BC100DE User Manual

BC100DE
User Manual for Industrial and
Commercial Battery Cabinet

Version V2.0 Date of Release 2023-02-16 I

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Overview
This Manual introduces the main features, performance indicators, system principles,

appearance and structure of the BC100DE industrial and commercial battery cabinet, and also

provides installation, use and operation instructions, maintenance management, etc.

Target readers
This document is primarily intended for the following engineers:

Sales engineer

Technical support engineer

System engineer

Hardware installation engineer

Commissioning engineer

Maintenance engineer

Convention of Symbols

The following symbols may appear in this document, and their meanings are as follows.

Symbol Description
Indicates a hazard with a high level of risk which, if not avoided, will
result in death or serious injury.
Indicates a hazard with a medium level of risk which, if not avoided,
could result in death or serious injury.
Indicates a hazard with a low level of risk which, if not avoided, could
result in minor or moderate injury.
Used to convey equipment or environmental safety warning
information. If not avoided, it could result in equipment damage, data
loss, degraded equipment performance, or other unpredictable results.
“NOTICE” does not cover personal injury.
Supplementary explanation of key information in the main text.
“NOTE” is not safety warning information, and does not involve
personal, equipment and environmental damage information.

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Revision History

Internal
Version Revision date Content Document
Number

V1.0 2022/11/30 First draft

Modified the description of the troubleshooting and

V2.0 2023/02/16 maintenance, the use of AC power supply, and
corrected the wrong description in the manual.

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Contents
1. General Safety Precautions ........................................................................................................... 1
1.1 General Safety ..................................................................................................................... 1
1.2 Personnel Requirements ...................................................................................................... 5
1.3 Electrical Safety .................................................................................................................. 5
1.4 Requirements of Installation Environment ......................................................................... 8
1.5 Machinery Safety .............................................................................................................. 10
1.6 Battery Safety .................................................................................................................... 13
1.7 Others ................................................................................................................................ 15
2. Overview ..................................................................................................................................... 17
2.1 Product Introduction ......................................................................................................... 17
2.1.1 Product Appearance ............................................................................................... 17
2.1.2 Product Structure.................................................................................................... 19
2.1.3 Product model and naming scheme ........................................................................ 22
2.2 Battery System Parameters ............................................................................................... 22
2.2.1 Cell Parameters ...................................................................................................... 22
2.2.2 Battery Module Parameters .................................................................................... 23
2.2.3 Battery Cluster Parameters ..................................................................................... 23
2.2.4 Battery Cabinet Parameters .................................................................................... 24
2.2.5 Interfaces of High-voltage box............................................................................... 25
3. Installation................................................................................................................................... 27
3.1 Site Planning ..................................................................................................................... 27
3.1.1 Dimensions of Battery Cabinet .............................................................................. 27
3.1.2 Precautions for Installation .................................................................................... 28
3.1.3 Space Reservation .................................................................................................. 28
3.2 Preparation of Tools and Instruments ................................................................................ 29
3.3 Preparation of Power Cables ............................................................................................. 30
3.4 Unpacking ......................................................................................................................... 30
3.5 Single Cabinet Installation ................................................................................................ 30
3.5.1 Installation Environment ........................................................................................ 30
3.5.2 Installing the Cabinet ............................................................................................. 31
3.5.3 Installation Instructions for Copper Bars between Battery Modules ..................... 32
3.6 Electrical Connection ........................................................................................................ 35
3.6.1 AC Input Connection.............................................................................................. 35
3.7 Cabinet Installation ........................................................................................................... 36
3.7.1 Parallel Connection of Battery Clusters in the Cabinet .......................................... 36
3.7.2 Parallel Connection of Battery Cabinets ................................................................ 38
3.8 Communication Wiring Instructions ................................................................................. 39
4. Operation Guide .......................................................................................................................... 41
4.1 Inspection after Installation ............................................................................................... 41
4.2 Running Environment Check ............................................................................................ 42
4.3 Power-on Operation .......................................................................................................... 42
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4.3.1 Prerequisites ........................................................................................................... 42

4.3.2 Operation Steps ...................................................................................................... 42
4.4 Power-off Operation.......................................................................................................... 43
4.4.1 Power-off Steps ...................................................................................................... 43
4.4.2 Emergency Power-off ............................................................................................ 44
4.5 Test Run of Battery Cabinet .............................................................................................. 44
5. Routine Maintenance .................................................................................................................. 46
5.1 Monthly Maintenance ....................................................................................................... 46
5.2 Quarterly Maintenance ...................................................................................................... 47
5.3 Annual Maintenance ......................................................................................................... 48
6. Troubleshooting and Maintenance .............................................................................................. 49
7. List of Accessories ...................................................................................................................... 54
8. Terms ........................................................................................................................................... 55

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1. General Safety Precautions

1.1 General Safety

Statement
Please read this manual before installing, operating and maintaining the equipment, and

follow the marks on the equipment and all safety precautions in the manual.

The “Caution”, “Warning” and “Danger” items in the manual do not represent all safety items

that should be observed, but are only supplements to all safety precautions. KSTAR does not

assume any responsibility caused by violation of general safety operation requirements or

violation of safety standards for design, production and use of equipment. This equipment should

be used in an environment that meets the design specifications, or it may cause equipment failure,

and the resulting abnormal equipment function or component damage, personal safety accidents

and property losses are not within the scope of equipment quality assurance.

Comply with local laws, regulations and norms when installing, operating, and maintaining

the equipment. The safety precautions in the manual are only a supplement to local laws,

regulations and norms.

KSTAR is not liable for any of the following situations.

 Fail to operate under the conditions of use described in this manual.

 The installation and use environment doesn’t comply with the regulations in relevant

international or national standards.

 Unauthorized dismantling, changing the product or modifying the software code.

 Failure to follow the operating instructions and safety warnings in the product and

documentation.

 Equipment damage caused by abnormal natural environment (force majeure, such as

earthquake, fire, storm, etc.).

 Damage caused by the customer’s own transportation.

 Damage caused by storage conditions not meeting documentation requirements.

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General requirements
 It is strictly forbidden to install, use and operate outdoor equipment and cables

(including but not limited to moving equipment, operating equipment and cables,

plugging/unplugging signal interfaces connected to outdoor, working at heights, outdoor

installation, etc.) in severe weather such as lightning, rain, snow, and 6-scale wind.

 Do not wear watches, bracelets, rings, necklaces or other conductive objects during

installation, operation and maintenance, so as to avoid electric shock.

 Special protective equipment must be used during installation, operation and

maintenance, such as wearing insulating gloves, goggles, safety clothing, safety helmet,

safety shoes, etc., as shown in the figure below.

 Installation, operation and maintenance must be carried out in accordance with the

sequence of steps in the instruction manual.

 Before touching any conductor surface or terminal, measure the voltage at the contact

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point to confirm that there is no risk of electric shock.

 After the equipment is installed, empty packing materials in the equipment area, such as

cartons, foam, plastic and cable ties, should be removed.

 In case of fire, evacuate the building or equipment area and press the fire alarm bell, or

call the fire alarm. Re-entry into a burning building is strictly prohibited under any

circumstances.

 Do not disable protective devices and ignore warnings, cautions and precautions in the

manual and on equipment. Timely replace hazard signs that have become unclear due to

long-term use.

 Except for the personnel who operate the equipment, other personnel are not allowed to

approach the equipment.

