1 Dimensions of Cabinet (mm) 3.1.2 Precautions for Installation Please place the battery cabinet on a horizontal ground, and ensure that it is placed stably without shaking or tilting. -
Page 36: Space Reservation
BC197DE User Manual The installation of the battery cabinet shall consider the bearing and load capacity of its installation ground and floor slab (according to the requirements of architectural drawings). Do not cover the ventilation holes with objects, so as not to hinder the heat dissipation of the battery cabinet, cause the internal temperature of the system to rise and affect the use safety and service life of the battery. - Page 37 BC197DE User Manual Tools and Instruments Ladder Electric forklift Manual forklift Rubber hammer Impact swivel Manual impact Alloy hole saw Heat gun swivel Electro-hydraulic Crimping tool Diagonal cutting plier Wire stripping plier press Multimeter Cable ties Clip-style ammeter Measuring level...
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Page 38: Unpacking
BC197DE User Manual 3.3 Unpacking Operation Steps Step 1 Use a forklift to transport the battery cabinet to the designated place. Step 2 Remove the outer packaging of the battery cabinet. Step 3 After confirming that the equipment is in good condition, remove the bolts securing the battery cabinet and pallet and remove the battery cabinet from the pallet. -
Page 39: Installation Of Cabinet
BC197DE User Manual the cells in the cabinet. It is recommended that the maximum ambient temperature should not exceed 50°C. Exceeding 50°C for a long time may accelerate the aging of the battery. 3.4.2 Installation of Cabinet 3.4.2.1 Selection of Installation Site When choosing an installation site, please consider at least the following principles: •... - Page 40 BC197DE User Manual Fig. 3-1 Reference Front View of Battery Cabinet Installation Foundation Fig. 3-2 Reference Top View of Battery Cabinet Installation Foundation An unreasonable foundation construction plan will bring great difficulties or troubles to the placement of the integrated PCS, opening and closing doors, and later operation. Therefore,...
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Page 41: Fixed Installation
BC197DE User Manual The bottom of the foundation pit for building the foundation must be compacted and • filled. The foundation should be sufficient to provide effective load-bearing support for the • integrated PCS. Elevate the integrated PCS to prevent rainwater from eroding the base and interior. It is •... -
Page 42: Installation Instructions For Cables Between Battery Modules
BC197DE User Manual steel should be treated for anti-rust, such as spraying anti-rust paint, etc. place a fire extinguisher next to battery Cabinet. Fig. 3-3 3.4.3 Installation Instructions for Cables between Battery Modules 3.4.3.1 Battery module... - Page 43 BC197DE User Manual Fig. 3-4 Battery Module Description: : the negative pole of the battery module; : the positive pole of the battery module; 3.4.3.2 Description of power connection of battery module (checking line marks) The connection between battery modules has been completed when the battery cabinet is shipped.
- Page 44 BC197DE User Manual the HV box B+. The wiring of the power circuit is completed. Except that there are two black and two red quick plugs at both ends of the quick-plug power cable connected to the HV box, all others are equipped with one black and one red plug.
- Page 45 BC197DE User Manual Fig. 3-6 Schematic Diagram of Single Cabinet Power Cable...
- Page 46 BC197DE User Manual Fig. 3-7 Power Wiring Diagram...
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Page 47: Electrical Connection
BC197DE User Manual 3.5 Electrical Connection Before installation, make sure that the circuit breaker switch on the HV box is off 3.5.1 AC Input Connection Step 1 Confirm that the AC Switch is in an "OFF" state. Note: The AC input is 230VAC single-phase alternating current, and it is necessary to confirm that it is non-live operation before wiring. - Page 48 BC197DE User Manual Reserved wiring position Wiring position with with mains 220VAC input mains 220VAC input Fig. 3-8 Connection of Mains AC Input Fig. 3-9 Schematic Diagram of AC Power Distribution The specifications of air conditioners are as follows: Item...
