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Installation

BA_sun_power_pack_LiOn_en_V1.05.docx

V1.05 (20/07/2017) 6140203036

25

7.2.

Installing the battery stacks

Note:

The system can be operated only when it is completely equipped, i.e. with the two battery stacks

supplied / fix assigned (identical capacity and nominal voltage). Check this based on the

information on the nameplate of the battery stacks.

1. The battery stacks are packed in separate cartons. The cartons should not be

opened with pointy tools or objects (see also Figure of the battery stack in Figure 9).

No. Description

1

Cover for safety fuse (do not remove)

2

Cover for connecting the plus terminal

3

Connection for the cable harness to the battery management system

4

Cover for connecting the minus terminal

5

Cover for minus terminal (do not remove)

Figure 9: Battery stack - Connections

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Summary of Contents for Sun Powerpack Premium

Page 1: ...Operating Manual HOPPECKE sun powerpack premium ...

Page 2: ...een the illustrations given in this documentation and the purchased product This installation manual is not covered by any change service Keep this documentation in such a manner that it is available immediately to all those who need to carry out work in connection with the battery system or its components Service Hotline Germany 0800 246 77 32 International service hotline 49 0 180 5 22 9999 Inte...

Page 3: ... Disposal instructions 12 3 7 Transport 12 3 7 1 Intact undamaged batteries and batteries at the end of their service life 13 3 7 2 Defective batteries 14 3 7 3 Check the delivery 14 4 SUN POWERPACK PREMIUM BATTERY SYSTEM 16 4 1 Hints for sizing of the system 18 5 STORAGE 19 5 1 Intact undamaged batteries and batteries at the end of their service life 19 5 2 Defective batteries 19 6 PREPARING FOR ...

Page 4: ...g 45 10 2 Repair Work 45 10 3 BMS software update 45 11 END OF SERVICE LIFE 46 12 WARNING AND ERORR MESSAGES 47 13 SYSTEM EXPANSION 49 14 DISASSEMBLY 49 15 TECHNICAL SPECIFICATIONS 50 15 1 System 50 15 2 Battery cell 50 15 3 Norms and Standards 50 16 CE DECLARATION OF CONFORMITY 51 17 ABBREVIATIONS 52 18 FURTHER INFORMATION 53 19 APPENDIX 54 19 1 Certification of the function of the smoke detector...

Page 5: ...lation operation maintenance and disassembly of the sun powerpack premium battery system The work of installation maintenance and disassembly should be done only by electricians Note Proper installation and commissioning must be certified by the respective electrician with his signature in this operating manual see chapter 19 The signed operating manual must remain with the end user of the battery...

Page 6: ...if it is not prevented WARNING Denotes a potential hazard with a medium level of risk that could lead to death or severe physical injury if it is not prevented CAUTION Denotes a hazard with a low level of risk that could lead to minor or medium degree of physical injury if it is not prevented ATTENTION Denotes a hazard in which the product other objects or the environment may get damaged if it is ...

Page 7: ...as with other batteries lithium ion batteries may represent a source of hazard even in an apparently discharged condition by high short circuit currents DANGER The battery stacks and the included battery cells should not be damaged mechanically puncturing deforming or disassembling Keep away from open flames or sources of intense heat There is a risk of heat developing and leakage of liquid electr...

Page 8: ...TION Only those inverters that have been approved by HOPPECKE must be used The overall system comprising inverter PV system battery system and any other components must be designed diligently In the process the system parameters and limit values of the battery as well as all relevant norms and standards must be complied with 3 3 Directives Legislation and Standards Observe and follow the rules and...

Page 9: ...ed while current is flowing through the battery connection cables Before opening the charging circuit check the condition of the battery inverter battery charger by measuring the voltage Secure the battery inverter battery charger against being switched on again Observe and follow the operating manuals of the battery inverter battery charger manufacturer 3 5 1 Personnel and Qualification Work on t...

Page 10: ...o contact with abnormal batteries discharge of contents deformations discolouration bulges or similar Explosive gases may get released Lithium ion batteries may react very severely for example in combination with fire WARNING In case of damaged or defective battery cells in sun powerpack premium or any abnormalities in the battery system shut down operation of the battery system immediately To do ...

Page 11: ...ediately 3 6 2 Fire fighting procedures Critical conditions may arise as a result of fire short circuits high temperatures more than 80 C intense mechanical impacts or damage As a consequence of this the battery cells may burst or catch fire and hazardous decomposition products and gases may be formed WARNING If a cell decomposes as a result of mechanical damage or blows off thermally temperatures...

