brianfox

I had my faulty US3000C replaced under warranty and before I sent it back I took some pictures to share with everyone. I did not strip it down completely for obvious reasons. Would have been interested to see what microcontroller and mosfets were used in this model. Not my best pictures but some are better than none.
Things to note; the battery packs which houses the cell pouches are now encased in some form of metal with a plastic top cover. The other distinct difference is the new board, now only one single board that handles Comms and Power management, probably costs less from a manufacturer perspective but this is the new V10R04 board revision. The same board is found in the US2000C models. Currently v1.9 firmware is available for them. The other notable difference is the orange cables joining each battery pack in series.
I was happy to see the improvements made. So thumbs up to Pylontech!

 

 

 

 

In December 2020, I unfortunately fell victim to a lightning surge from the grid. Various items in my house was impacted. Thankfully my Axpert inverters(x2) survived with no issues, although the Raspberry Pi that runs ICC was effected, Pi booted but USB and network ports dead. My Pylontech bank(5 x US2000 Plus) was impacted as well. The communication ports(console, RS485, CAN etc) was impacted on all 5 Pylontech modules. Fortunately they were still charging and discharging normally but i could not get any info from them. I sent them back to the supplier to get a full report. The report stated that the CMU boards in all 5 modules had to be replaced and Pylontech warranty does not cover surges, so I had to claim from insurance. Got all approvals and all boards were replaced. I commissioned the entire bank after the repairs was done. After a few days I was noticing that 2 modules cell voltages was going over 3.65v during charge and these units were throwing High Voltage and Over voltage errors in the logs. When this happens, it stopped accepting any current and waits for those effected cells voltages to drop below 3.5v before accepting a charge again. This happened over a few days and the SOH counts were increasing for these 2 modules. I decided to pull them out of the bank and to my surprise they were swollen! I was actually was shocked(no pun) when I saw this. I returned those 2 modules back to the supplier and there new report concluded that the cells are damaged from the surge and irrepairable. Their recommendation was to replace those 2 modules, which i did with a US3000C and a US2000. 
I collected the damaged modules and in the spirit of science, being inquisitive and sharing knowledge I decided to salvage some parts before disposing the cells. I took the following pics:
Bottom cover off, we can see 3 x 16v battery packs(notice them being swollen), connected in series. Power Management Unit(PMU) board on the bottom left and Communication Management Unit(CMU) on the bottom right. 

 
PMU Top: 

 
PMU Bottom, notice all the MOSFETS here.... this side of the board is attached to a heatsink situated on the front right top side of an installed module: 



 
CMU Top:


 
CMU Bottom:


 
LED Strip:

 
Internal power cable size 8AWG - 10mm2:


 
Battery Packs:





 
If you counted, there are 10 pouches per pack. A total of 30 pouches in a single US2000 Plus module, equates to 1.6v per pouch. BatteryView software shows 15 cells, so i am guessing that 2 pouches make up a cell of 3.2v.
Enjoy the pics.