FOX-ESS HV2600 High Voltage Batteries User Manual

User Manual

HV2600

In order to prevent improper operation before use, please carefully read this manual.

Introduction

The document describes the installation, commissioning, maintenance, and troubleshooting of the following high voltage battery listed below.
HV2600
Note: HV2600 = 2.6kWh High Voltage
The battery chemistry of these products is Lithium Iron Phosphate. This manual is designed for qualified personnel only. The tasks described in this document should be performed by authorized and qualified technicians only.
After installation, the Installer must explain the user manual to the end- user.

Symbols

| Caution, risk of electric shock.
---|---
| Do not place nor install near flammable or explosive materials.
| Install the product out of reach of children.
| Read the instruction manual before starting installation and operation.
| Do not dispose of the product with household wastes.
| Recyclable.
| Disconnect the equipment before carrying out maintenance or repair.
| Observe precautions for handling electrostatic discharge-sensitive devices.
| Protective Class 1.
****| Caution, risk of electric shock, energy storage timed discharge.

Safety

Any work on the Batteries should be handled by authorized technicians and hence it is understood that the technicians should familiarize themselves with the contents of this manual before any maintenance or installation is carried out on the system.

Handling

• Do not expose the battery to open flame.
• Do not place the product under direct sunlight.
• Do not place the product near flammable materials. It may lead to fire or explosion in case of an accident.
• Store in a cool and dry place with ample ventilation.
• Do not store the product near water sources.
• Store the product on a flat surface.
• Store the product out of reach of children and animals.
• Do not damage the unit by dropping, deforming, impacting, cutting, or penetrating with a sharp object. It may cause leakage of electrolyte or fire.
• Do not touch any liquid spilled from the product. There is a risk of electric shock or damage to the skin.
• Always handle the battery wearing insulated gloves.
• Do not step on the product or place any foreign objects on it. This can result in damage.
• Do not charge or discharge a damaged battery.
• Do not store the battery near water sources.

Installation

• Do not connect the HV2600 to inverter conductors or Photo-Voltaic conductors. This will damage the battery and may result in an explosion.
• After unpacking, please check the product for damages and missing parts.
• Make sure that the inverter and battery are completely turned off before commencing installation.
• Do not interchange the positive and negative terminals of the battery.
• Ensure that there is no short circuit of the terminals or with any external device.
• Do not exceed the battery voltage rating of the inverter.
• Do not connect the battery to any incompatible inverter.
• Do not connect different battery types together.
• Please ensure that all the batteries are grounded properly.
• Do not open the battery to repair or disassemble. Only Fox is allowed to carry out any such repairs.
• In case of fire, use only a dry powder fire extinguisher. Liquid extinguishers should not be used.
• Install the batteries only inside the approved Fox enclosure. Installing the battery anywhere outside is strictly forbidden.
• Do not install the battery near water sources or places where the battery can get wet.
• Install the battery away from children or pets.
• Do not use the battery in a high static environment where the protection device might be damaged.
• Do not install with other batteries or cells.

Response to Emergency Situations

The batteries comprise multiple batteries connected in series. It is designed to prevent hazards or failures. However, Fox cannot guarantee their absolute safety.
Underexposure to the internal materials of the battery the following recommendations should be carried out by the user.

• If there has been inhalation, please leave the contaminated area immediately and seek medical attention.
• If there has been contacting with eyes, rinse the eyes with running water for 15 minutes and seek medical attention immediately.
• If there has been contacting with the skin, wash the contacted area with soap thoroughly and seek medical attention immediately.
• If there has been ingestion, induce vomiting and seek medical attention.

Fire Situation
In situations where the battery is on fire if it is safe to do so, disconnect the battery pack by turning off the circuit breaker to shut off the power to the system. Use FM-200 or Co2 fire extinguisher for the battery and an ABC fire extinguisher for the other parts of the system.
Under any fire situation, please evacuate the people from the building immediately before trying to extinguish it.