Page 12: ...he transport to the end customer takes place either by a freight forwarding company appointed for this purpose or by the installation agency In case of new supply each unit of delivery consists of the components of an individual system with either 5 or 7 5 kWh energy content One individual system is always packed on one Euro pallet There is one carton with the housing of the battery system on the ...

Page 13: ...eries and batteries at the end of their service life Intact undamaged batteries as well as batteries at the end of their service life should not have any visible mechanical signs of damage or deformations A battery must be classified as defective if at least one of the following criteria is met Note If at least one of the following criteria is met the regulations for packaging and transport of def...

Page 14: ...lease contact the HOPPECKE Service hotline Germany 0800 246 77 32 International 49 0 180 5 22 9999 3 7 3 Check the delivery This chapter pertains to the transport of the system components from the HOPPECKE factory Depending on the agreement the transport is done to the wholesale dealer installer or the end customer The transport from the HOPPECKE factory is done by a freight forwarding company app...

Page 15: ...s Check the goods for damage in transit Note down any damage on the outer packaging Note down any visible spots or moisture If the delivery is incomplete or there are signs of transportation damage write a brief report on the defects or shortcomings on the consignment note before you sign the same Request the freight forwarder to check the consignment and note down the name of the person carrying ...

Page 16: ...4 Battery Management Systems BMS 5 Display unit 6 Connector 7 Service interface Figure 1 Sun powerpack premium battery system without cover ATTENTION If the selected version of the sun powerpack premium is not compatible with the application there may be loss of functionality e g safety shut downs HOPPECKE offers multiple versions of sun powerpack premium with different capacities For optimal util...

Page 17: ...battery connection cable incl data cable Mat No 6154310006 1 x operation manual Mat No 6140203036 4 x Washer DIN 9021 6 A2 Mat No 6234000002 4 x Toothed washer M6 Type M A4 Mat No 4234000083 4 x Hexagon nut ISO 10511 M6 05 ZN Mat No 4242000111 1 x Sticker for sealing of housing Mat No 6142000002 1 x Protective foil for nameplate Mat No 4142000095 The battery stacks consist of individually connecte...

Page 18: ...via a data interface CANOpen 4 1 Hints for sizing of the system The battery system communicates with the battery inverter and therefore realizes an automatic system operation It is not required to operate the system manually However for system sizing and operation the following hints shall be observed Note Sizing of the entire system including installed PV and inverter power and the operation sche...

Page 19: ...d installation agencies Coordinate other safety measures with the local authorities and loss insurers Storage period For ambient temperatures of 20 C to 35 C the battery stacks may be stored up to 6 months If the maximum storage period is exceeded please contact HOPPECKE Service ATTENTION The battery stacks should be charged only when they are installed in the system and during normal operation 5 ...

Page 20: ...stacks inside the battery system are in an upright position For the installation of the battery system on a wall it must be ensured that the wall concerned has adequate load bearing capacity see also specifications of the weight in chapter15 1 ATTENTION Keep a distance of at least 0 3 m at the installation site between adjacent sun powerpack premium battery systems as well as other items side wall...

Page 21: ...e and above the battery system 6 2 Tools and Equipment The following tools are required for installation Allen key 4 mm for fixing the battery stacks in the housing and connecting the housing with screws to the wall mount Box spanner 8 mm torque wrench for fixing the protective earth conductor to the grounding point of the housing Tools and installation material for the wall mount Insulated torque...

Page 22: ...tended position of the battery system on the installation wall Use a spirit level in order to align the subsequent position of the wall mount see also Figure 4 No Description 1 Wall mount 2 Borehole for wall mounting 3 Threaded borehole for attaching the housing to the wall mount Figure 4 Boreholes in the wall mount 2 Fix the wall mount with appropriate screws The wall mount must lie flush with th...

Page 23: ...de from the top into the wall mount see Figure 6 No Description 1 Wall mounting 2 Fastening rail 3 Rear side of the housing 4 Housing cover Figure 6 Suspended housing 4 Fix the Allen screw M6 supplied with the housing to the wall mount see Figure 7 No Description 1 Fixing the wall mount with the housing Figure 7 Fixing the wall mount and the housing ...

Page 24: ...g see Figure 8 No Description 1 Grounding point Figure 8 Grounding point 2 Fix the protective ground conductor with a ring cable lug to the grounding point on the housing Use the spring washer and nut supplied for this purpose The tightening torque is 12 Nm Use a suitable protective ground conductor with appropriate cross section not included in the scope of supply ...

Page 25: ...the information on the nameplate of the battery stacks 1 The battery stacks are packed in separate cartons The cartons should not be opened with pointy tools or objects see also Figure of the battery stack in Figure 9 No Description 1 Cover for safety fuse do not remove 2 Cover for connecting the plus terminal 3 Connection for the cable harness to the battery management system 4 Cover for connecti...