 The handle of the tool used needs to be insulated and protected, or use an insulated tool,

as shown in the figure below.

 The wiring holes with cables routed need to be sealed with fire putty, and un-routed

wiring holes need to be sealed with the cover that comes with the cabinet. The correct

construction standard for fire putty plugging is shown in the figure below.

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 It is strictly forbidden to alter, damage or cover the identification and nameplate on the

equipment.

 Use tools to tighten the screws when installing the equipment.

 Live operation is strictly prohibited during the installation process.

 Paint scratches that occur during equipment transportation and installation must be

repaired in time; it is strictly prohibited to expose the scratched parts to the outdoor

environment for a long time.

 Before operation, securely fix the equipment on the floor or other stable objects, such as

a wall or a mounting bracket.

 Do not wash the electrical components inside and outside the cabinet with water.

 Do not change the structure and installation sequence of the equipment without

authorization.

Personal safety
 If a fault that may cause personal injury or equipment damage is found during the

operation of the equipment, terminate the operation immediately, report to the person in

charge, and take effective protective measures.

 To avoid the risk of electric shock, it is forbidden to connect the safety extra low voltage

(SELV) circuit to the telecommunication network voltage (TNV) circuit.

 Do not power on the equipment until it is installed or confirmed by a professional.

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1.2 Personnel Requirements

 The personnel responsible for the installation and maintenance of KSTAR equipment

must first undergo strict training to comprehend the safety precautions and master the

correct operation methods.

 Only qualified professionals or trained personnel are allowed to install, operate and

maintain the equipment.

 Only qualified professionals are allowed to remove safety devices and repair equipment.

 The personnel who operate the equipment, including operators, trained personnel, and

professionals, should have the special operation qualifications required by the local

government, such as high-voltage operation, climbing, and special equipment operation

qualifications.

 Professionals: People who have experience in training or operating equipment, and who

can clearly understand the potential sources and levels of danger in the process of

equipment installation, operation, and maintenance.

 Trained personnel: A person who has received appropriate technical training and has the

necessary experience can be aware of the dangers that may be brought to him when

performing a certain operation, and can take measures to minimize the danger to him or

other personnel.

 Operators: Operators who may come into contact with the equipment except trained

personnel and professionals.

 Replacement of equipment or components (including software) must be done by

professionals or authorized personnel.

1.3 Electrical Safety

Grounding requirements

 When installing equipment that needs to be grounded, the protective ground wire must

be installed first; when removing the equipment, the protective ground wire must be

removed last.

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 Do not damage the grounding conductor.

 Do not operate the equipment without a grounding conductor installed.

 The equipment should be permanently connected to the protective earth. Before

operating the equipment, check the electrical connection of the equipment to ensure that

the equipment is reliably grounded.

General requirements
 When performing high-voltage operation, please use special insulated tools.

AC and DC operating requirements

It is forbidden to install or remove the power cord while it is live. When the power wire core touches the
conductor, an arc or electric spark will be generated, which may cause fire or personal injury.

 If the equipment is marked with “High Leakage Current”, the protective grounding

terminal of the equipment case must be grounded first before connecting the AC input

power to prevent the leakage current of the equipment from causing electric shock to the

human body.

 Before installing or removing the power cord, the power switch must be turned off.

 Before connecting the power cord, make sure the label on the power cord is correct.

 If the equipment has multiple inputs, all inputs should be disconnected, and the

equipment can be operated only after it is completely powered off.

 It is not recommended to configure an air switch with leakage protection function.

 If the power cord is damaged, it must be replaced by the manufacturer, service agent or

professionals to avoid risks.

 Personnel performing high-voltage operations and installing AC equipment must have

high-voltage and AC work qualifications.

Wiring requirements

 Use of the cable in a high-temperature environment may cause aging and damage to the

insulation layer. The distance between the cable and the outer periphery of the heating

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device or heat source area must be at least 30 mm.

 Cables are not allowed to pass through the air inlet and outlet of the equipment.

 The cables should meet the VW-1 flame retardant requirements.

 Cables of the same type should be bundled together, and cables of different types should

be laid at least 30 mm apart. Intertwining or crossing of cables is prohibited.

 When the temperature is too low, severe impact and vibration may cause the plastic

sheath of the cable to be brittle and crack. To ensure construction safety, the following

requirements should be followed:

 All cables should be laid and installed above 0℃. When moving cables, especially

when constructing in low temperature environments, they should be handled with

care.

 If the storage environment temperature of the cables is below 0℃, the cables must

be stored at room temperature for more than 24 hours.

 It is forbidden to push the cables directly from the truck or have other non-standard

operations.

 The selection, installation, and routing of cables must comply with local laws,

regulations, and specifications.

Static protection requirements

The static electricity generated by the human body will damage the static-sensitive components on the board,
such as large-scale integrated circuits (LSI).

 The static electricity generated by the human body will damage the static-sensitive

components on the board, such as large-scale integrated circuits (LSI). Before touching

the equipment, holding a board or an application-specific integrated circuit (ASIC) chip,

you must wear ESD gloves or ESD strap. The other end of the ESD strap should be

properly grounded.

 When holding the board, you must hold the edge of the board that does not contain

components, and do not touch the components with your hands.

 The disassembled board must be packed in ESD packaging materials before storage or

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transportation.

Fig. 1-1 Diagram of wearing ESD strap

Neutral ground voltage

 It is recommended that the user balance the three-phase load so that the neutral-ground
voltage is less than 2V and meets the power distribution requirements.

1.4 Requirements of Installation Environment

 When the equipment is running, do not cover the vents or heat dissipation system in

order to prevent fire due to high temperature.

 The equipment should be installed in an area away from liquids; it is forbidden to install

it under water pipes, air outlets and other places that are prone to condensation, or under

places that are prone to water leakage, such as air-conditioning outlets, vents, and outlet

windows in the machine room, so as to prevent liquids from entering the inside of the

equipment and causing malfunction or short circuit.

 If any liquid enters the equipment, please turn off the power immediately and notify the

administrator.

 Do not place the equipment in an environment with flammable or explosive gas or

smoke, and do not perform any operations in such environment.

 The equipment should be installed away from desert or sandy environment.

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High-altitude installation

 The operations carried out more than 2m above the ground are all high-altitude

operations.

 The high-altitude operations must be stopped in case of one of the following situations:

the rainwater on the steel pipe is not dry, and other situations that may cause danger.

When the above-mentioned situation has passed, the company’s safety director and

relevant technical personnel must check the operating equipment, and the operation can

only be carried out after confirmation and approval.

 High-altitude operations must meet the requirements of local laws and regulations on

operations at heights.

 The person must accept relevant training and obtain relevant certificates before taking

up work and perform high-altitude operations.

 Before high-altitude operations, carefully check the climbing tools and safety appliances,

such as safety helmets, safety belts, ladders, springboards, scaffolding, lifting equipment,

etc. Any incompliance must be improved immediately or the high-altitude operations

should be stopped. Take appropriate safety protection, wear a safety helmet, safety belt

or waist rope, and tie it to a solid structural member. It is strictly forbidden to hang on an

unstable object or metal with sharp edges and corners to prevent the hook from slipping

and causing a fall accident.

 At the high-altitude operation site, the dangerous restricted area should be marked out,

and obvious signs should be set up to strictly prohibit irrelevant personnel from entering.

 Carry the operating equipment and tools properly to prevent the tools from falling and

hurting others.