Water Situation
The battery modules are not water-resistant. Hence care should be taken not to get it wet. If you find the battery completely or partially submerged in water do not try to open it. Contact authorized personnel or Fox for further instructions.

Warning Labels

Warning labels and other relevant labels are attached to the battery pack.

Lithium-ion Battery Module
Model No.: HV2600
Nominal Capacity: 50Ah
Nominal Energy: 2.56kWh
Nominal Voltage: 51.2V
Voltage range: 40-58.4V
Max.charge/Discharge Current: 50A/50A
Ingress Protection: IP21
Protective Class: 1
Operating Temperature: -10-50°C
Storage Temperature: -20-50°C

DANGER/ HIGH VOLTAGE
Manufacture: FOXESS CO., LTD.
Factory: FOXESS CO., LTD. WUXI BRANCH
Made in China 10-200-20029-04

Product Information

1. HV2600 is a battery module, it needs to be used with a BMS BOX controller;
2. BMS BOX is the controller of the whole system, so each system must have one BMS BOX;
3. Our system consists of at least 2 HV2600 + 1 BMS BOX and up to 8 HV2600 + 1 BMS BOX.

Battery Module Specifications

Specifications for HV2600

Battery module| HV2600
Nominal capacity (kWh)| 2.6
Maximum charge voltage (V)| 58.4
Discharge cut voltage (V)| 40
Max. charge/discharge current (A)| 50A/50A
Operating temperature (°C)| -10 ~ 50
Storage temperature (°C)| -20 ~50
Charge/Discharge efficiency (%)| >98
Ingress protection| IP21
Protective class| I
Cycle life| >6000 @25°C @90% DOD
Available SOC range| 10%~100%
Weight (kg)| 29.7±1 kg
Dimensions (LWH) (mm)| 420480116

BMS Specifications

Specifications for BMS BOX

Model NO.| BMS-BOX
Operating voltage range(V)| 60-500VDC
Max. charge/discharge current (A)| 50A/50A
Total voltage measurement accuracy| ±1.0%FSR
Total voltage measurement channel| 2
Current measurement range| -65A~+65A
Insulation measurement accuracy| ±5%@≤100KΩ
Communication interfaces| RS485/CAN
Available SOC range| 10%~100%
Charge/Discharge efficiency (%)| >98
Operating temperature (°C)| -10 ~ 50
Storage temperature (°C)| -20 ~50
Humidity| 10%~90%
Weight (kg)| 4.5±1 kg
Dimensions (LWH) (mm)| 443410116

Battery System Specifications

Specifications for Battery System

The number of batteries| 2HV2600| 3HV2600| 4HV2600| 5HV2600| 6HV2600| 7HV2600| 8*HV2600
Normal voltage(V)| 102.4| 153.6| 204.8| 256| 307.2| 358.4| 409.6
Normal capacity (Ah)| 50| 50| 50| 50| 50| 50| 50
Voltage range(V)| 80-116.8| 120-175.2| 160-233.6| 200-292| 240-350.4| 280-408.8| 320-467.2
Recommended charging current(A)| ****

25

Max. charge/discharge current (A)| ****

50

CC-CV charging cut-off current(A)| 2.5
Peak charge current(A)(the 30s)| 60
Peak discharge current(A)| 60
Operating temperature (°C)| Charge: 0°C ~50°C Discharge: -10°C ~50°C
Storage temperature (°C)| -20°C ~50°C
Discharge capacity (Ah)| 0±2°C @1C @80%
25±2°C @1C @100%
45±2°C @1C @96%
Cycle life| ≥6000 @25°C @ 90%DOD
Ingress protection| IP21(Indoor)/IP65(Outdoor)| IP21
Protective class| I
Communication interfaces| RS485/CAN
Weight (kg)| 69.1±1kg (Net) 72.3±1 kg(Gross)| 103.7±1kg (Net) 108.5±1 kg (Gross)| 138.2±1kg (Net) 144.6±1 kg (Gross)| 172.8±1kg (Net) 180.8±1 kg (Gross)| 207.3±1kg (Net) 216.9±1 kg (Gross)| 241.9±1kg (Net) 253.1±1 kg (Gross)| 276.4±1kg (Net) 289.2±1 kg (Gross)

