gwl/modular bpf
TRANSCRIPT
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GWL/Modular BPF
(Batt ery Pack Flexi)
Installati on Manual
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GWL/Modular BPF package contents:The product Modular BPF contains all parts required to construct the metal frame box. The BPF product is designed especially for the indicated size of battery cells.The Lithium-Iron-Phosphate cells by ThunderSky-Winston described in the manual are sold separately and are not part of the product GWL/Modular BPF.
Module DescriptionThe GWL BPF (Battery Pack Flexi) module contains massive metal frames, side plates and the corresponding connecting materials. These parts can be used easily to construct a box to hold the corresponding LiFePO4 prismatic cells. The Battery Pack can be delivered as building blocks or in various stages of assembly and electric connections to additional extension modules. The BPF module is the basic module in the GWL/Module series; it is a so-called open solution, which is and will continue to be compatible with related GWL products as well as other available components.
Main functions and features: • Individual cells are attached into the functional whole and the terminal positions are stabilized • Mechanical protection of cells during external accidents (shifts, deformation, puncturing…) • Mechanical protection of cells during electrical accidents (overcharge swelling, short-circuit...) • Simple and safe manipulation as well as integration into an environment • Simple checks and replacement of components • Mechanical readiness for attaching additional extension modules • Optimization of the heat mode of the battery • Attractive industrial design, extremely durable
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Usage Options The quality of all the components, the overall durability of the product as well as its versatility make this module perfect for all different types of industrial applications as well as demanding home installations. Its flexibility allows for the creation of new solutions based on LiFePO4 technology and further also the replacement of current lead batteries and their configurations.
• Stationary storage of energy • Machines, industrial electromobility • Basic box for configurations from 12V to 48V • Connection of boxes that is parallel or in a series for increased capacity and voltage • Vertical and horizontal box configurations • Goes with the user BMS or supplemental GWL/BMS modules • Anyone can build the box using GWL technical support (manual, instructional videos, individual
support) • Standardized as well as customized configurations are delivered
Description of Functions The front stainless steel plate with a strength of 1.5mm (towards the cell electrodes) attach the battery cells and hold their shape in place. The cells are compressed between them using steel threaded rods. The battery is also protected thanks to 1.5mm plates below and on the sides. The vertical edges of the box are further protected using a pair of stainless steel threaded rods, which hold the batter in place between the frames.
The basic module can be stacked vertically and attached using vertical threaded rods and coupling nuts. The low or the high superstructure with a lid (additional extension GWL/Modular products) can be attached in the same way. The module is delivered with terminal covers and terminal connectors to connect the cells in a series (48V).
The basic box set-up helps with cooling of the cells, if needed, via metal circumference plates and profiles into the surrounding areas. Conversely, when used in a cold environment, it is possible to insert adequate heat isolation or a heating rack into the space in the frame. The side space in the frame can also be used e.g. to place coolers of passive balancers etc.
The upper frame allows for the pack to be held securely by one or more persons during transport. The lower frame can be fitted with wheels or rubber mats etc. The frames and the threaded rods allow for various types of anchoring of the battery box and the attachment of additional components to it especially when used in mobile applications (caravans, heavy equipment…).
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Technical Specification The interconnection of cells for 24V or 12V power voltage increases capacity of the box in Ah and its current load twofold or fourfold. The capacity of the box in kWh and performance in kW remain the same.
Model: GWL/Modular BPF 48V 40Ah 48V 100Ah
Dimensions and Weight
Length/width: 420 mm / 276 mm 581 mm / 333 mm
Height with terminal covers: 205 mm 243 mm
Total weight: 31.1 kg 62.1 kg
Box weight (all components including protective terminals): 5.5 kg 9.3 kg
Weight of LiFePO4 cells: 25.60 kg 52.80 kg
No. of LiFePO4 cells: 16 ks 16 ks
Capacity and Voltageí
Capacity of the LiFePO4 cell Ah/Wh: 40 Ah/132 Wh 100 Ah/330 Wh
Nominal capacity of the pack Ah/kWh: 40 Ah/2,11 kWh 100 Ah/5,28 kWh
Pack capacity - recommended for use at Ah/kWh: 32 Ah/1,7 kWh 80 Ah/4,2 kWh
Nominal voltage of a LiFePO4 cell: 3.3V 3.3V
Nominal pack voltage (connection in series): 52.8 V 52.8 V
Pack voltage with recommended/maximum charge: 56.0V/58.4V 56.0V/58.4V
Minimal/emergency pack voltage: 48V/40V 48V/40V
Current and Performance
Maximum (short-term) discharge/charge current of the LiFePO4 cell: 400A/120A 1000A/300A
Max. discharge/charge pack current (connection in a series): 400A/120A 1000A/300A
Recommended (optimal) discharge/charge current (connection in a series):
20A/20A 50A/50A
Max. discharge/charge performance: 19.2kW/5.7kW 48.0kW/14.4kW
Recommended discharge/charge performance: 1.0kW/1.0kW 2.4kW/2.4kW
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Assembly Manual
2x Side plate
2x Frame
1x Bottom plate16x Cell
2x Front plate
18x M4 Closed nut
10x M6 Vertical threaded rod9x M4 Horizontal threaded rod
18x M4 Spring washer 20x M6 Spring washer 20x M6 Nut
18x M4 Washer 40x M6 Washer 20x M6 Closed nut
2x Foam tape
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Orientation of terminals according to a selected voltage!
