i-G3N Z-Range 48V Z-Range Lithium LifePO4 100Ah 5.1kW Battery Installation Guide
- October 28, 2023
- i-G3N
Table of Contents
i-G3N Z-Range 48V Z-Range Lithium LifePO4 100Ah 5.1kW Battery
Contents of the Box
Inside each box is the 5.14 kWh battery (51.2 Vnom, 100 A capacity), negative and a positive DC cable with Amphenol connectors (battery side) and M8 lugs (inverter/DC busbar side). Each box also contains a pin-to-pin CAT cable for communication to either the inverter or between the battery units.
Handling the Battery
Work on the battery should be carried out by qualified personnel only.
Please use the provided handles to lift and move the battery. Please handle
the battery with care as the battery is sensitive to mechanical shock.
Ports used During Operation of the Battery
Figure 1shows the ports that are used during the operation of the battery.
Please pay close attention to which ports are used and connected during
operation. The Figure should be read in conjunction with Table 1.
Instructions
- Negative DC post #1
- Negative DC post #2
- On/ Off switch
- SOC indicator
- Alarm indicator
- Run indicator
- Dry contact
- GND
- Address dial switch
- RS232 port
- Link B
- Link A
- Reset button
- CAN/RS485 port
- Positive DC post #1
- Positive DC post #2
Stacking
The Z-Range battery can be stacked in 3 different configurations:
- Standing on its back
- Stacked with brackets
- Stacked in a cabinet (each battery is 3U in height)
A maximum of 4 units can be stacked when using the brackets. It is recommended to use two or more stacks when more than 4 units are installed. Figure 2 illustrates the stacking methodology of the Z-Range using the brackets.
The battery voltages need to be within +- 0.5 V to be integrated. The batteries are shipped at 100%, and tend to settle around 53.5 V during transport. If an additional battery is added to the system, it is recommended that the existing units be charged to 100% and allowed to settle (be without loads or charging) to integrate the new battery.
Figure 3 shows the Z-Range dimentions
Wiring
Before connecting the DC cables, please ensure the polarity of the connections
are correct.
Note that it is required to have a DC disconnect between the battery and the
inverter.
DC Connections
The Amphenol connections on the battery can only sustain 100 A output. There
are two different ways to connect the battery in parallel.
It is recommended that the disconnect be 1.25 x Rated current.
Wiring methodology #l
Connect all the batteries to a common busbar. Each battery can produce its
maximum recommended output current, with this methodology. This methodology
allows each battery unit to produce its maximum recommended output current.
Connect the provided DC cables to the top DC post of each unit, and the M8 lug
to the common busbar. Figure 4 depicts the connection methodology.
Wiring methodology #2:
Daisy chain the DC connections, from bottom to top. This wiring methodology
limits the current output to the maximum recommended output of a single
battery, but increases the available capacity. Figure 5 illustrates how to
connect the batteries with this method. For this configuration we recommend
that the provided cable from the master box be connected to the top unit and
the DC disconnect. The interconnecting cables can be made from the other
batteries’ DC cables by cutting the lug side cable, and crimping the provide
amphenol connecter. The recommended length of this interconnecting cable is
150 mm.
Communication
The communication cables start from the master unit’s Link A port to Link B on
the second unit. This A -> B loop continues, in sequence, up to the last unit.
No termination plug is necessary on the final Z-Range unit. Figure 6 shows the
connection of the communication cables between the batteries
The communication cables between the units must follow the address of the
units. Address 1 needs to be connected to Address 2, and Address 2 is
connected to Address 3, as mentioned in Table 3.
The CAN connection between the GX device and the battery connects on the CAN
port of the master unit. The battery has a baud rate of 500 kbps.
Table 2 below shows the pin outs of the inverters that the Z-Range battery is
compatible with.
These are the only cables that are necessary to connect.
Table 2: Inverter and Battery communication pinouts (CAN/RS485)
Master Configuration
The configuration of all the Z-Range units can be set to either be the master or a secondary in a stack. The dip switches are used to change the address of the unit in the stack. Table 3 illustrates the arrangement of dip switches to configure each individual unit in a stack.
Table 3: Assignment of Addresses to Z-Range Battery
Note that the 1 indicates that the dip switch needs to be in the “up” position, while the 0 indicates a “down” dip switch.
Battery Parameters
The following are the recommended voltage parameters for the Z-Range battery.
Note that each battery has a capacity of 100 A.
- Low voltage alarm – 50V
- Low voltage cut off – 46 V
- Restart- 48V
- Low voltage alarm -30%
- Low voltage cut off – 20%
- Restart – 30%
- Absorption – 56 V
- Float 54 V
- Equalization 56.2 V
Recommended charge limit – 70A
Recommended discharge limit – 90A
Startup Procedure
Refer to Table l and Figure 1 for the port and switches layout. Double-check polarity of the DC connections between the battery and inverter
-
Ensure the fuses to the battery are completely open or removed. The communication cable to the Gx device/inverter must also be removed.
-
Before switching on the battery ensure the wiring of the battery is done correctly, according to this manual
a. Communication cable
b. Electric cables -
Start by switching on the Master unit (using switch 3).
a. The battery will go through a boot up procedure where the soC, Alarm and Run lights flicker on
b. The Run light will flicker on for 1 second and off for 3 seconds if the start up procedure is done correctly and the Soc lights are on -
Ihe next unit can be switched on if the previous units Run light flashes as mentioned in step 5b
a. The next unit’s Run light must flash at the same tempo as the master unit before any additional unit can be switched on
b. The lights will not flicker simultaneously, but at the same tempo -
Repeat step 4 for all the additional units
-
Connect the communication from the GX device to the CAN port on the master unit once all the units in the stack have been switched on and the Run lights flash correctly
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Close the fuses
The battery bank might indicate an Alarm event when the fuses are closed. if the bank does not recover on its ovwn, it is recommended to first energize the DC busbar with the inverter berore start by switching on the Master unit.
The battery bank might indicate an Alarm event, when the fuses are closed. Especialy when the inverter:Battery ratio is lower than 11. if the battery does not recover on its own, it is recommend to energize the DC busbar with the inverter or PV (if present) before closing the fuses.
Restart Procedure
-
Switch system over to grid
-
Switch off entire system
a. Switch off PV inverter
b. Switch off Inverter/charger (Victron) -
Switch off battery
a. Start at the top unit and switch the unit off
b. Switch off the secondary unit
C. Repeat -
Isolate Battery (remove Fuses)
-
Restart battery (Start at the top unit and move down sequentially)
a. Switch the unit on
b. Wait until the “Run” light (green light) flashes
i. 1 sec on, 3 sec off
C. Switch the second unit on -
Wait until both the units’ “run” light flashes at the same tempo
a. They don’t have to flash simultaneously, but just at the same tempo -
Repeat step 5 and 6 until the final unit
-
Close the DC disconnect if the battery run light flashes at the same tempoo