TESVOLT TS 48V Page 1 Installation And Operating Manual Download

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TS 48V LITHIUM

STORAGE SYSTEM

Installation and Operating Manual

The
Energy

Storage
Experts

THE ENERGY STORAGE EXPERTS

Summary of Contents for TS 48V

Page 1: ...TS 48V LITHIUM STORAGE SYSTEM Installation and Operating Manual The Energy Storage Experts THE ENERGY STORAGE EXPERTS ...

Page 2: ...TESVOLT TS48V 13 5 TS 48V battery storage system 14 5 1 Cabinet structure and components 14 5 2 Cabinet scope of delivery 15 5 3 Construction and storage system components 16 5 4 Scope of delivery for storage system components 17 5 5 Other components 18 5 6 Scope of delivery for other components 19 5 7 Connections and structure of the APU LV 20 5 8 Connections and structure of the battery module 2...

Page 3: ...anding the storage system 47 10 1 Expanding the capacity using the TESVOLT expansion module 47 10 2 Expanding capacity using additional TS 48V units 48 10 3 Capacity upgrade with SMA Sunny Island 51 11 TESVOLT battery monitoring software BatMon 52 11 1 Views and functions 52 11 2 Menu structure 54 11 3 The most important cell parameters 54 12 Fault and warning messages on the TESVOLT TS48V 55 13 M...

Page 4: ...4 TESVOLT Wereservetherighttomaketechnicalchanges VersionRD TI 015 E ENG_Installation_Manual_TS48V_v C 01 Lastrevised06 2020 ...

Page 5: ...ds and legal regulations in other countries may contradict the specifications in this manual In this case please contact the TESVOLT Service Line 49 0 3491 8797 200 1 2 MEANING OF SYMBOLS Symbols in the manual This manual contains the following types of warnings and information DANGER This symbol indicates that electric shock may result if you fail to follow the instruction even when the unit is d...

Page 6: ...on in the immediate vicinity of the storage system is prohibited DO NOT INSERT ANY OBJECTS INTO THE STORAGE SYSTEM CASING S OPENINGS No objects such as screwdrivers may be inserted through openings in the casing of the storage system WEAR SAFETY GOGGLES Wear safety goggles when working on the unit FOLLOW THE MANUAL It is imperative that you follow the Installation and Operating Manual when working...

Page 7: ...be exposed to direct sunlight or placed directly beside sources of heat The battery cabinet may not be exposed to corrosive atmospheres When installing the battery storage system ensure that it is standing on a sufficiently dry horizontal and flat surface with sufficient load bearing capacity The altitude of the installation site may not be higher than 2000 m above sea level without approval in wr...

Page 8: ...om 2 SAFETY DANGER Life threatening electric shock from damaged components or short circuit Bridging the battery poles causes a short circuit that results in a flow of electrical current A short cir cuit of this type should be avoided under all circumstances For this reason please follow these instructions Use insulated tools Do not place any tools or metal components on the battery modules or the...

Page 9: ... fire extinguishers Do not use defective or damaged battery modules DANGER Danger of death due to misuse Any use that extends beyond or deviates from appropriate use of the energy storage system can lead to significant hazards DANGER Danger of death due to unqualified operators using the unit Incorrect handling of the battery storage system can result in significant hazards for the operator For th...

Page 10: ... Road ADR must be adhered to The TS 48V may only be transported by the manufacturer or by a forwarding agency engaged by the manufacturer Should transport on public roads nevertheless be necessary this may only be carried out by personnel who have received appropriate training and instruction This instruction is to be documented and carried out periodically Smoking is prohibited in the vehicle dur...

Page 11: ...essively causing injuries or material damage CAUTION Risk of injury if safety shoes are not worn when the cabinet is being transported If hazards occur injuries such as crushing injuries can occur due to the heavy self weight of compo nents when the cabinet or battery modules are being transported For this reason all individuals involved must wear safety shoes with protective toe caps CAUTION Risk...