 It is strictly forbidden to throw objects from high altitude to the ground or throw objects

from the ground to high altitude. Strong cables, hanging baskets, elevated vehicles or

cranes should be used to transport objects.

 Guardrails and signs should be set up at the edges and holes of high-altitude operations

to prevent stepping into the air.

 On the ground below the high-altitude operation area, it is strictly forbidden to pile up

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scaffolding, springboards, and other sundries. Ground personnel are strictly prohibited

from staying or passing directly under the high-altitude operation area.

 Scaffolding, springboards and workbenches for high-altitude operations must be

inspected and appraised for safety in advance to ensure that the structure is firm and the

scaffolding is not overloaded.

 If the person in charge of the site and the safety officer find that the construction

personnel working at heights do not operate according to the regulations, they should

immediately ask them to make corrections; otherwise, their operations must be stopped.

1.5 Machinery Safety

Hoisting safety

 When hoisting heavy objects, it is strictly forbidden to walk under the boom and the

hoisting objects.

 The personnel who carry out the hoisting operation must accept relevant training and

can only work after passing the qualification.

 The hoisting tools must be inspected and can only be used if they are complete.

 Before hoisting, ensure that the hoisting tools are securely fixed to load-bearing fixtures

or walls.

 During hoisting, ensure that the angle between the two cables is not greater than 90°, as

shown in the figure below.

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 During hoisting, it is forbidden to drag the steel wire rope and lifting gear, or hit with
hard objects.

Ladder use safety

 Use wooden ladder or fiberglass ladder when climbing operations may be involved.

 When using a herringbone ladder, the rope must be firm, and the ladder must be held by

dedicated personnel during operation.

 Before using the ladder, please confirm that it is intact and the load capacity meets the

requirements. Overweight use is strictly prohibited.

 The ladder should be placed in a stable place. The inclination of the ladder is preferably

75°, which can be measured with a square, as shown in the figure below. The ladder

should be used with the wide legs pointing down or with protection at the bottom of the

ladder to prevent slipping.

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 When climbing a ladder, please pay attention to the following actions to reduce danger

and ensure safety.

 Keep your body steady.

 The maximum height at which workers can stand on their feet should not exceed the

fourth step from the top to the bottom of the ladder.

 Make sure that the center of gravity of the body does not deviate from the edge of the

ladder frame.

Drilling safety

 When drilling holes on walls and ground, consider the following safety precautions:

Drilling holes in the equipment is strictly prohibited. Drilling will damage the electromagnetic shielding
performance of the equipment, internal components, and cables, and metal shavings generated by drilling
will enter the equipment and cause a short circuit on the circuit board.

 The consent of the customer, the contractor and KSTAR should be obtained before

drilling.

 Wear goggles and protective gloves when drilling.

 During the drilling process, the equipment should be covered to prevent debris from

falling into the equipment, and the debris should be cleaned in time after drilling.

Safety when handling heavy loads

When pulling the equipment out of the cabinet, be careful of equipment that may be unstable or heavy on the
cabinet to avoid being crushed or smashed.

 When handling heavy objects, be prepared to bear the weight to avoid being crushed or
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sprained.

 When carrying the equipment by hand, wear protective gloves to avoid injury.

 When moving or lifting the equipment, hold the handle or the bottom edge of the

equipment instead of the handle of the module installed in the equipment.

 Avoid scratching the surface of the cabinet or damaging the components and cables of

the cabinet when moving the equipment.

 When using a forklift to transport, the fork must be in the middle position to prevent

overturning. Before moving, please use ropes to fasten the equipment on the forklift;

when moving, special care is required.

 When transporting, try to choose railway, sea or roads with good conditions to ensure

the safety of the equipment. Bumps and tilts should be minimized during transportation.

 Move the cabinet carefully to avoid equipment damage caused by any impact or drop.

1.6 Battery Safety

Basic requirements

Before working on the battery, you must carefully read the safety precautions for operation
and master the correct connection method of the battery.

 Do not expose the battery to high-temperature environments or heat-generating devices, such as

sunshine, fire, transformers, heaters, etc. Batteries may explode if overheated.
 Do not incinerate the battery, or it may cause an explosion.
 It is strictly forbidden to disassemble, modify or destroy the battery (such as inserting foreign objects,
immersing in water or other liquids), so as to avoid electrolyte leakage, overheating, fire or explosion.

 Wear goggles, rubber gloves, and protective clothing to prevent harm caused by

electrolyte spillage. If the electrolyte leaks, do not let the skin or eyes come into contact

with the electrolyte. If it touches the skin or eyes, rinse with clean water immediately

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and go to the hospital for medical treatment.

 Please use special insulation tools.

 When moving the battery, carry in the direction required by the battery; it is strictly

forbidden to invert or tilt it.

 During installation and maintenance operations, the battery circuit should be kept

disconnected.

 Please use the specified type of battery, or it may cause damage to the battery.

 Please dispose of used batteries according to local laws and regulations, and do not

dispose as domestic waste. Improper battery disposal may cause the battery to explode.

 There must be fire-fighting facilities that meet the requirements on site, such as

fire-fighting sand and dry powder fire extinguishers.

In order to ensure the safety of battery use and the accuracy of battery management functions, please use the
battery provided with the PCS host by KSTAR. KSTAR will not be responsible for any battery-related
failures caused by using batteries not provided by KSTAR.

Battery installation specifications

 Before installing and operating the battery, the following basic precautions should be

observed in order to ensure safety:

 The battery should be installed in a ventilated, dry and cool environment, away from

heat sources, flammables, humid, large amounts of infrared radiation, organic solvents,

and corrosive gases, and fire prevention measures should be taken. The battery should

be placed and fixed horizontally.

 Pay attention to the battery polarity during installation. It is strictly forbidden to

short-circuit the positive and negative poles of the same battery or the same battery

string, or it will cause a short circuit.

 Check the battery connection terminal screws regularly to make sure they are tight and

not loose.

 It is strictly forbidden to place installation tools on the battery during installation.

Battery short circuit protection

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A short circuit of the battery will generate an instantaneous large current and release a large amount of energy,
which may cause personal injury and property damage.

In order to avoid battery short circuit, the battery does not allow online maintenance.

Lithium battery special scene

Refer to lead-acid batteries for the safety precautions of lithium battery operation. In addition,
the following matters need to be noted.

There is risk of explosion if battery is replaced by an incorrect type.

 Replace only with the same or similar type battery recommended by the manufacturer.

 Inversion, tilting and collision are prohibited when handling the lithium batteries.

 During installation, maintenance and other operations, the circuit of the lithium battery

module should be kept disconnected.

 Charging is prohibited when the lithium battery is lower than the lower limit of the

working temperature (charging is prohibited at 0℃), so as to avoid internal short circuit

of the battery due to low temperature charging crystallization.

 Do not exceed the temperature range, which will affect the performance and safety of

the battery.

 Do not throw the lithium battery module into a fire source.

 After the maintenance is completed, return the used lithium battery module to the

maintenance site.

1.7 Others

Transportation, storage and maintenance

 For long-term storage, charge and discharge every 6 months according to the method

specified in the manual.

 Be careful not to drop the battery when loading and unloading it during transportation.

Do not turn it over.

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Warnings and precautions

Please read the specifications and the warning signs on the surface of the battery box

carefully before using the battery. Improper use of the battery may cause overheating and damage

to the battery. KSTAR will not be responsible for any accidents caused by failure to operate

according to the specifications. In order to ensure the safe use and disposal of the battery, please

read the operating instructions carefully before use.