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Page 49: Description Of Communication Wiring
BC197DE User Manual 3.6 Description of Communication Wiring 1) Network communication interface wiring The battery cabinet is equipped with a built-in switch, which has been connected to the network port of the EMS controller. Users need to connect to the cloud platform or upper monitoring system and directly connect to the switch through standard network cables;... -
Page 50: Schematic Diagram Of Ems Wiring
BC197DE User Manual 3.7 Schematic Diagram of EMS Wiring As an energy management system, EMS not only controls the working mode of the system but also undertakes the function of human-machine interaction. It is convenient for users to view system information. In addition to some system communication interfaces, EMS also controls the tripping, EPO and smoke detection of the AC main circuit of the battery cabinet. -
Page 51: Schematic Diagram Of Single Pack
BC197DE User Manual 3.8 Schematic Diagram of Single Pack J1 and J2 are mainly acquisition harnesses, including cell voltage acquisition and temperature acquisition. J5 is connected to the previous communication cascade cable, and J4 is connected to the next communication cascade cable. J3 is the fan interface. -
Page 52: Operation Guideline
BC197DE User Manual 4 Operation Guideline 4.1 Inspection after Installation The personnel responsible for equipment installation and maintenance must first receive strict training, understand various safety precautions and master the correct operation methods. Only qualified professionals or trained personnel are allowed to install, operate and maintain the ... -
Page 53: Operating Environment Inspection
Check the power supply of the fire starter box. At this time, the power indicator of the fire starter box should be always on or flashing. If the power indicator fails to light up, please contact Kstar New Energy. Check whether the harnesses for the fire starter, power supply and feedback ... - Page 54 BC197DE User Manual three-hole plug of the HV box; Step 3 Turn the switch handle of the HV box in the battery cabinet to the "ON" position, and confirm whether the green light of the indicator is normally on; Step 4 Confirm whether the air conditioner is running;...
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Page 55: Power-Off Operation
BC197DE User Manual 4.4 Power-off Operation 4.4.1 Power-off Steps Step 1 Confirm whether the charging/discharging power of PCS is zero through EMS of the system, or set the operating power of PCS to zero; Step 2 Turn the switch handle on the HV box in the battery cabinet to the "OFF" position;... -
Page 56: Trial Operation Of Battery Cabinet
BC197DE User Manual Emergency stop switch button Fig. 4-1 Emergency Stop Switch Button Press the emergency stop switch. The trip unit of the HV box will be disconnected, the AC air switch will be tripped, and the battery system will be powered off. - Page 57 BC197DE User Manual out a capacity calibration during the trial operation, with charging/discharging depth DOD=100%. The test shall be carried out according to the rated power of the product. The default process is "emptying + standing (2h) + full charging", which is described as follows: Emptying: The battery cluster is discharged to SOC=0% during the emptying test.
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Page 58: Routine Maintenance
Devices behind the protective cover plate that can only be opened with tools are unmaintainable devices for users. If maintenance is required, please consult Kstar New Energy for details. ● The battery cabinet shall be maintained regularly according to the following requirements; otherwise, it will affect its normal operation and reduce its normal service life. - Page 59 BC197DE User Manual than 2 minutes. If the alarm still is loose or abnormal. sounds when the door is closed, 2. Check whether further troubleshooting is required NO/NC wiring correct 3. Check whether voltage of the interface on the panel seat of the HV box is triggered by mistake.
- Page 60 BC197DE User Manual integrity of the cabinet. If it is intact, the aerosol in the cabinet needs to be cleaned first. The fire extinguisher after spraying out needs to be replaced. 2. If it is a false alarm, check whether harness is abnormal.
- Page 61 BC197DE User Manual parameter value and carry out forced discharge. After recovery, restore the cell overvoltage parameter value, and find out the cause of overvoltage level 4. It can be restored by the Cell overvoltage levels 1, 2 Cell voltage between 3.6-3.8V,...
- Page 62 BC197DE User Manual occur after crossing the platform voltage, which normal phenomenon. 2. With gradual aging of the electric cabinet, internal resistance of the cell increases, it is more likely to occur under high current charging discharging. normal phenomenon. As long as the cell...
- Page 63 BC197DE User Manual temperature sampling is faulty or not 4. NTC fault or not 1. Check whether the A/C works normally 2. Whether the ambient temperature is too low Charging temperature too 3. Whether Cell temperature ≤ 0°C acquisition is normal 4.
- Page 64 BC197DE User Manual connected connected 1. Lack of or excessive terminal resistors 2. Check the harness for Parallel communication SBMU-MBMU poor contact fault communication abnormalities 3. The board works abnormally, etc. 1. Check the harness 2. The A/C is not turned...
- Page 65 BC197DE User Manual in total too large 2. Short circuit of load 3. The power device of the precharging circuit is damaged, etc. 4. The board works abnormally 1. The NO/NC contacts of lightning arrester are connected reversely SPD lightning protection Lightning arrester trigger alarm 2.
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Page 67: List Of Accessories
BC197DE User Manual 6 List of Accessories A single battery cabinet contains the following accessories (placed in the accessory box): Description Quantity Purpose Main battery cabinet-CAN Parallel Accessory 1 (Optional) communication harness of slave communication cable battery cabinet Fill the threading holes for the... -
Page 68: Terms
BC197DE User Manual 7 Terms 1 Cell Single cell. 2 Battery Module A combination of multiple cells connected in series, parallel or series-parallel mode, with only a pair of positive and negative output terminals, and used as a power supply. - Page 69 BC197DE User Manual 9 State of Health (SOH) The deviation ratio between the actual performance of the battery and the normal design index.
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