Page 12: ... the necessary site clearance WARNING Possible damage to the building due to excessive static loads Once installed the battery storage system usually weighs from several hundred kilograms to signifi cantly more than 1 000 kilograms Ensure that the installation site has sufficient load bearing capacity If in doubt consult a structural engineer Dimensions 190 65 65 60 60 70 15 B A TS 25 145 130 TS 4...

Page 13: ... 163 x 490 x 480 mm Certificates standards Cell IEC 62619 UL 1642 UN 38 3 Product CE UN 38 3 IEC 61000 6 1 2 3 4 BattG 2006 66 EG Guarantee 10 year performance guarantee 5 year system guarantee Recycling TESVOLT provides a free battery collection scheme in Germany COMPLETE SYSTEM Number of battery modules 2 3 4 5 6 7 8 9 10 TS 25 2 5 modules 1300 x 600 x 600 mm H x W x D TS 40 6 8 modules 1900 x 6...

Page 14: ...extension set TS cabinet extension set B Base corner cover plate C C 1 L 1 L 2 L 3 E Cage nut left and auxiliary tool for fitting E 1 F Cable retention clip Spacer with accessories for lifting the top of the cabinet H H 1 H 3 H 2 Pan head screw with washer D 1 D Crane lug G Grounding strip door with accessories J J 1 J 2 J 3 I Grounding point with fitting accessories I 2 I 3 I 4 I 1 Grounding set ...

Page 15: ...ping screw Torx TX 30 I 2 1 1 1 L M8 nut I 3 1 1 1 L Washer I 4 1 1 1 L Contact washer J 1 1 1 10 mm grounding strip M8 ring cable lugs on both ends pre installed on VX cabinet J 1 2 2 2 L M8 nut J 2 2 2 2 L Washer J 3 2 2 2 L Contact washer K 1 TS cabinet extension set K 1 6 L Baying connectors K 2 24 L ST5 5 x 13 mm pan head screw Torx TX 30 L 1 VX cabinet extension set L 1 8 L Baying connectors...

Page 16: ... 48V Installations und Betriebsanleitung The Energy Stor THE ENERGY STORAGE EXPERTS TESVOLT USB Stick 8 14 Battery room sticker 9 Empty VX cabinet Empty VX cabinet 1 2 4 4 3 1 3 3 5 1 5 2 3 2 3 4 4 1 4 2 3 6 4 3 C 1 C LV APU connector kit 3 3 3 3 4 3 5 3 6 3 1 3 2 LV module connector kit 4 4 1 4 2 4 3 4 4 1 APU LV 2 4 8 1C LV48 battery module Type plate TS 48 V 6 5 5 1 5 2 5 3 5 4 5 5 5 6 5 7 LV D...

Page 17: ... connector 4 2 8 14 18 L DIN 6921 M8 x 20 hexagon flanged bolt 4 3 4 7 9 L CAT 6 patch cable 0 27 m ribbon 4 4 4 7 9 L Rack balancing bridge 5 1 1 1 LV DC connecting cable set 5 1 1 1 1 L DC connecting cable 5 00 m 120 mm2 with red marking on one end M8 ring cable lug 5 2 1 1 1 L DC connecting cable 5 00 m 120 mm2 with blue marking on one end M8 ring cable lug 5 3 1 1 1 L CAT6 patch cable 5 00 m 5...

Page 18: ...LV B01 2X bat fuse and NH1 250 A tag fuse LV B03 4X bat fuse and NH1 250 A tag fuse SMA Sunny Island SMA Sunny Home Manager 2 0 SMA Data Manager M incl external 24 V power supply unit 18 19 20 18 1 18 2 18 3 18 4 Cabinet connector kit 1 20 m or 2 30 m Single phase emergency power distribution Three phase emergency power distribution 17 17 1 17 4 17 5 17 3 17 2 16 1 15 1 DC connector kit bat fuse t...