Product Features

Battery System Features

The batteries have been fitted with multiple protection systems to ensure the safe operation of the system. Some of the protection systems include:

• Inverter interface protection: Over voltage, Over current, External Short Circuit, Reverse Polarity, Ground Fault, Over-Temp, Inrush current
• Battery Protection: Internal Short Circuit, Over voltage, over current, over temp, Under voltage

The battery system contains the following Interface to allow it to connect and operate efficiently.

HV2600 Features:
– interface:

Power LED
This LED is used to indicate if the battery is operating effectively. A green light on this LED means the battery is ON and operating normally.

Alarm LED
This LED is used to indicate if the battery is operating in failure. A red light on this LED means the battery is operating abnormally.

Communication Port A(RS485-1) and B(RS485-2)
HV2600 has two 485 communication units in series operation, one for master control and one for slave control.
Network interface description: RS485-1 is connected to the upper battery module, RS485-2 is connected to the lower battery module.

Pin configuration is as follows:
– RS485-1

– RS485-2

Earth Terminal
This terminal is used to connect the battery to the earth for safety purposes.

Handle
The handle is used to push or pull the battery from its compartment. DO NOT LIFT THE BATTERY USING THIS HANDLE.

Power Terminal
A set of positive and negative terminals to connect the battery to the inverter. When you are unplugging the wires from the terminals, make sure you press the lock button and then pull it. When installing the plug, do not press the button and push the plug until you hear a click sound.
In addition to the above physical features, the battery has the following performance:

1. 90% Depth of Discharge
2. Cycle life >6000 cycles

BMS BOX Features:
– interface

BAT IN +
The positive electrode of the battery.
BAT IN –
The negative electrode of the battery.
DC switch
Power switch, battery charge, and discharge circuit switch.
DC OUT +
Connect bat + of the inverter.
DC OUT –
Connect bat – of the inverter.
POWER switches
System power on switch, press this switch, the system starts to work.
B-Start switches
Black start switches, if you want to start the battery system when there is no grid, press this switch first and then power on the system.
DIP switches
BMS relies on DIP switches to confirm the number of HV2600 in the system.
SOC LED
LED display battery system power and specific alarm information.
Alarm LED
If there is a fault in the system, the LED will display.
Battery Awaken Breaker
For maintenance only, please do not open the metal cover without authorization. Please contact the service department for further operation on this breaker. Only Fox unauthorized personnel are allowed to dismantle it.
CAN & RS485 communication

– CAN

Pin| Function Definitions|

Function Declaration

---|---|---
1| NC|
2| GND| Power/signal ground
3| B1| RS485-B
4| CANL| CANL
5| CANH| CANH
6| NC|
7| NC|
8| A1| RS485-A

– RS485

Pin| Function Definitions|

Function Declaration

---|---|---
1| GND| Power/signal ground
2| GND| Power/signal ground
3| P+| Signal P+
4| VCC_485_2| Wake up the power supply+5v
5| N-| Signal N-
6| B2| RS485-B
7| A2| RS485-A
8| VCC_485| power supply+5v

Earth Terminal
This terminal is used to connect the battery to the earth for safety purposes.

Installation

Items in the package

Please check if the following items are included with the package:
For HV2600

Number| Items| Number|

Items

---|---|---|---
A| Communication cable (0.21m)| D| Grounding cable (0.19m)
B| Battery power cable (0.19m)| E| Mounting screw pack
C| Fixing bracket| F| Installation guide

Note: item C is provided separately, not included in the battery pack. Please contact your dealer if you do not have it.