Page 26: ...tom of the cover see Figure 10 No Description 1 Left fastening screw 2 Right fastening screw Figure 10 Fastening screws on the cover 4 Push the battery stacks one after the other into the housing of the battery system Use the carry grips fixed on the sides to lift the battery stack see Figure 11 and Figure 12 Begin with the lower level see Figure 13 Note Each battery stack is marked on the front s...

Page 27: ...1 05 20 07 2017 6140203036 27 No Description 1 Lower level 2 Upper level Figure 11 Upper and lower levels in the housing No Description 1 Carry grip of the battery stack see the left and right side on the battery stack Figure 12 Battery stack Carry grip ...

Page 28: ...03036 28 No Description 1 Lower level with battery stack 2 Upper level Figure 13 Battery stack in the housing 5 Fix the battery stack with the screws supplied along with it on the lower level see Figure 14 No Description 1 Fastening screw Figure 14 Fixing the battery stack ...

Page 29: ...sun_power_pack_LiOn_en_V1 05 docx V1 05 20 07 2017 6140203036 29 6 Push the second battery stack into the upper level of the housing see Figure 15 and fix it to the upper level Figure 15 Housing with two battery stacks ...

Page 30: ... substances are leaking leave the room immediately and alert the fire brigade see also chapter 3 6 WARNING The battery terminals or the associated connecting cables must not be grounded WARNING Use only insulated tools see chapter 6 2 1 Connect the minus terminals of the lower battery stack right side with the connecting cable marked in blue colour 2 To install the connector the plastic cover of t...

Page 31: ...interchanged No Description 1 Connection to the BMS Figure 17 BMS connection at the lower battery stack 5 For serial connection of the two battery stacks the plus terminal of the battery stack in the lower level left side must be connected to the minus terminal of the battery stack in the upper level right side To do this use the prepared and ready made connecting cable both ends are marked in bla...

Page 32: ...management system with the connection at the upper battery stack The associated cable harness is prepared and kept ready accordingly see Figure 19 No Description 1 Connecting the Battery Management System to the upper battery stack Figure 19 Connecting the BMS to the upper battery stack 8 Connect the plus terminal of the upper battery stack to the associated black connecting cable with marked in r...

Page 33: ... to the upper battery stack Figure 20 Connecting the plus terminal to the upper battery stack Note The voltages and temperatures of the individual battery cells are acquired via the cables in the cable harness This data is needed urgently for trouble free operation and management of the system Figure 21 Battery stacks with connections ...

Page 34: ...f compatible battery inverters ATTENTION Observe and follow the sequence of the electrical connection strictly Note Switch off the battery inverter before connecting the battery connecting cable Follow the information provided in the manufacturer s documentation 1 First connect the battery connecting cable to the battery inverter Follow the information provided in the manufacturer s documentation ...

Page 35: ...necting cable 4 Insert the connector of the battery connecting cable in the connection jack on the top of the battery system see Figure 23 7 Note The connector has to be pushed into the connection jack up to the stop Insertion is made intentionally stiff The connection of the communication cable CAN bus is also located in the connector of the DC connection jack No Description 1 Battery connection ...

Page 36: ...on With this the installation has been completed successfully Note Configure the battery inverter according to the manufacturer s specifications Note If the battery is in deep discharge condition after restarting the BMS there are 3 minutes left to set up the charging current If the BMS detects a charging current within the 3 minutes time the BMS remains active and the battery may be charged fully...

Page 37: ...ng for fastening the cover 2 Right opening for fastening the cover Figure 26 Openings for fastening the cover 2 Press the cover against the bottom side of the housing Fasten the Allen screws at the bottom of the cover see Figure 27 Note Owing to the peripheral gasket on the housing pressing the cover may be somewhat difficult No Description 1 Left fastening screw 2 Right fastening screw Figure 27 ...

Page 38: ...ousing 4 Enter the date of commissioning and the details of the installation engineer on the nameplate of the battery system Name and Company The nameplate is located on both sides of the housing see sample in Figure 29 Stick the protective foil over the nameplate afterwards Figure 29 Nameplate Sample 5 Certify proper assembly and installation of the battery store system in the appropriate form se...

Page 39: ...nsorship programme for renewable energy Storage Programme no 275 the battery system must be registered immediately but latest within two weeks after commissioning For this purpose you may choose between on line registration https register hoppecke batterien de and registration via telephone at 02963 61 526 Mon Fri 09 00 AM 4 00 PM You may download the current terms and conditions for warranty from...