Page 19: ...L NH1 250 A tag fuse 17 Optional DC connector kit bat fuse to Sunny Island 10 m 17 1 1 L DC connecting cable 10 00 m 50 mm 17 2 6 L 50 mm M8 ring cable lug 17 3 6 L 50 mm M10 ring cable lug 17 4 6 L Thin wall heat shrink tubing 40 mm red 17 5 6 L Thin wall heat shrink tubing 40 mm blue 18 Optional Cabinet connector kit 1 20 m or 2 30 m 18 1 1 L DC connecting cable 1 20 m or 2 30 m 120 mm M8 ring c...

Page 20: ...sing BatMon DHCP router required 9 ADDRESS Further information can be found in the section Overview of all addressing options on page 51 10 BAT COM Communication port to the first battery module 11 BATTERY The battery s DC connection for the negative pole 12 BATTERY The battery s DC connection for the positive pole 13 DISPLAY Display interface 14 MARKING Marking for activating and changing the dis...

Page 21: ... Wereservetherighttomaketechnicalchanges VersionRD TI 015 E ENG_Installation_Manual_TS48V_v C 01 Lastrevised06 2020 5 9 WIRING THE BATTERY MODULES TS 25 wiring 1 2 3 4 5 1 DC module connector Rack balancing BAT COM Order in the battery string ...

Page 22: ...stem TESVOLT Wereservetherighttomaketechnicalchanges VersionRD TI 015 E ENG_Installation_Manual_TS48V_v C 01 Lastrevised06 2020 TS 40 wiring 1 1 2 3 4 5 6 7 8 DC module connector Rack balancing BAT COM Order in the battery string ...

Page 23: ...23 TESVOLT Wereservetherighttomaketechnicalchanges VersionRD TI 015 E ENG_Installation_Manual_TS48V_v C 01 Lastrevised06 2020 TS 50 wiring 1 2 3 4 5 6 7 8 9 10 1 DC module connector Rack balancing BAT COM Order in the battery string ...

Page 24: ...Wereservetherighttomaketechnicalchanges VersionRD TI 015 E ENG_Installation_Manual_TS48V_v C 01 Lastrevised06 2020 2 x TS 40 wiring 1 1 2 3 4 5 6 7 8 16 15 14 13 12 11 10 9 DC module connector Rack balancing BAT COM Order in the battery string ...

Page 25: ...he section 3 3 Transport at the end customer s site on page 11 4 Optional Lifting the cabinet covers for additional ventilation First of all remove all crane lugs or fixing screws and the upper cabinet cover TS cabinet variant shown in picture as example 5 Optional Lifting the cabinet covers for additional ventilation Now screw the four spacers H into the threaded holes at each corner of the cabin...

Page 26: ...opening empty fit the first two cage nuts in the next opening on both sides leave the next four openings empty and fit another pair of cage nuts in the next opening in both rack rails 10 VX cabinet only You can now fit the cage nuts E for fastening the battery modules 2 using the auxiliary tool E 1 Distribute the cage nuts from bottom to top Fit the first two cage nuts in the second opening on bot...

Page 27: ...hese with two M6 x 16 pan head screws D Phil lips and two plastic washers D 1 TS 25 only The APU has to be installed first due to the TS 25 cabinet s small dimensions The C rail can then be fitted 15 Prepare the base for fitting the storage system A brush strip can be used in the base of the cabinet for easy cable routing Simply install the brush strip on the required side of the base To relo cate...

Page 28: ...tom in the middle and at the top To do this firstly place two ST5 5 x 13 pan head screws K 2 in the diago nally converging extended holes with the bent end of the baying connector at the top For now tighten the screws hand tight only 4 Cabinet extension for TS cabinet only Once all the baying con nectors have been pre fitted take a hammer and carefully tap down each baying connector in turn This r...