For BMS BOX

Number| Items| Number|

Items

---|---|---|---
A| Mounting screw pack| F| Fixing bracket
B| Main negative battery connection cable (0.17m)| G| DC negative output cable (1.2m)
C| Main positive battery connection cable (1.3m)| H| DC positive output cable (1.2m)
D| Grounding cable (1m)| I| User manual
E| Communication cable (BMS-inverter) (1.2m)| |

Note: item H is provided separately, not included in the battery pack. Please contact your dealer if you do not have it.

Clearance

Make sure to leave a space of at least 300 mm. A clearance of at least 300 mm must be Ieft around the battery pack for proper cooling.
Note: Make sure that the battery pack is always exposed to the ambient air. The battery pack is cooled by natural convection. If the battery pack is entirely or partially covered or shielded, it may cause the battery pack to stop operating.

Tools

The following tools will be required to install the BMS BOX and the battery.

Installation Steps

Step 1: Place the front bracket and back bracket as shown below.

Step 2: Insert the battery module into the bracket from the front horizontally, and tighten the four screws on the side.

Step 3: Locate the brackets for the second battery on top of the first pair of the bracket and fasten the connecting button on the side.

Step 4: Insert the battery module into the bracket from the front horizontally, and tighten the four screws on the side.

Step 5: Connect the inverter as shown in the figure below.

Note: If the Battery modules are more than 4 pieces, please separate them into multiple stacks. Please make sure each stack only includes max. 1 BMS and 4 battery modules.

Note: For another installation, please refer to the All-In-One user manual.

Wiring Steps

A. Battery power cable
Step 1: Connect the power cable starting from the first battery module in series with other battery modules (Orange opposite, black negative). A ‘click’ sound indicates the connections are secured. The positive and negative connection of the battery cable is shown below.

Step 2: Measure voltage value: After all battery modules are connected in series, use a multimeter to measure the DC voltage on the DC terminal. The total voltage should be N *52±10V (N is the total number of battery modules). Please refer to the picture below for the voltage test.

B. Communication cable connection:
Step 1: Take the main positive cable (two orange plugs), the main negative line (two black plugs) to connect the BMS BOX.
Step 2: Then connect the 485 on the BMS BOX to the RS485-1 of the first battery module, connect the RS485-1 of the previous battery module to RS485-2 of the next battery module, leave the last module’s RS485-2 vacant. Wiring shall be connected in the sequence as shown below.

C. Grounding cable:
Connect the grounding cable to ensure that all batteries are grounded. Wiring shall be connected in the sequence as shown below.

System Startup

• When the grid-connected system is started, the inverter should be turned on first to avoid the current pulse of the inverter increasing to the battery pack.
• All installation and operation must comply with local electrical standards.
• Check all power cables and communication cables carefully.

1. Turn on the POWER switch
   • Before starting, please dial DIP to the correct position. DIP represents the number of HV2600 in the system. Please refer to the following table for details: DIP position|

The number of HV2600

---|---
0| 2
1| 3
2| 4
3| 5
4| 6
5| 7
6| 8

• Turn on the DC switch and press the POWER switch, all the lights will light up, and the green and red LED on the HV2600 module will light up for 1s at the same time, you will hear the sound of closing and cutting off the relay in BMS BOX to prove that the system works normally.

2. Module address assignment
   If the system is powered on for the first time, BMS will automatically assign the module address of HV2600 without manual configuration.

Commissioning

There are two LED indicators on the front of the battery packs to show its operating status.