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2. Overview

2.1 Product Introduction

The industrial and commercial battery cabinet includes high-voltage box, battery module,
EMS, MBMU(optional) 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 battery
cabinet use high-voltage direct current.
 Battery charging: The output of the battery cabinet is connected to the energy storage
terminals (BAT+, BAT-) of the energy storage converter. Under the control of the energy
storage converter, it charges the battery, and transfers the energy in the photovoltaic or
mains to the battery.
 Battery discharging: When the photovoltaic energy is not enough to supply power to the
load, the system needs to control the battery to supply power to the load, and output the
stored battery energy to the load through the energy storage converter.
According to the functional configuration, industrial and commercial battery cabinet can be
divided into master battery cabinet and slave battery cabinet. Each battery cabinet contains 2
battery clusters with independent output. Wherein:
Master battery cabinet includes 2 battery clusters, EMS module, and MBMU battery array
management module.
Slave battery cabinet includes 2 battery clusters, MBMU battery array management module
(optional).

2.1.1 Product Appearance

PCS and EMS

display screen

Master battery cabinet

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Cluster slave
Fig. 2-1 Battery cabinet
Functions of the master battery cabinet: manage battery clusters, communicate with PCS,

display and save all system data, EMS management, modify system parameters, etc. There is an

EMS display on the side panel of the cabinet of the master battery cabinet.

Functions of the cluster slave: accept the energy management of the master battery cabinet,

judge the fault information and report it to the master battery cabinet, perform protection actions,

obtain the current and voltage information of the battery cluster, and perform fault judgment, etc.

The cabinet of the cluster slave does not contain a display screen.

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2.1.2 Product Structure

Air conditioner
Battery Module

High-voltage box

Fig. 2-1 Product structure

2.1.2.1 High-voltage box

The high-voltage box contains the protection components of the whole system, such as relays,
MCCBs (Molded case circuit breaker), fuses, SPDs (surge protection device), etc.

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Fig. 2-2 High-voltage box

Features
The High-voltage box is used to collect information such as cluster voltage, current, temperature,

and external digital input signals, and cooperates with the BMS to implement system operation

strategies. The dimensions of the High-voltage box are as follows:

Fig. 2-3 Dimensions of High-voltage box (mm)

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2.1.2.2 Battery Module

Fig. 2-4 Battery module

Features

The battery module composed of cells, which is the power source of the entire system. The BMU

unit is used to collect information such as the voltage and temperature of the lithium battery, and

upload the information to the SBMU control unit. There is also a firefighting unit for automatic

fire extinguishing inside the battery module. The battery module dimensions are as follows:

Fig. 2-5 Dimensions of the battery module (mm)

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2.1.3 Product model and naming scheme

2.1.3.1 Naming scheme of Battery cabinet：

BC XXX D E

Part1 Part2 Part3 Part4

Part1 Part2 Part3 Part4

BC: Battery Energy D: Outdoor E：EMS unit
cabinet 100：100KWH Blank：No EMS
090:90KWH unit
080:80KWH

2.1.3.2 Naming scheme of Battery Module：

BC - PACK - 5.1 - 16S - 100A

Part1 Part2 Part3 Part4 Part5

Part1 Part2 Part3 Part4 Part5

BC: Battery Battery Pack Energy 16S：16 cells in 100A：The max
cabinet 5.1：5.1KWH series current of Cell

2.2 Battery System Parameters

2.2.1 Cell Parameters

No. Item Characteristics

1 Cell type LFP(LiFePO4)

2 Rated voltage 3.2V

3 Rated capacity 100AH

4 Rated energy 320WH

5 Maximum continuous charging current 1C

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6 Recommended charging current ≤0.5C

7 Maximum continuous discharging current 1C

8 Recommended discharging current ≤0.5C

2.2.2 Battery Module Parameters

No. Item Characteristics

1 Cell connection 16S1P

2 Rated voltage 51.2V

3 Rated capacity 100AH

4 Rated energy 5.1KWH

5 Rated charging voltage 57.6V

Recommended charging and discharging

6 ≤50A @25±5℃
current

7 Weight About 44kg

Charging instructions for battery module:

If the user wants to charge a separate battery module, it is necessary to set the charger parameters

in strict accordance with the above battery module parameters, otherwise the battery module may

be damaged.

2.2.3 Battery Cluster Parameters

No. Item Characteristics

1 Cell connection 160S1P

2 Rated voltage 512V

3 Rated capacity 100AH

4 Rated energy 51.2KWH

5 Rated charging voltage 576V

6 Recommended charging and discharging ≤50A @25±5℃

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current

2.2.4 Battery Cabinet Parameters

No. Item Characteristics

1 Total Energy 102.4KWh

2 Rated Voltage 512VDC

3 Depth of Discharge (DOD) 90%

4 Operating Voltage Range 448VDC–576VDC

5 QTY of Battery Cluster Per Cabinet 2

6 Maximum Charging Current 50A (0.5C)

7 Maximum Discharging Current 50A (0.5C)

Battery cluster voltage,

current, cell voltage, cell
8 Monitoring Parameters
temperature, ambient
temperature, etc.

9 Communication CAN/Ethernet

10 Operating Temperature Range -30℃ - +50℃

-30℃ - +55℃（Recommended
11 Storage Temperature Range temperature 25℃ for long term
storage）

12 Related Humidity 5%~95%, no confidence

13 Ventilation Type Air conditioner

14 Net Weight About 1400Kg

15 Dimension 1100mm*1100mm*2380mm

16 IP degree IP54

Charging instructions for battery cabinet:

Rated charging voltage: 576V

Charging current: The charging current limit of each cluster in the battery cabinet is calculated and

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defined by BMS system according to voltage and temperature. When the cell voltage is lower than

3.5V, the recommended charging current of the system is 50A; When the cell voltage is higher

than 3.5V, the battery enters the floating charge mode, and the charging current recommended is

0.1C~0.5C. At this time, the specific charging current is calculated and defined by BMS according

to the system working state.

2.2.5 Interfaces of High-voltage box

Fig. 2-6 Panel of High-voltage box

Definition of components on panel:

Port Description
P+ Positive terminal of DC output
P- Negative terminal of DC output
B+ Positive terminal of battery modules in series
B- Negative terminal of battery modules in series
DC START DC start button/black-start button
AC POWER 220VAC input

RUN Run indicator

ALARM Warning indicator

MCCB switch DC output switch

Definition of weak current/communication ports

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Port Description
R-485 Resistor DIP of RS485 communication terminal
R-CAN Resistor DIP of CAN communication terminal
BMU Battery modules communication port
24VOUT 24V power output port
CANH/L CAN communication interface
RS485A/RS485B Air conditioner communication interface
NO_1/NC_1 Switch output port 1
DI1H Digital input port 1
DI2H Digital input port 2
DI3H Digital input port 3
DI_COM Digital input negative common terminal

Communication ports between high-voltage boxes

COM1/COM2
inside or outside the cabinet

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3. Installation

3.1 Site Planning

3.1.1 Dimensions of Battery Cabinet

Fig. 3-1 Dimensions of the cabinet (mm)

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3.1.2 Precautions for Installation

Please place the battery cabinet on a level ground and ensure it is stable without shaking or

tilting.

The bearing and load capacity of the installation ground and floor (according to the

requirements of the architectural drawings) should be considered for the installation of the battery

cabinet.