Page 29: ...the fitting area 9 Cabinet extension for VX cabinet only Now fasten the middle and the top baying connectors using their four front holes using four ST5 5 x 13 pan head screws L 2 Then refit the relevant slide rail 10 Cabinet extension for TS VX cabinet only optional The sealing strip M 5 can be fitted between the cabinet frame abutting faces The sealing strip has a self adhesive side use this to ...

Page 30: ...are the grounding cable N 6 for installation To do this put a spring washer N 2 a washer N 3 the grounding cable s cable eyelet N 6 and finally the contact washer N 4 onto the M8 x 30 screw N 1 Ensure that the teeth of the contact washer N 4 are pointing downwards towards the end of the screw 16 Fit the prepared grounding cable N 6 using the M8 speed nuts N 5 already installed in the central adjac...

Page 31: ...ction 6 4 E stop contact on page 35 of this Installation and Operating Manual 5 All battery modules 2 of a TS 48V battery storage system must have exactly the same state of charge So be sure to check the voltage of the battery modules before fitting them A battery module s correct voltage must be 50 0 0 1 V If you notice anything different please contact the TESVOLT Service Line 49 0 3491 8797 200...

Page 32: ... removed using combination pliers At the contact protection point on the last battery module remove only the upper section for the module connector The lower section remains closed to provide a touch guard 11 Now fit the DC connector from the APU 1 to the first battery module 2 Start with the S connector 3 1 from the APU LV connector kit 3 The S connector connects the BATTERY connection 11 on the ...

Page 33: ...oduce an electric arc which can lead to serious injuries Pay careful attention to the following points in order to avoid a short circuit Install the DC connecting cables 18 1 18 2 one after the other and always fasten the first DC con necting cable to both battery modules first before proceeding to fit the second DC connecting cable Ensure the DC connecting cables contacts 18 1 18 2 do not acciden...

Page 34: ...n the battery module located beneath the APU LV You can then use a patch cable 4 3 to connect the same module s BAT COM OUT connection to the next module s BAT COM IN connection Connect the remaining battery modules in the same way using the patch cables 4 3 The last battery module s BAT COM OUT connection remains unused 19 Now tighten the self locking nuts 3 5 on the BATTERY connec tions on the A...

Page 35: ...ection can be connected to an external control system using the matching Wago 734 102 socket If necessary the external control system can switch off the unit as quickly as possible using a separate i e completely independent switching path The shutdown is much faster than the normal shutdown process The wiring connection may only be implemented using a floating contact WARNING Possible damage to t...

Page 36: ...ystem The circuit situations are shown in the figure below 1 without e stop function due to bridge 1 2 2 with e stop function and emergency shutdown button 1 2 3 with e stop function and external control system 1 A1 A2 2 1 APU 1 APU 2 APU 3 APU n APU 1 APU 2 APU 3 APU n 2 1 APU 1 APU 2 APU 3 APU n APU 1 APU 2 APU 3 APU n 2 A1 A2 Figure 6 1 Various circuit situations for the e stop NOTE If you are ...

Page 37: ...system structure three phase example Consumer Switch SMA Sunny Island SMA Data Manager M Sunny Portal ennexOS Sunny Portal TS 48 V storage system max 4 x TS 48 V per SMA Sunny Island cluster Bat Fuse B03 Grid Sunny Home Manager 2 0 SMA Energy Meter 2 0 PV Wind Inverter Inverter Energy transfer Communication Router www Off grid system structure and back up power three phase example Switch SMA Sunny...

Page 38: ... Sunny Island 3 1 APU per cluster Sunny Island system with multi cluster box 3 2 APUs per cluster Off grid 1 1 APU per SMA Sunny Island 3 2 APUs per cluster Split phase 2 1 APU per SMA Sunny Island Depending on the consumer units e g old motors with high start up currents we would recommend 2 APUs per cluster 7 3 CONNECTING SUNNY ISLAND TO BATTERY INVERTER DANGER Life threatening electric shock or...