For HV2600

Green LED

| Red LED|

Batteries Status

---|---|---
On for 1s| On for 1s| Initial power on
On for 4s| Off| Work
Off| On| Communication lost
On for 4s| On for 4s| Recoverable alarm
Off| On for 4s| Unrecoverable Alarm

For BMS-BOX
– Alarm LED

BMS-BOX Condition| Green|

Red

---|---|---
Error| Off| Flash
Standby| Flash| Off
Charge/Discharge| On| Off

– SOC LED indication

Status| ****| Charge| Discharge|

Stand By

---|---|---|---|---

=100%

| ****| On| On|

Off

| On| On
| On| On
****| On| On

> 100%>soc>=75%

| | Flash| On
| On| On
| On| On
| On| On

75% >soc>=50%

| | Off| Off
| Flash| On
| On| On
| On| On

50% >soc>=25%

| | Off| Off
| Off| Off
| Flash| On
| On| On

25% >soc>=0

| | Off| Off
| Off| Off
****| Off| Off

| Off| On

– SOC LED fault message

Exclusion

The warranty shall not cover the defects caused by normal wear and tear, inadequate maintenance, handling, storage faulty repair, modifications to the battery or pack by a third party other than Fox or Fox agent, failure to observe the product specification provided herein, or improper use or installation, including but not limited to the following.

• Damage during transport or storage.
• Incorrect Installation of the battery into pack or maintenance.
• Use of battery pr pack in an inappropriate environment.
• Improper, inadequate, or incorrect charge, discharge, or production circuit other than stipulated herein.
• Incorrect use or inappropriate use.
• Insufficient ventilation.
• Ignoring applicable safety warnings and instructions.
• Altering or attempted repairs y unauthorized personnel.
• In case of force majeure (ex: lightning, storm, flood, fire, earthquake, etc.).
• There are no warranties-implied or express-other than those stipulated herein. Fox shall not be liable for any consequential or indirect damages arising or in connection with the product specification, battery, or pack.

Troubleshooting and Maintenance

Maintenance

A. Regularly check whether the service environment of the battery meets the requirements, and the installation position should be far away from the heat source.
B. In case of one of the following situations, it needs to be charged in time:
– The battery is often undercharged;
– The battery has been out of the use or stored for more than 3 months.
C. Regularly check whether the battery and its supporting terminals, connecting cables, and indicator lights are normal.

Troubleshooting

When the red / green LED on the panel is flashing or normally on, it does not mean that the HV2600 is abnormal, it may be just an alarm or protection. Please check the ‘LED status indicators’ in chapter 7 for the detailed faulty definition before any trouble-shooting steps. In general, the alarm indication is normal without manual intervention. When the alarm triggering state is removed, HV2600 will automatically return to normal use.
– Problem determination based on the following points

1. Whether the green light on the power switch is on;
2. Whether the buzzer in BMS box on;
3. Whether the battery system can be communicated with inverter;
4. Whether the battery can be output voltage or not.

– Preliminary determination steps
The battery system cannot work, when DC switches on and POWER on, the LED doesn’t light up or flash, please consider contacting the local distributor.

1. The LED display of BMS-BOX and HV2600 is normal, but it cannot charge and discharge. Observe the display screen of the inverter and there is no SOC. Please check whether the CAN communication between BMS-BOX to the inverter is well connected. If the connection is good, please replace a CAN communication cable. If the SOC is still not visible on the inverter display screen, please contact the local distributor.
2. After the battery system is powered on if you can see the alarm information on the LED and inverter display screen at the same time, please contact the local distributor.

The copyright of this manual belongs to FOXESS CO., LTD WUXI BRANCH. Any corporation or individual should not plagiarize, partially, or fully copy (including software, etc.), and no reproduction or distribution of it in any form or by any means is permitted. All rights reserved.
FOXESS CO., LTD WUXI BRANCH
The copyright of this manual belongs to FOXESS Co., Ltd Wuxi Branch. Any corporation or individual should not plagiarize, partially, or fully copy (including software, etc.), and no reproduction or distribution of it in any form or by any means is permitted. All rights reserved.
FOXESS Co., Ltd Wuxi Branch
Add: No.11, Lijiang Road, Xinwu District, Wuxi
Add: No.11, Lijiang Road, Xinwu District, Wuxi City,
Jiangsu Province, China
Tel: 0510- 68092998
WWW.FOX-ESS.COM.

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