Do not cover the ventilation holes with objects, so as not to hinder the heat dissipation of the

battery cabinet, which will cause the internal temperature of the system to rise and affect the safety

and life of the battery.

Please keep the installation environment of the battery cabinet well ventilated. Avoid

installing in places with high or low temperature and high humidity. Keep away from water,

flammable gases, corrosive agents, heat sources, and direct sunlight. Keep the air inlet/outlet

dust-free.

Please avoid using it in an environment with dust, volatile gas, corrosive gas or high salt

content, and do not place flammable and explosive items around the battery cabinet.

In order to reduce the possibility of fire and reduce the damage, the walls, ceilings and floors

of the room where the battery cabinet is placed should be made of fireproof materials as much as

possible, and should be provided with portable dry powder fire extinguishers.

During the installation process, please refer to the relevant applicable safety regulations for

installation.

3.1.3 Space Reservation

A certain space for operation and ventilation should be reserved around the cabinet:

 At least 1200mm of space for ventilation and operation must be reserved in front.

 At least 1200mm of operating space must be reserved on the back.

 At least 600mm of operating space must be reserved on the side.

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3.2 Preparation of Tools and Instruments

Use insulated tools to avoid electric shock.

Table 3-1 Preparation of tools and instruments

Tools and instruments

Electric forklift Manual forklift Ladder Rubber hammer

Manual impact
Impact drill Alloy hole saw Heat gun
drill

Electro-hydraulic
Diagonal cutters Crimping tool Wire stripper
press

Clamp ammeter Multimeter Cable ties Measuring level

Insulating tape Cotton cloth Label Electrician’s knife

Insulation protective
ESD gloves Lead rubber gloves Heat insulation gloves
shoes

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Flat head screwdriver

Torque screwdriver Cable cutter Brush
(2-5mm)

Insulated torque
Phillips screwdriver Insulated adjustable
wrench Heat shrink tube
(M3/M4/M5/ M6/M8) wrench
(M6/M8/M12/M16)

3.3 Preparation of Power Cables

The cables between the cabinets should be 25 mm2, low-smoke, halogen-free and flame-retardant
cables.

3.4 Unpacking

Steps
Step 1 Transport the battery cabinet to the designated location with a forklift.

Step 2 Remove the outer packaging of the battery cabinet.

Step 3 After confirming that the equipment is in good condition, remove the bolts fixing the

battery cabinet and the pallet and remove the battery cabinet from the pallet.

3.5 Single Cabinet Installation

3.5.1 Installation Environment

 Do not install the battery cabinet in a place with high temperature, low temperature or

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humidity beyond the technical specifications.

 Keep the battery cabinet away from water sources, heat sources, and flammable and

explosive items.

 Avoid installing the battery cabinet in the desert or the surrounding environment of the

desert;

 Avoid installing the battery cabinet in an environment with direct sunlight, dust, volatile

gas, corrosive substances, and high salt content.

 Avoid installing the battery cabinet on unstable or vibrating foundations.

 Do not install the battery cabinet in a working environment with metal conductive dust.

 The optimum temperature for battery operation is 20 ℃ ~30 ℃ . Working in an

environment with a temperature higher than 30℃ will reduce the service life of the

battery, and working in an environment lower than 20℃ will shorten the battery backup

time.

3.5.2 Installing the Cabinet

Step 1 According to the design requirements, determine the installation position of the
cabinet on a flat ground and draw a line mark.
Step 2 Transport the battery cabinet to the designated location by means of a forklift and

install it at the marked location.

Step 3 After the installation is complete, check whether the cabinet body is tilted and whether

the gap between cabinets meets the requirements.

Fix the battery cabinet on the foundation with fastening bolts. After fixation, U-shaped angle

steel shall be treated with anti-rust treatment, such as spraying anti-rust paint.

--- Installation ends

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3.5.3 Installation Instructions for Copper Bars between

Battery Modules

3.5.3.1 Battery Module

Fig. 3-2 Battery module

NOTE:

: The negative terminal of the battery module;

: The positive terminal of the battery module;

3.5.3.2 Instructions for Battery Module Power Connection

The connection between the battery modules has been completed before the battery cabinet is

shipped. If the customer still needs to maintain the connection between the battery modules, please

refer to the following:

Part specifications:

Name Description

Soft copper bar -1 Connecting soft copper bar between battery modules

Power cable “B-” Connection cables of module 01 “B-” and High-voltage box “B-”

M8*12 combined bolts Used to fix copper bars and “B-” power cables

Cable tie Used to fix “B-” power cable

Copper bar connection between battery modules:

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Wear insulating gloves, and lock the copper bars from the top battery module to the bottom.

Place the soft copper bars on the “+” of the top battery module 01 and the “-” of the battery

module 02, and fix the copper bars (M8*12 combined bolts, torque 5.5~6.0 N.M). Lock the

battery modules 02, 03...10 down in this order until the “B+” connection of the High-voltage box

is completed.

Note: Do not open the covers of all the DC connection terminals at the same time in order to

avoid short circuit caused by misuse. It is recommended to only open the terminals on both sides

of the copper bar (or power cable) to be locked, and close the cover of the terminal after the

copper bar (or power cable) is fixed.

Fig. 3-3 Copper bars connected in series

Step 3 Install the “B-” power cable. One end of the “B-” power cable is connected to the “-”

position of the battery module 01 on the top, the other end is connected to the “B-” terminal

position of the High-voltage box, and fastened with bolts (M8*12 combined bolts, torque 5.5~6.0

N.M). Secure the “B-” power cable with the cable tie from the accessory bag.

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Battery module 01 “-”

High-voltage box “B-”

Fig. 3-4 Slot diagram of the battery module

Step 4 Install another cluster of battery modules. Repeat steps 1~3 to complete the

connection and fixation of the power cables and soft copper bars of another cluster of battery

modules in the battery cabinet in sequence, as shown in Fig. 3-5.

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Fig. 3-5 “B-” power cable connection

3.6 Electrical Connection

Before installation, make sure MCCB breaker switch on the High-voltage box is off

3.6.1 AC Input Connection

Step 1 Confirm that the AC Switch is in the OFF state.

Note: The AC input is 220VAC single-phase alternating current. Please confirm whether it is

live before wiring.

The 220VAC power supply will be used for power the air conditioner and the AC/DC power

supply module.
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Step 2 Connect the L/N/PE cables of the 220VAC power cable to the corresponding

terminals according to the marks in the figure below, and fasten them with bolts (torque ≤ 2 N.M).

Note: The 3 terminals (L/N/PE) at the right side of the “INPUT” side are reserved AC input

terminals which can be used as AC power source when connected to the another battery cabinet.

The two groups of terminals at the “OUTPUT” side are used for internal wiring to power the

High-voltage box and the air conditioner.

Connecting with grid Reserved 220VAC

220VAC input terminals

Fig. 3-6 AC input connection

3.7 Cabinet Installation

3.7.1 Parallel Connection of Battery Clusters in the Cabinet

Step 1 Connect the P+/P- ports of the High-voltage box 01 and the High-voltage box 02 with

the parallel power cable (accessory 9), and connect the P+/P- power cable connected to the PCS to

the P+/P- port of the High-voltage box 01 or 02. The connection method is shown in the figure

below.

