User Manual

52V RacPower Range

BN52V-100-5.2k DU

( Daily Use )

1. DOCUMENT SCOPE
   

Congratulations on purchasing a high quality BlueNova® product.

This document covers structural information, installation instructions, troubleshooting, safety & maintenance instructions, storage guidelines as well as emergency & first aid procedures specific to:

• BlueNova® 52V RacPower product range, consisting of BN52V-100-5.2k
  

If you are unsure whether this document is applicable to your battery, or if you have any questions or comments, kindly contact BlueNova® Technical Support:

 Office: +27 21 205 2000        E-mail: support@bluenova.co.za   

Please do not discard this document as it contains valuable information that might have to be referenced at a later stage.

2. STRUCTURAL OVERVIEW
   

The BlueNova® 52V RacPower range has been designed to be installed in 19” (11U) server racks.

The weight & dimensions of each enclosure in this range is listed below:

Note: The dimensions above are the dimensions of the main chassis (excluding the front panel) in each case.

For a more detailed overview of dimensions, please see latest product data sheets.

 Diagram: BN52V-50-5.2k RacPower

3. FRONT INTERFACE PANEL
   

Diagram: Front Interface Panel (BN52V-100-5.2k)

SYSTEM START / SHUT DOWN / RESET:

COMMUNICATION PORTS:

DIP SWITCH PANEL CONFIGURATION:

It is essential to set the DIP address number in order when connected with Can bus inverter, otherwise the BMS will report an internal communication error.

STATE-OF-CHARGE:

LED indicators:

4. INSTALLATION
   

1. VOLTAGE-BASED INSTALLATION
   

If the battery is not connected to hardware that is serial communication compatible, the following values highlighted in blue must be set on the inverter/charger:

• Maximum Continuous Charge Current limit = 50 A 
  
• Recommended Charge Current = 30 A
  
• Discharge Current limit = 70 A
  

IMPORTANT: Inverter/charger voltage calibration

Some inverters/chargers have been known to return inaccurate results when measuring voltage.

In such cases, the inverter/charger should be calibrated as follows:

Compare the voltage values displayed by the inverter/charger with that of a calibrated voltmeter.

If the actual voltage differs by more than 100mV from that measured by the inverter/charger, apply this difference to the highlighted values above (i.e. if actual voltage = 56V while inverter voltage = 56.5V,

the voltage difference = 0.5V should be subtracted from each of the set values above).

Note: Some inverters/chargers have pre-programmed lead-acid related algorithms & functionalities such as auto-desulfation and equalisation. These functionalities should be disabled, where possible.

2. SERIAL COMMUNICATION
   

BlueNova® 52V RacPower batteries include serial communication functionality via CAN protocol. 

Serial-connecting a 52V NG battery to a compatible inverter, charger or other third-party hardware device normally negates the necessity of manual voltage-based installation procedures, as described above. 

The installation procedure for serial integration varies and is determined by the serial-compatible peripheral hardware that is being integrated with.

Please note for Victron installations the DVCC must be switched on.

3. PARALLEL CONNECTION
   

BlueNova batteries can be connected in parallel to each other to increase overall capacity ONLY IF ALL

the requirements below are met:

1. The nominal voltage of all parallel-connected batteries is the same (52V), and
   
2. The installed capacity for all batteries is the same, and
   
3. Each battery is operating within its warranty period.
   

A total of 9 units can be connected in parallel, for total installed capacity of 46.8kWh @C2, 25°C.

Diagram: Parallel Connection

1. PARALLEL CONNECTION: STEP-BY-STEP INSTRUCTIONS
   

1. Ensure that all units are grounded by connecting each chassis to GROUND from the rear right panel.
   

Wire diameter should be equal to or exceed 1mm².

2. Connect the POSITIVE terminals of the first (top) unit to the second unit, then from the second unit to the third etc. as illustrated above. Wire diameter should be equal to or exceed 8mm².
   

3. Connect the NEGATIVE terminals of the first (top) unit to the second unit, then from the second unit to the third etc. as illustrated above. Wire diameter should be equal to or exceed 8mm².
   

4. Connect the CAN port of each unit as illustrated above with a standard 1-to-1 pin RJ45 network cable.
   

5. Connect the bottom- or topmost unit’s CAN to the third-party serial communication device. Cable connector pin configuration is determined by the device being connected to. See C. CONTROL PANEL in this manual for the battery’s RJ45 port pin configuration.
   

6. Configure the dip switches for the master battery and slave batteries respectively.
   

2. Start-up sequence for parallel batteries
   

1. After the system has been fully installed ensure that all the battery units are switched off (All LED’s on the front panel are off). Ensure that the provided RJ45 cable (black) is connected between the master battery and the inverter.
   

2. Each battery should not be tuned on individually! Instead press and hold the reset button on the master battery only, this will automatically turn on all the batteries in parallel.
   

3. Ensure that the communication between the BMS and the inverter is functioning correctly by checking the visible devices on the inverter’s interface.
   

5. EXTRA FEATURES
   

1. Standby Mode
   

The system will enter Standby Mode immediately whenever the battery is not being charged nor discharged.

In standby mode, the green RUN LED will flash (as with discharging).

2. Sleep Mode
   

The system will enter Sleep Mode whenever Standby Mode has been active & uninterrupted for 96 hours.

In Sleep Mode, the system will become inactive & all LED’s on the Control panel will switch off.

The system will wake up from sleep mode:

• (automatically) whenever a charge current is detected, or
  
• (manually) the battery/batteries are switched off and then on again.
  

6. MAINTENANCE
   

1. General Guidelines
   

1. Do not short circuit the battery terminals.
   
2. Do not use the battery without a BlueNova® approved integrated BMS solution.
   
3. Do not disassemble, pierce, cut or in any way physically alter any part of the battery.
   
4. Do not burn, incinerate or otherwise subject the battery to extreme heat.
   

2. Storage Instructions
   

1. Ensure that the battery is switched off when stored.
   
2. Disconnect the communication cable.
   
3. Always store batteries in a cool and well-ventilated area – ideally 25°C ± 3°C.
   
4. Store away from moisture and heat.
   
5. Do not store batteries upside down for overly long periods.
   
6. Check the open circuit voltage of stored batteries at least once per month. Recharge batteries sufficiently and frequently enough to prevent the open circuit voltage falling below 40V. 
   
7. The battery needs to be charged every 6 months if out of use.
   
8. Ensure that the stored battery’s state of charge is always above 50%. 100% SOC is optimal.
   
9. Don’t place more than 6 units on top of each other.
   

7. EMERGENCY & FIRST AID
   

1. In case of fire
   

1. Evacuate danger zone. Open ventilation in the room if possible.
   
2. Extinguish fire with a CO2 fire extinguisher.
   
3. After the fire has been extinguished, immerse any remaining smoking cells completely in water.
   

Wear protective gear during this procedure.

2. Skin contact
   

1. Wash the affected area immediately with soap and water.
   
2. If irritation persists, seek medical attention.
   

3. Eye contact
   

1. Rinse eyes immediately with clean water continuously for at least 15 minutes.
   
2. Seek medical attention immediately afterwards.
   

4. Ingestion
   

1. Refrain from taking any emetic or vomit-inducing medicine.
   
2. Seek medical attention immediately.