SEPLOS MASON 230L 51.2V 230AH Battery Pack Assembly
Step 1. Wheels Mounting
1. Mount the wheels with 16 M6 * 14
hexagon Philip screws. As shown in "Figure1", Set the
torque index of the electric screwdriver to 8nm。
（Standard torque：10nm) until the electric batch clicks.
2. Rip off the epoxy insulation board
A/B/C and stick them to the inner sides of the box. And
paste it at the corresponding position as shown in "Figure
2".
Materials:
1 pcs battery box and 4pcs wheel,
2 pcs Epoxy board A,
2 pcs Epoxy board B,
2 pcs Epoxy board C,
16 pcs M6 * 14 hexagon Phillip screws.
Tool:
Electric screwdriver
10mm sleeve and PH3 cross screwdriver
cell to separate cells.
2. As shown in "Figure 2", Put the cells into the case. Paste epoxy
board B to separate cell from cell, and cells from front plate paste
epoxy board C.
3. Fix the front plate with six M8 *20 hexagon Philips screws as
shown in "Figure 4" Set the torque index of the electric
screwdriver to12nm. (Standard torque: 25nm) until the electric
batch clicks.
Material:
16pcs cells, 18pcs cell foams，
2 pcs Epoxy board A, 1 pcs Epoxy board B,
Tool:
Electric screwdriver,
Note: Due to different manufacturers of the cell tolerance, according to the instructions after the foam is still loose, increase the foam filling.
2. As shown in "Figure 2", Fix the top bracket with eight M5 * 8 hexagon Philips screws. Set the torque index of the electric screwdriver to “6”.(Standard torque:6nm) until the electric batch clicks. 3. Install the aluminum row, as shown in "Figure 3" to install the serial aluminum row on the pole.
Material:
2 pcs top bracket EVA foams
2 pcs top brackets
8 pcs M5* 8hexagon Phillips screws
30 pcs gaskets
14 pcs EV-1 aluminum bar
1 pcs SF-L1 aluminum bar
Tool:
10mm sleeve
Electric screwdriver
PH3 Phillips screwdriver
Torque wrench
Step 4. Install PCB A/B board
1. Fix PCB A/B board with twelve M4 * 8 hexagon Phillips screws as shown in "Figure 1". Set the torque index of the electric screwdriver to “4”（Standard torque：3nm)until the electric batch clicks.
2. Connect the lug connectors with battery terminals at the corresponding position as shown in "Figure 1 ". Fix the aluminum bar with thirty M6 flange nuts. Set the torque index of the electric screwdriver to “10”(Standard torque:10nm)
Material:
2 pcs PCB board
12 pcs M4 * 8 hexagon Philips screws
30 pcs M6 flange nuts Tool:
Electric screwdriver
10mm sleeve
PH3 philips screwdriver
Torque wrench
BMS*1 PCS,
PH3cross screwdriver,
PH2cross screwdriver,
PH4cross, screwdriver,
Torque wrench
Step 6.Top Plate Installation
1. Top plate installation: As "Figure" installation connector socket *2; use eight M4*10 Hex socket flat head screws to lock, and adjust the torque of the electric batch to “5”(Standard torque：3Nm）until the electric batch clicks.
2. Install the adapter plate: Use three M3*8 Phillips round head screw to lock, and adjust the torque of the electric batch to”1”,(Standardtorque:1Nm), until the electric batch clicks.
3. Install key: The switch key is welded on the plug, and then the corresponding ON/OFF insertion buckle.
4. Install the fuse holder: Use two M6*14Phillips hex screws with a spring washer to lock, the torque of the electric batch is adjusted to “8”, (Standard torque:8Nm), until the electric batch clicks.
5. Install fuses and copper bars: YS-4, YS-2; Use the screws that come with the safety seat to lock and adjust the torque of the electric batch to “8”(Standard torque:8Nm), until the electric batch clicks.
Material:
Copper bar: YS-2*1PCS YS-4*1PCS
Top plate *1PCS
Connector socket *2PCS
M4*10Hex socket flat head screw *8PCS
Adapter plate *1PCS
M3*8 Phillips round head screw *3PCS
Switch key *1PCS Fuse holder *1PCS
M6*14 Phillips hex screw with spring washer *2PCS
Fuse *1PCS
Tool:
Electric screwdriver
PH3 Phillips head
PH2 Phillips screwdriver,
PH4 Phillips screwdriver,
Torque wrench
Step 7. Install the BMS Bracket and the top plate onto the chassis
1. As shown in "Figure 1" and "Figure 2" install the BMS bracket with four M5 * 8 Phillips hex screw with a spring washer. Set the torque index of the electric screwdriver to “6”.(Standard torque:6nm)until the electric batch clicks.
2. As shown in "Figure 3", Fix the front panel with M4 * 10 Hex socket countersunk screws. Set the torque of the electric screwdriver to “5”.(Standard torque:3nm)
3. As shown in "Figure 4", Insert the communication cable of the adapter board, and plug the switch cable into the BMS.
4. As shown in "Figure 5", B+/B- terminals are locked with M6 flange nut. The torque of electric screwdriver is "10nm".(Standard torque:10nm) P+/P- terminals are locked with M8*16 Phillips hex screw with spring washer. The torque of the electric screwdriver is set to "12nm". ( Standard torque:25nm)YS-2 copper bar is locked with M6*14Phillips hex screw with spring washer. Electric torque set
to"8",(Standard torque:10nm), until the electric batch clicks.
5. Connected BMS to cells with BMS wires as shown in the figure.
Material:
M5*8 Phillips hex screw with spring washer 4pcs,
M8*16 Phillips hex screw with spring washer 2pcs,
M6*14 Phillips hex screw with spring washer1pcs,
M4*10 Hex socket countersunk screw 14PCS,
M6 flange nuts * 2PCS.
Tool:
Electric screwdriver,
PH4cross screwdriver,
10mm sleeve and 13mm sleeve.
2. As shown in "Figure 2", Insert the display and LED light with cables.
3. As shown in "Figure 3/4 ", Mount the cover with M4 * 10 Hex socket countersunk screw. The torque of the electric screwdriver is set to “5”.(Standard torque:3nm) until the electric batch clicks.
4. Assembly completed BMS needs to carry out capacity learning specific steps:
- Fully charge the battery first (recommended current 100A)
- Put it into the battery system protection (recommended current 100A)
- Charge to 50% power (recommended current 100A)
- Complete capacity learning
Case cover * 1PCS
Display * 1PCS
LED light * 1 PCS
M3 * 8 Phillips round head screw* 6PCS
M4 * 10 Hex socket countersunk screw* 17PCS
PVC sticker * 1 PCS
Tool:
Electric screwdriver
PH3cross screwdriver
Hexagonal H2.5