Page 40: ...tion of assembling or disassembling the system by an electrician Keep children away from the battery system Used batteries that have the Recycling icon are reusable commodities and should not be disposed of in household waste According to this marking batteries and or electronic components should not be added to household waste Returning and recycling the batteries must be agreed upon with the man...

Page 41: ... get oxidised Warning against flammable substances Warning against toxic substances With proper assembly and installation and during regular operation no liquids or gases are released Warning against explosive substances by release of gases e g by mechanical damage to the cells With proper assembly and installation and during regular operation no liquids or gases are released Observe and follow th...

Page 42: ...end user to intervene manually The display unit is used only to display information on the instantaneous state of the battery system as well as general information see below The information output on the display unit can also be retrieved with the help of the button at the bottom right of the display unit 9 2 Display Unit Note The display unit is switched on using the button at the bottom right co...

Page 43: ...ped and the BMS interrupts the DC link to the battery inverter in the charging and discharging direction of current The display unit cannot be activated No current can be drawn from the battery This state is suitable for storing or decommissioning the battery system Note For specialists By pulling the cable attached to the service interface the battery system is also switched off Deep Discharge Pr...

Page 44: ... within 3 minutes so that the normal operating mode can be reached for this purpose see also the operating manual of the battery inverter Fault If overshoot of the operating limits or a BMS internal error has been identified then depending on the respective error the semiconductor switch is opened in order to interrupt the flow of current in the charge and or discharge direction The error codes ar...

Page 45: ...intain and check the smoke detector at the installation site in accordance with the manufacturer s specifications 10 1 Cleaning Wipe off the system occasionally with a cloth slightly moistened with water 10 2 Repair Work Repair of the battery system is not allowed Depending on the defect it might be necessary to replace the battery management This must only be carried out by an electrician or HOPP...

Page 46: ...of health as well as the charge discharge cycles is taken into consideration If the end of service life is reached the battery system is shut down The battery then can neither be charged nor discharged An appropriate message is output on the display unit The end of service life is reached when the SOH is at 0 In this condition the battery storage system has left 70 of its initial capacity Note In ...

Page 47: ...eck environmental conditions 5 to 45 C 5 16 Undertemperature Minimum cell temperature discharging 10 C BMS interrupts battery operation Check environmental conditions 5 to 45 C 6 32 Overtemperature BMS temperature 90 C BMS interrupts battery operation until temperature is in an acceptable range 7 64 Deep discharge Switch the BMS on by plugging in the connection cable to the battery system and appl...

Page 48: ...atchdog Warning internal BMS monitoring Contact HOPPECKE Service 2 4 Deep discharge Charge battery immediately do not shut down otherwise error code 64 3 8 Data memory Contact HOPPECKE Service 4 16 Hardware warning Contact HOPPECKE Service 5 8192 End of use The function of the battery system is not affected However the end of service is coming in the near future Table 4 Warnings Note In case of mu...

Page 49: ...for setting up and connecting the accessories kit 14 Disassembly You need to carry out the following steps to disassemble the battery store system for repair replacement or disposal 1 Switch off the battery inverter 2 Pull out the connecting plug on the top of the battery store system 3 Open the cover of the battery store system 4 Start from the top left to the bottom right 5 Disconnect the termin...

Page 50: ...harge voltage 56V Power consumption Approx 1 W CAN Bus active In the switched off condition the self consumption falls to approx 10 mW Storage period of the battery system of at least 6 months with subsequent Wake Up possible 15 2 Battery cell Technologies Prismatic cells lithium iron phosphate LiFePo Nominal capacity 50 Ah C3 5 kWh or 78 Ah C3 7 5 kWh system Nominal voltage 3 2 V cell 51 2V batte...

Page 51: ...CE Declaration of Conformity BA_sun_power_pack_LiOn_en_V1 05 docx V1 05 20 07 2017 6140203036 51 16 CE Declaration of Conformity ...

Page 52: ...7 2017 6140203036 52 17 Abbreviations BMS Battery Management System CAN Controller Area Network DC Direct Current DOD Depth of Discharge Li Ion Lithium Ion SoC State of Charge SOH State of Health Available capacity with full charge related to the nominal capacity ...

Page 53: ...03036 53 18 Further information 1 Operation in stationary lithium solar energy stores Notes on fire fighting and technical assistance issued by Federal Association for Solar Industry Bundesverband Solarwirtschaft 1st Edition December 2014 See also under http www solarwirtschaft de ...

Page 54: ... _______________________ Name Installation Engineer ____________________ Company ____________________ Signature ______________________________ 19 2 Certification of installation and commissioning I certify herewith that the requirements of the place of installation have been met and installation as well as commissioning of the battery system has been done according to the specifications of this op...

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