Page 39: ...connection terminals AC 2 Gen Grid terminals L NTT and PE connection connection to the public utility grid using triple core cables conductor cross section 6 mm2 16 mm2 B DC connection terminals Battery connection Conductor cross section 50 120 mm cable diameter 14 25 mm Tightening torque 12 Nm C ComETH connection Speedwire network cable connection to switch The cable length between the two networ...

Page 40: ...on to the public utility grid using triple core cables conductor cross section 6 mm2 16 mm2 B DC connection terminals Battery connection Conductor cross section 50 120 mm cable diameter 14 25 mm Tightening torque 12 Nm C ComETH connection Speedwire network cable connection to switch The cable length between the two network participants may not exceed 50 m with patch cables or 100 m with laid cable...

Page 41: ...ing cables The assembly arrange ment and the distances between the components are shown in the figure below LENGTH POLE POINT OF CONNECTION 1 POINT OF CONNECTION 2 200 cm Positive Bat Fuse Master Sunny Island 200 cm Negative Bat Fuse Master Sunny Island 100 cm Positive Bat Fuse Slave 1 Sunny Island 100 cm Negative Bat Fuse Slave 1 Sunny Island 200 cm Positive Bat Fuse Slave 2 Sunny Island 200 cm N...

Page 42: ...y Ensure the APU is switched off Insert the tag fuses in the load discon necting switch on the Bat fuse 15 16 Fasten the load disconnecting switch to the bracket in the Bat fuse and close the bracket Then close the housing cover on the Bat fuse WARNING Possible damage to the APU due to undetected errors during installation Carry out the check carefully in accordance with step 2 as damage to the AP...

Page 43: ...the switch lights up permanently The status point on the battery display reads OK The TS 48V is now operational 8 Tap beside the display again to access the next menu item You will now be shown the assigned IP address provided the LAN connection 8 is connected to the APU by a DHCP enabled router 9 Next commission the SMA Sunny Island System in accordance with the SMA specifications NOTE The APU di...

Page 44: ...ressing settings for TS 48V TERM 4 and ADDRESS 9 in accordance with the section Over view of all addressing options on page 51 and the figures in section 10 2 Expanding capacity using additional TS 48V units on page 48 et seq In the case of master slave systems TERM 4 is to be set to ON for APUs of the master and the last stor age system in the master slave configuration TERM 4 is to be set to OFF...

Page 45: ...perational 8 On the master APU tap beside the display again to access the next menu item You will now be shown the assigned IP address provided the LAN connection on the APU 8 is connected by a DHCP enabled router 9 Next commission the SMA Sunny Island System in accordance with the SMA specifications Depending on the number of modules installed the storage capacity in ampere hours can be taken fro...

Page 46: ...missioning the output must be 0 kW before the APU is decommissioned using the On Off switch as this may otherwise damage the APU NOTE The SMA Sunny Island is an SMA product For this reason TESVOLT cannot guarantee the accuracy of information provided about this and other products belonging to SMA Binding information can only be found in SMA s valid product documentation for the product 1 First sto...

Page 47: ...y modules are supplied with a state of charge SoC of approx 20 Before you inte grate a new battery module into an existing battery system the existing system must be brought to the same voltage level First check state of charge of the new battery modules by carrying out a volt age measurement this must be exactly 50 0 0 1 V In any other event please contact the TESVOLT Service Line 49 0 3491 8797 ...

Page 48: ... master slave principle NOTE When expanding a single phase storage system to include one or more slave storage systems a Bat fuse 15 single phase or a 16 three phase must be ordered and installed at the same time If the system already has a three phase Bat fuse 16 up to four APUs can be connected to it each with a maximum of 16 battery modules System with one master and one slave SMA Sunny Islands...

Page 49: ... TERM ON ADDRESS 2 1 CAN IN CAN OUT Slave 1 CAN IN CAN OUT CAN SMA LAN APU configuration for Slave2 Slave 1 TERM OFF ADDRESS 2 0 CAN IN CAN OUT Master CAN OUT CAN IN Slave 2 TERM ON OFF CAN IN CAN OUT CAN SMA LAN ADDRESS APU configuration for Slave1 BATTERY CHARGER TS 48 V TS 48 V SMA Sunny Islands Bat Fuse B03 APU configuration for Master TERM ON ADDRESS 0 0 CAN OUT CAN IN Slave 1 CAN SMA ComSync...

