How to Manually Charge a High Voltage (HV) Stackable Battery Pack

How to Manually Charge a High Voltage (HV) Stackable Battery Pack

Overview

This guide explains how to manually charge a GivEnergy HV Stackable Battery Pack using either the test pins or the stack pins.
There are two hardware versions of the HV Stackable battery — one includes test pins, and one omits them. Follow the appropriate method below based on your battery model.

Manual charging should only be carried out by qualified personnel familiar with DC electrical systems. Always follow standard safety precautions when working with high voltage equipment.

Equipment Required

  • 120 V DC charger (adjustable output)
  • Multimeter (for voltage verification)
  • Insulated test leads
  • Flat, level, non-conductive surface

Method 1 – Charging Using Pack Test Pins

Use this method if your HV Stackable battery pack has accessible test pins on the top and bottom of the casing.

Steps

  1. Place the battery on a flat, level surface.
  2. Verify voltage presence:
    • Using a multimeter, measure between the top-left and bottom-right test pins.
    • If no voltage is detected or if pins are not present, use Method 2.
  3. Configure the DC charger:
    • Voltage: 75 V DC
    • Current: 3–5 A
  4. Turn off the charger before connecting leads.
  5. Connect charger leads:
    • Positive (+): Bottom-right pin
    • Negative (–): Top-left pin
  6. Power on the charger.
    • The voltage will fall to the pack’s current voltage.
    • Charging current will become visible.
  7. Charge until:
    • Current drops to 0 A and voltage reaches 75 V.
  8. Turn off the charger and disconnect leads.
  9. Repeat for any additional packs.

Method 2 – Charging Using Stack Pins and Base Unit


Use this method if your HV Stackable battery does not include test pins.

Steps

  1. Place the battery on the stack base plate, ensuring the front label faces you and the connector is on the right-hand side.
  2. Verify voltage presence:
    • With a multimeter, check between the top-right and bottom-left stack pins.
    • A reading between a few volts and ~70 V indicates connection is valid.
  3. Configure the DC charger:
    • Voltage: 75 V DC
    • Current: 3–5 A
  4. Turn off the charger before connecting.
  5. Connect charger leads:
    • Positive (+): Bottom-left pin
    • Negative (–): Top-right pin
  6. Power on the charger and monitor current flow.
  7. Charge until the current drops to 0 A and voltage reaches 75 V.
  8. Turn off the charger and remove all connections.
  9. Repeat for other battery packs.

Safety Notes

  • Do not exceed 75 V charging voltage.
  • Avoid touching connectors during operation.
  • Ensure correct polarity before energising charger.
  • Always monitor the pack temperature during manual charging.

Completion Check

  • Battery voltage stabilised at 75 V ±0.5 V.
  • No charging current detected.
  • Connections securely removed and insulated.

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