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Fig. 3-7 Parallel power cable connection

Step 2 When the number of battery cabinets in the energy storage system is greater than or

equal to 2, connect one end of the parallel CAN/power communication cable (accessory 05) to the

COM2 port of the high-voltage box shown above (both high-voltage box 01 and 02 are

acceptable), and connect the other end to the COM2 port of the High-voltage box in other battery

cabinets.

Fig. 3-7 Parallel wiring cable connection when the number of battery cabinets is greater than or equal to 2

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3.7.2 Parallel Connection of Battery Cabinets

Fig. 3-9 Schematic diagram of placement of 2 parallel battery cabinets

Step 1 Connect the P+/P- ports of the High-voltage box 01 and the High-voltage box 02 with

the parallel power cable (accessory 9), and connect the power cable (accessory 11) connected to

the P+/P- of the other cabinet to the High-voltage box 01 or 02 on the P+/P- port. The connection

method is shown in the figure below.

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Fig. 3-8 Schematic diagram of connecting two battery cabinets in parallel

Step 2 Connect one end of the parallel CAN/power communication cable (accessory 05) to

the COM2 port of the high-voltage box in the above picture (both high-voltage box 01 and 02 are

acceptable), and connect the other end to COM2 port of the high-voltage box in other battery

cabinets.

3.8 Communication Wiring Instructions

1) Network communication interface wiring

The battery cabinet has a built-in switch, which has been connected to the network port of the

EMS controller. The user needs to connect it to the cloud platform or the upper monitoring system,

and directly connect to the switch through a standard network cable;

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Fig. 3-9 Schematic diagram of switch interface

2) PCS (KAC) communication wiring

The four-core signal cable is connected through the position shown in the figure below, and

the other end is connected to the PCS communication interface

PCS 防逆流电表 预留

CANH CANL A1 B1 A2 B2 A3 B3 A4 B4

四芯信号电缆至PCS

Fig. 3-10 PCS communication cable connection diagram

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4. Operation Guide

4.1 Inspection after Installation

 Personnel responsible for installing and maintaining equipment must first accept strict

training to comprehend various safety precautions and correct operation methods.

 Only qualified professionals or trained personnel are allowed to install, operate and

maintain the equipment.

Steps of checking:
Step 1 Check fixation of module box
 Check whether the battery module, high-voltage box, and battery cabinet are
fixed:
Step 2 Check power cable

 Check whether the copper bars between the battery modules and between the

battery modules and the high-voltage box or the fastening bolts of the power

cables are missing, loose, or not tightened with recommended torque;

 Check whether the quick plug power cable of P+/P- is reversed, and whether

the plug and socket are completely locked;

 Check whether the 220VAC input cable is reversed, and whether the fastening

bolts are missing, loose, or not tightened with recommended torque;

Step 3 Check communication cable

 Check whether the communication cable among the battery modules, the

high-voltage box, the MBMU module, and the EMS unit is loose or missing;

 Check whether the communication cable between the PCS and the MBMU

module is loose or missing;

 Check whether the CAN communication cable between two battery cabinets is

correctly connected, and check whether is loose or missing;

Step 4 Check the power supply, drive and communication cable of the firefighting

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starter

 Check the power supply of the firefight starter, and the power indicator light

or flash. If the power indicator can’t be lit, please contact KSTAR staff.

 Check whether the firefighting start, power supply, feedback and other wiring

cables are loose or missing;

If abnormalities are found and can’t be recovered, please contact KSTAR staff.

4.2 Running Environment Check

Check environment temperature: -20℃~55℃

Check environment humidity: 10%~95%, no condensation

4.3 Power-on Operation

4.3.1 Prerequisites

 Before powering on, make sure that all items to be checked after installation have been

checked.

 Before powering on, measure total battery and it should be within the range of

400~576V.

 Before powering on, make sure that all switches are turned off.

4.3.2 Operation Steps

 If there is 220VAC input

Step 1 Supply the grid 220VAC to the battery cabinet;
Step 2 Turn on the “AC Switch” in the cabinet, and close the “AC POWER” switch on the

panel of high-voltage box;

Step 3 Turn the switch handle of the high-voltage box to the “ON” position, and check

whether the indicator light turn green;

Step 4 Confirm whether the air conditioner is powered on;

Step 5 Check whether EMS screen on the right side of the battery cabinet is power on, and
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whether there is any fault;

Step 6 Repeat steps 2~3 to turn on another cluster of batteries in the battery cabinet;

----End

 If there is no 220VAC input

Step 1 Turn the switch handle of the High-voltage box to the “ON” position;

Step 2 Press the “DC START” button on the high-voltage box for 3-6 seconds. After the

indicator light is on, release the button to realize DC black start;

Step 3 Confirm whether the run indicator light turn green;

Step 4 Turn on the “AC POWER” switch of the High-voltage box;

Step 5 Check whether EMS screen on the right side of the battery cabinet is power on, and

whether there is any fault;

Step 6 Close the “AC Switch” inside the cabinet,

Step 7 Repeat steps 2~4 to turn on another battery cluster in the cabinet;

----End

After the battery clusters in the battery cabinet have successfully self-checked, set the EMS

unit and send the control command to close the relays in the battery cabinet. Check whether

fault occur during the process, if all the relays are closed successfully, that means the

power-on operation of the system is completed.

4.4 Power-off Operation

4.4.1 Power-off Steps

Step 1 Setting the EMS unit, and turn off the relays in the battery cabinet by the control

command.

Step 2 Turn the switch handle on the High-voltage box to the “OFF” position;

Step 3 Turn off the “AC POWER” on the High-voltage box;

Step 4 Repeat steps 2~3 to disconnect the DC output and AC input of another cluster in the

cabinet;

Step 5 Disconnect the “AC Switch” in the cabinet;

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----End

4.4.2 Emergency Power-off

Emergency stop
button

Fig. 4-1 Emergency stop button

Step 1 Press the emergency stop button.

Step 2 Turn the switch handle on the High-voltage box to the “OFF” position;

Step 3 Turn off the “AC POWER” switch on the High-voltage box;

Step 4 Repeat steps 2~3 disconnect the DC output and AC input of another cluster in the

cabinet.

Step 5 Disconnect the “AC Switch” in the cabinet;

----End

Note: The emergency stop button can only be configured on the master battery cabinet.

4.5 Test Run of Battery Cabinet

The battery cabinet exchanges energy with the outside through the PCS.

The precautions during test run are as follows:

Capacity calibration: to ensure that the battery can finish a complete normal charge and

discharge cycle. By default, the rated capacity will be corrected in the first ten times of the

initial operation of the system, so deep charging and discharging should be performed during

test run and joint debugging. It is recommended to do a capacity calibration during the test

run with the charge and discharge depth DOD=100%, and test according to the rated power

of the product. The default process is “empty + stand still (2h) + fully charge”. The specific

description is as follows:
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 Empty: discharged battery to SOC=0%.

 Stand still: Stand still for more than 2 hours (for SOC correction). When standing still,

there must be no charging or discharging current, the aux power supply is allowed to run

during the standing still.

 Fully charge: After the standing time is up. charge battery to SOC=100%.

After the battery is empty, if it is not used for a long time, it should be recharged in time (in 6

months) to >50% SOC.

Operational stability: All components in the power circuits, communication circuits, and

sampling circuits should be validated when run testing if conditions permit. It is used to

determine whether there is any abnormality in each link of the system installation, especially

in the case of over-temperature, overcurrent, overvoltage, over-discharge and other abnormal

conditions, it should be dealt with in time to avoid potential safety hazards.