5. 6.
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A
B
B
A
9.
Repeat 9x
BA
A B10.
Recommended
Recommended
TIP: For better manipulation, you can use for example a wing nutto guide the middle rods through the battery pack.
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Assembly Manual Instructi ons • Carry out a visual check of the LiFePO4 cells, check the cell voltage, clean the cell terminals and
the terminal connectors. Reatt ach the transport terminal covers for assembly. Insert the shorter threaded rods M6 with the nut, the recommended spring washer and the fl at washer into the lower frame. Turn the frame over and att ach the rods using the closed nut and the washer.
• Insert the lower plate into the frame and tape the foam tape to the inside shorter side of the frame. You can eliminate manufacturing tolerance in LiFePO4 cell dimensions by doubling up and removing the foam tape.
• Insert the LiFePO4 cells into the lower frame. Make sure you place the positi ve and negati ve terminals correctly for the required connecti on. First insert the front cells and work your way towards the center of the confi gurati on.
• Insert the side plates along the sides and att ach the constricti ng front plates (with holes for the rods).
• Connect the threaded rods and gently constrict the LiFePO4 cells using the corresponding nuts and washers. You can for example use a wing nut to simplify the assembly of the center rods.
• Att ach the verti cal rod using nuts and washers. Att ach the frame on the top side of the LiFePO4 cell confi gurati on. Connect the lower and upper frame using verti cal threaded rods using the corresponding nuts and washers. Constrict the frames using the external nuts and lock them in place using the internal nuts. Check to make sure the parts are att ached correctly and ti ghtened.
Electrical Connecti on of the Cells Clean the terminal connectors and cell terminals using a soft emery sponge. Att ach spring and fl at washers and ti ghten. Conti nue to att ach terminal covers of the corresponding colors.
12V (27 pcs of connectors) 24V (23 pcs of connectors) 48V (15 pcs of connectors)
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Electrical Connecti on of the BoxesThe capacity of the boxes can be doubled by connecti ng them in a series or using a parallel connecti on. If you choose the connecti on in a series, e.g. 48V / 10kWh from two 5 kWh packs, connect two 24V in a series. Maintain adequate dimensions of the connecti ng wires and their minimum length (Illustrati on 1). Two 48V packs can be connected in a shared 48V bus. They must then be connected using indicati ve wires along the individual cells. Then you can run both packs usine one BMS. Use as a temporary or a fl exible soluti on (Illustrati on 2). The above is true for packs comprising identi cal cells (capacity, manufacturer, similar age…). If these parameters are not kept or if the system is more fl exible, then only connect those packs, which have an autonomous BMS on a parallel into the shared bus.
24V 24V
48V
48V
Illustrati on 1
Illustrati on 2
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If you are connecti ng packs in a series, a more signifi cant resistance may be created on the atypical connector. This can have an impact on the system functi on, mainly on the distorti on of the cell voltage value behind the connector in the event that one BMS is used for all cells in the series confi gurati on.
The opti mal soluti on is to use a separate BMS for every pack and to ensure their mutual communicati on. You can also eliminate the problem by using a terminal BMS (single modules on each cell, which communicate along the shared bus).
48V
96V
144V
OKBMS BMS
!?BMS
R
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Principles for Assembly, Placement and Operations • Remove all metal from the hands prior to assembly (watches, rings, bracelets…) • Use personal protection equipment and isolated tools • Protect the live parts of the battery from short-circuit (moving or turning the jumper, a falling
conductive object…) • Proceed with full concentration, caution and precision • Place the battery box with the terminals and safety valves facing up • During high operating current usage, ensure that heat is ventilated away from the area• If possible, place the battery in a location where temperatures do not go below freezing and
over 40°C. • Allow for open access for visual and service checks • Make sure the battery can be disconnected safely (manually)• Provide adequate monitoring, supervision and service, train your operators • Make sure that the configuration is in balance, protect the box from dangerous mechanical
and electrical statuses • Learn about the features and principles of operating the battery as per the “How To Operate
LiFePO4 Batteries” brochure
Delivery and Service Conditions • Purchase of components + basic free support for assembly of the pack by the customer• Purchase of the components + individual paid support• Purchase of the components + purchase of assembly services for the BPF module, e.g. additional
extension modules
GWL a.s.Průmyslová 11, 102 00 Prague 10Czech Republic, European Union