Step-by-Step Guide to Assembling the MASON-280 51.2V 280Ah Battery Pack

Assembly Steps for the MASON-280 Battery Pack

Step 1: Handle and Hasp Installation

• Materials Needed:
  1 battery pack box, 4 concealed handles
• Tools:
  Electric screwdriver, hexagonal nuts (H2.5)
• Instructions:
  1. Use an electric screwdriver with a torque index set to 3.
  2. Secure the handles to the box with the folding side facing downward using M4 countersunk nuts.
  3. Tighten screws until you hear the sound of "da-da," ensuring the handles are secure.

Step 2: EVA Tape Installation

• Materials Needed:
  Epoxy insulation boards (A, B, and C)
• Instructions:
  1. Remove the backing from each insulation board.
  2. Attach the insulation boards to the inner sides of the box for added safety and stability.

Step 3: Battery Cover Insulation

• Materials Needed:
  Polycarbonate sheet, box cover
• Tools:
  Utility knife
• Instructions:
  1. Align the polycarbonate sheet with the box edges and secure it.
  2. Use the utility knife to expose screw holes for future assembly.

Step 4: Battery Cell Placement

• Materials Needed:
  16 battery cells, 18 EVA-1 foam pads, fixed plate, 9 M6*14mm Phillips hex screws
• Tools:
  Phillips screwdriver
• Instructions:
  1. Arrange battery cells as indicated, ensuring the positive and negative electrodes are positioned correctly.
  2. Add EVA foam pads for insulation.
  3. Cover with the fixed plate and secure screws with a torque setting of 8-9 Nm.

Step 5: Top Bracket Insulation

• Materials Needed:
  2 top plates, 8 M5*8mm Phillips hex screws
• Tools:
  Screwdriver with torque index
• Instructions:
  1. Apply EVA-2 foam to the top plates.
  2. Attach top plates to the battery cells with M5 screws for added protection and structure.

Step 6: Battery Cell Connections

• Materials Needed:
  Aluminum busbars, M4*8mm screws, M6 flange nuts
• Tools:
  Torque screwdriver
• Instructions:
  1. Arrange aluminum busbars for maximum contact.
  2. Tighten connections using M6 flange nuts with a torque index of 5 Nm.
  3. Verify module voltage (approximately 3.2V per pin).

Step 7: Front Plate Assembly

• Materials Needed:
  Battery terminals (yellow and black), BMS, display screen, fuses, wiring harnesses
• Tools:
  Torque screwdriver
• Instructions:
  1. Attach components to the front plate following torque recommendations.
  2. Secure wiring harnesses and confirm tight connections.

Step 8: BMS Wiring

• Materials Needed:
  Insulated copper busbars, wiring harnesses
• Instructions:
  1. Insulate busbars and connect electrodes.
  2. Perform a turn-on test to ensure proper voltage (52V) and zero output current.

Step 9: Battery Pack Fixing

• Materials Needed:
  Screws and torque screwdriver
• Instructions:
  1. Lock the box, cover, and front plate securely.
  2. Ensure all components are firmly in place with no loose parts.

Step 10: Battery Monitor Calibration

• Instructions:
  1. Log in to the Battery Monitor system using the default credentials ("admin"/"admin").
  2. Fully charge the battery and calibrate settings.
  3. Run capacity learning by charging the battery to its full capacity under recommended settings.

Why Choose DIY Kits for Your Battery System?

The Seplos MASON 280 48V 280Ah 14.3KWh Battery DIY Kits offer unmatched flexibility and efficiency, making them ideal for energy storage enthusiasts. With easy-to-follow assembly steps and reliable components, these kits ensure seamless integration into any system. Explore available kits here:

• Seplos MASON 280 48V Server Rack Battery DIY Kit
• MASON-280 Vertical Battery Pack DIY Kit

Conclusion

Building your own MASON-280 51.2V 280Ah battery pack is not only cost-effective but also a rewarding experience. With easy-to-follow instructions and premium components, the process ensures reliable performance and durability. For ready-to-assemble kits and fast delivery (4-7 days within Europe), explore Vnice Power's online store: Shop Vnice Power.