Page 50: ...HARGER CAN IN CAN OUT CAN SMA LAN TERM ON OFF Slave 3 TERM ON OFF ADDRESS BATTERY CHARGER Slave 1 Master TERM OFF ADDRESS 2 0 CAN IN CAN OUT Master CAN OUT CAN IN Slave 2 TERM ON OFF CAN IN CAN OUT CAN SMA LAN ADDRESS APU configuration for Slave1 BATTERY CHARGER TERM ON ADDRESS 2 2 CAN IN CAN OUT Slave 2 CAN IN CAN OUT CAN SMA LAN APU configuration for Slave3 TS 48 V TS 48 V TS 48 V TS 48 V APU co...

Page 51: ...2 Slave 3 of Master 3 0 0 Master 4 2 0 Slave 1 of Master 4 2 1 Slave 2 of Master 4 2 2 Slave 3 of Master 4 10 3 CAPACITY UPGRADE WITH SMA SUNNY ISLAND Bat Fuse B03 SMA Sunny Island TS 48 V Figure 10 1 Three phase system with three SMA Sunny Island units By connecting a total of three SMA Sunny Island units it is possible to increase the capacity of the sys tem and or carry out a three phase connec...

Page 52: ...ection must be connected to the switch see also 7 1 System structure page 37 In addition to this the switch must be connected to a DHCP enabled router After installation launch the file BatMon exe Tick all the boxes in the firewall query about full access to the network The System menu item at the bottom of the BatMon interface includes a Communi cation Port button Here the APU LV serial number se...

Page 53: ...ATTeRy MONITORINg sOfTwARe bATMON 53 TESVOLT Wereservetherighttomaketechnicalchanges VersionRD TI 015 E ENG_Installation_Manual_TS48V_v C 01 Lastrevised06 2020 Figure 11 2 Battery screen Figure 11 3 Cells screen ...

Page 54: ...ode Module voltage Firmware update Charging cycle kWh Charging discharging power Communication port Discharging cycle kWh ABO temperature SoC state of charge SoH state of health Warning time Displayed Expert settings Functions APU temperature data Only with password 11 3 THE MOST IMPORTANT CELL PARAMETERS SoC state of charge This value indicates the percentage that the battery has been charged to ...

Page 55: ... and increase the ambient temperature to at least 5 C F927 W943 Battery high current Excessive current Switch off the battery and check the battery parameters and the SMA Sunny Island parameters Restart the battery F928 W944 Battery high current charge Charging current too high when charging the battery Switch off the battery and check the battery parameters and the SMA Sunny Island parameters Res...

Page 56: ... free However to ensure safe operation all plug screw connections on the electrical components should be inspected and if necessary returned to an operational condition by qualified specialists at least once a year Check all the screwed electrical connections and check the tightening torque with the specified values APU connections 1 2 and 11 12 12 Nm battery connections 17 18 12 Nm central ground...

Page 57: ...disposal Immediately decommission any damaged batteries and please con tact your installer or sales partner first before disposal Ensure that the battery is not subjected to moisture or direct sunlight Ensure quick removal by your installer or TESVOLT 1 Batteries including rechargeable batteries may not be disposed of in household waste You are legally obligated to return used batteries 2 Used bat...

Page 58: ...20 We reserve the right to make technical changes TESVOLT GmbH Am Heideberg 31 06886 Lutherstadt Wittenberg Deutschland Germany TESVOLT Service Line 49 0 3491 8797 200 service tesvolt com www tesvolt com Legal note on the use of contents The information contained in this documentation is the property of TESVOLT GmbH It cannot be pub lished in whole or in part without written permission from TESVOL...

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