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5. Routine Maintenance

● All maintenance work inside the battery cabinet must use insulated tools and should be performed by
personnel who have received relevant training. Components behind protective covers that require tools to be
opened are not user-serviceable. If maintenance is required, please consult KSTAR for details.
● The battery cabinet must be regularly maintained according to the following requirements, or the normal
operation of the battery cabinet will be affected and the normal service life of the battery cabinet will be shortened.

5.1 Monthly Maintenance

The battery system needs to be checked at least once a month to see if the cell voltage is

normal and the temperature is normal. Check the historical data to see if there are serious failures.

Table 5-1 Monthly maintenance

Content of check Baseline requirements Handling method
The cell voltage is
Cell voltage Contact KSTAR staff
between 2.55V~3.60V
The temperature is
Cell temperature Contact KSTAR staff
between -20~65℃
Voltage difference within a The voltage difference
Contact KSTAR staff
single cluster is less than 500mV
During the standing process of
The voltage jump is less
the battery system, the cell
than 10mV when Contact KSTAR staff
voltage fluctuation range is
standing still
small
System fault data, is there a cell
No level-4 fault Contact KSTAR staff
overvoltage fault
Check the cause of the level-3
System fault data, is there a cell
No level-4 fault fault;
under-voltage fault
Feedback level-4 fault;
Check the cause of the level-3
System fault data, is there an
No level-4 fault fault;
over-temperature fault
Feedback level-4 fault;
Check the cause of the level-3
System fault data, is there an
No level-4 fault fault;
under-temperature fault
Feedback level-4 fault;
Check the cause of the level-2
System fault data, is there a
No level-3 fault fault;
fault of discharge overcurrent
Feedback level-3 fault;

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Check the cause of the level-2

System fault data, is there a
No level-3 fault fault;
fault of charging overcurrent
Feedback level-3 fault;
Check the cause of the level-2
System fault data, is there a low
No level-3 fault fault;
insulation fault
Feedback level-3 fault;
Check the cause of the level-3
System fault data, is there a
No level-4 fault fault;
fault of cluster voltage too high
Feedback level-4 fault;
Check the cause of the level-3
System fault data, is there a
No level-4 fault fault;
fault of cluster voltage too low
Feedback level-4 fault;
System fault data, is there an Check the cause of the level-2
excessive temperature No level-3 fault fault;
difference fault Feedback level-3 fault;
Check the cause of the level-2
System fault data, is there a
No level-3 fault fault;
charging over-temperature fault
Feedback level-3 fault;
System fault data, is there a Check the cause of the level-2
charging under-temperature No level-3 fault fault;
fault Feedback level-3 fault;
Fault indicator can be
Is the fault indicator normal Contact KSTAR staff
lit
Running indicator can
Is the running indicator normal Contact KSTAR staff
always be on

5.2 Quarterly Maintenance

Table 5-2 Quarterly maintenance

Content of check Baseline requirements Handling method
The cell voltage is between
Cell voltage Contact KSTAR staff
2.55V~3.60V
The temperature is between
Cell temperature Contact KSTAR staff
-20~65℃
Check the cause of level-1/2
History fault content fault; Contact KSTAR staff
Feedback level-3/4 fault;
Is the fault indicator
Fault indicator can be lit Contact KSTAR staff
normal
Is the running indicator Running indicator light can
Contact KSTAR staff
normal always be on
Can the system perform The system can perform a Contact KSTAR staff

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a complete complete charge-discharge cycle

charge-discharge cycle
The cabinet has no obvious rust,
Cabinet status no traces of water ingress, and Contact KSTAR staff
no abnormal bending
Cabinet firefighting
The power indicator can be lit. Contact KSTAR staff
starter box

5.3 Annual Maintenance

Table 5-3 Annual maintenance

Content of check Baseline requirements Handling method
The cell voltage is between
Cell voltage Contact KSTAR staff
2.55V~3.60V
The temperature is between
Cell temperature Contact KSTAR staff
-20~65℃
Check the cause of level-1/2
History fault content fault; Contact KSTAR staff
Feedback level-3/4 fault;
Is the power cable
The power cable is normal Replace the wiring cable
normal
Is the communication The communication cable is
Replace the wiring cable
cable normal normal
Is the fault indicator
Fault indicator can be lit Contact KSTAR staff
normal
Is the running indicator Running indicator light can
Contact KSTAR staff
normal always be on
Status of fixed power No rust, no obvious oxidation,
Replace or tighten the screw
copper bar screw no loose.
The cabinet has no obvious rust,
Cabinet status no traces of water ingress, and Contact KSTAR staff
no abnormal bending
Cabinet firefighting
The power indicator can be lit Contact KSTAR staff
starter box
Accuracy of battery
system current Error < 2% Contact KSTAR staff
collection
Accuracy of battery
system cluster voltage Error < 2% Contact KSTAR staff
collection

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6. Troubleshooting and Maintenance

For common faults, refer to Table 6-1 for troubleshooting methods. If you encounter other
problems during troubleshooting, you can check the alarm list, or contact KSTAR.
Table 6-1 Troubleshooting

Fault Type Symptom Analysis of cause Handling method

Product not The external load is too large,
Pre-charge timeout Restart the battery system
running affecting the pre-charging process
Abnormal charging，Abnormal Discharge or check the
Level 1
communication with PCS communication cable
Abnormal charging，Abnormal Discharge or check the
Level 2
communication with PCS communication cable
Cell overvoltage
Abnormal charging，Abnormal Discharge or check the
Level 3
communication with PCS communication cable
Abnormal charging，Abnormal
Level 4 Contact KSTAR staff
communication with PCS
Abnormal discharging，Abnormal Charge or check the
Level 1
communication with PCS communication cable
Abnormal discharging，Abnormal Charge or check the
Level 2
communication with PCS communication cable
Cell under-voltage
Abnormal discharging，Abnormal Charge or check the
Level 3
communication with PCS communication cable
Abnormal discharging，Abnormal
Level 4 Contact KSTAR staff
communication with PCS
Cluster Voltage
Level 3 Abnormal sampling circuit Contact KSTAR staff
difference- fault
Abnormal charging，Abnormal Discharge or check the
Level 1
communication with PCS communication cable
Abnormal charging，Abnormal Discharge or check the
Level 2
communication with PCS communication cable
Cluster overvoltage
Abnormal charging，Abnormal Discharge or check the
Level 3
communication with PCS communication cable
Abnormal charging，Abnormal
Level 4 Contact KSTAR staff
communication with PCS
Abnormal discharging，Abnormal Charge or check the
Level 1
communication with PCS communication cable
Abnormal discharging，Abnormal Charge or check the
Cluster Level 2
communication with PCS communication cable
under-voltage
Abnormal discharging，Abnormal Charge or check the
Level 3
communication with PCS communication cable
Level 4 Abnormal discharging，Abnormal Contact KSTAR staff

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communication with PCS

Abnormal operation of air
clean the air conditioner or lower
Level 1 conditioner or the air temperature
the temperature
is too high.
Abnormal operation of air
clean the air conditioner or lower
Level 2 conditioner or the air temperature
Cell the temperature
is too high.
over-temperature
Abnormal operation of air
when discharging clean the air conditioner or lower
Level 3 conditioner or the air temperature
the temperature
is too high.
Ambient temperature too high or
Level 4 battery end of life. A risk of Contact KSTAR staff
thermal runaway.
Abnormal operation of air
clean the air conditioner or lower
Level 1 conditioner or the air temperature
the temperature
is too high.
Abnormal operation of air
clean the air conditioner or lower
Level 2 conditioner or the air temperature
Cell the temperature
is too high.
over-temperature
Abnormal operation of air
when charging clean the air conditioner or lower
Level 3 conditioner or the air temperature
the temperature
is too high.
Ambient temperature too high or
Level 4 battery end of life. A risk of Contact KSTAR staff
thermal runaway.
Abnormal operation of air
clean the air conditioner, rise the
Level 1 conditioner or the air temperature
temperature
is too low.
Cell Abnormal operation of air
clean the air conditioner, rise the
under-temperature Level 2 conditioner or the air temperature
temperature
when charging is too low.
Abnormal operation of air
clean the air conditioner, rise the
Level 3 conditioner or the air temperature
temperature
is too low.
Abnormal operation of air
clean the air conditioner, rise the
Level 1 conditioner or the air temperature
temperature
is too low.
Cell Abnormal operation of air
clean the air conditioner, rise the
under-temperature Level 2 conditioner or the air temperature
temperature
when discharging is too low.
Abnormal operation of air
clean the air conditioner, rise the
Level 3 conditioner or the air temperature
temperature
is too low.
Cell temperature – Level 1 Abnormal cooling channel clean the air conditioner or
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difference fault resistance，abnormal sampling contact KSTAR staff

circuit
Check whether the
communication cable between
Abnormal charging，Abnormal
Level 1 the PCS and battery cabinet is
communication with PCS
missing or unstable, and PCS
setting
Check whether the
Battery cluster communication cable between
Abnormal charging，Abnormal
charging Level 2 the PCS and battery cabinet is
communication with PCS
overcurrent missing or unstable, and PCS
setting
Check whether the
communication cable between
Abnormal charging，Abnormal
Level 3 the PCS and battery cabinet is
communication with PCS
missing or unstable, and PCS
setting
Check whether the
communication cable between
Abnormal discharging，Abnormal
Level 1 the PCS and battery cabinet is
communication with PCS
missing or unstable, and PCS
setting
Check whether the
Battery cluster communication cable between
Abnormal discharging，Abnormal
discharging Level 2 the PCS and battery cabinet is
communication with PCS
overcurrent missing or unstable, and PCS
setting
Check whether the
communication cable between
Abnormal discharging，Abnormal
Level 3 the PCS and battery cabinet is
communication with PCS
missing or unstable, and PCS
setting
Check whether the grounding is
Water retention in the cabinet, bad
Level 1 loose and whether there is water
grounding
in the cabinet.
Check whether the grounding is
Water retention in the cabinet, bad
Insulation fault Level 2 loose and whether there is water
grounding
in the cabinet.
Check whether the grounding is
Water retention in the cabinet, bad
Level 3 loose and whether there is water
grounding
in the cabinet.
Check whether the
PCS communication Abnormal communication with
Level 2 communication cable between
fault PCS
the PCS and battery cabinet is

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missing or unstable.
Check whether the
Internal The communication cables in the communication cable between
Level 2
communication fault cabinet is missing or unstable. the High-voltage box and battery
cabinet is missing or unstable
Positive relay fault Level 4 Relay damaged Contact KSTAR staff
Negative relay fault Level 4 Relay damaged Contact KSTAR staff
Check the sampling cables
Cell voltage fault Level 2 Cell sampling circuit abnormal
connection of battery module
Cell temperature Check the sampling cables
Level 2 Cell sampling circuit abnormal
fault connection of battery module
AFE IC fault Level 3 BMU unit damaged Contact KSTAR staff
Cell voltage balance
Level 3 BMU unit damaged Contact KSTAR staff
fault
Current sampling circuit
Current sensor fault Level 3 Contact KSTAR staff
abnormal in High-voltage box
Battery system fault Level 3 High-voltage box function failure Contact KSTAR staff
Check whether the
The power cables in the cabinet is communication cable between
Cluster voltage fault Level 2
missing or unstable. the High-voltage box and battery
cabinet is missing or unstable
Abnormal discharging，Abnormal Stop running and lower the cell
Level 1
communication with PCS temperature
B+/B- Terminal Abnormal discharging，Abnormal Stop running and lower the cell
Level 2
over-temperature communication with PCS temperature
Abnormal discharging，Abnormal Stop running and lower the cell
Level 3
communication with PCS temperature
Ambient Temperature sampling failure in
Level 1 Contact KSTAR staff
temperature fault High-voltage box
Ambient Change the place of battery
Level 1 Ambient temperature is too high
Over-temperature cabinet
Ambient Change the place of battery
Level 1 Ambient temperature is too low
under-temperature cabinet
Fire alarm Level 4 Battery thermal runaway Contact KSTAR staff
Waterproof fault Level 4 Waterproof failure Contact KSTAR staff
Check the cabinet door and lock
Access control fault Level 2 The door of cabinet is unlocked
it
Check whether the
Cluster Connection abnormal between
communication cable between
voltage-difference Level 2 battery module and High-voltage
the High-voltage box and battery
fault box
cabinet is missing or unstable.
B+ terminal Sampling circuit abnormal in
Level 1 Contact KSTAR staff
temperature fault High-voltage box

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B- terminal Sampling circuit abnormal in

Level 1 Contact KSTAR staff
temperature fault High-voltage box
SPD fault Level 3 Abnormal Surge protect device Contact KSTAR staff
Remark:
Blockage of the air conditioner condenser is the main reason for the decline in cooling
capacity. In order to make the air conditioner work better, it is recommended to clean the
condenser every 6 months.

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7. List of Accessories

A single battery cabinet contains the following accessories (placed in the

accessories box):

No. Name Quantity Purpose

Communication cable CAN communication cable for
Accessory 1 between battery Optional master battery cabinet-slave battery
cabinets cabinet
Fill the wiring holes for the input
Accessory 2 Fire putty Reserved
and output of the battery cabinet.
Accessory 3 Base baffle Optional Battery cabinet base baffle
Power cable connecting the PCS
Accessory 4 PCS power cable 2PCS
and the battery cabinet
Accessory 5 Parallel power cables Reserved Cluster parallel power cable

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8. Terms
1. Cell
A battery cell
2. Battery Module
A combination of multiple cells connected in series, parallel or series-parallel, with only one
pair of positive and negative output terminals, used as a power supply.
3. Battery Cluster
Multiple battery modules, a high-voltage box and connecting cables form a complete battery
cluster, which can independently complete energy transfer and self-protection functions.
4. Battery Array
Multiple battery clusters form a battery array, and the energy transfer of the following
clusters is managed through the BMS with the three-level architecture.
5. Battery Management System (BMS)
An electronic device that controls or manages the electrical or thermal performance of a
battery system.
Battery Management Unit (BMU)
Slave Battery Management Unit (SBMU)
Master Battery Management Unit (MBMU)
Energy Management System (EMS)
6. Battery System
Energy storage devices, including integration of battery modules or packs, battery
management systems, high voltage circuits, low voltage circuits.
7. Battery Capacity
The size of the battery storage capacity.
8. State of Charge (SOC)
The percentage of the capacity can be released by cell, battery pack or system according to
the conditions specified by the manufacturer to the actual capacity, also known as the remaining
capacity.
9. State of Health (SOH)
The deviation ratio between the actual performance of the battery and the normal design
index.

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