Weco HeSU 4k4 PRO Installation Manual Download

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WeCo Srl Italia

www.wecobatteries.com

[email protected]

4K4 PRO V 1.11 28-9-2021

I n s t a l l a t i o n M a n u a l

HeSU 4k4 PRO Battery Module

Summary of Contents for HeSU 4k4 PRO

Page 1: ...WeCo Srl Italia www wecobatteries com weco wecobatteries com 4K4 PRO V 1 11 28 9 2021 I n s t a l l a t i o n M a n u a l HeSU 4k4 PRO Battery Module ...

Page 2: ... final explanation of any content in this manual SYSTEM DESIGN Systems Design is the process of defining the architecture components modules interfaces and load data for a system to satisfy specified requirements For a solar system these components are the PV modules inverter charge controller batteries as well as the different interfaces of those components BATTERY OPERATION There are several fac...

Page 3: ...sequent recharge regardless of depth of discharge The number of cycles at a specific DoD and the projected life in years the battery battery system will provide prior to needing replacement Charging Majority of battery capacity life issues can be traced to improper charging Improper charging settings may lead to an overcharging or undercharging condition WeCo guarantee only batteries connected via...

Page 4: ... a Li Ion is slowed down by a lowering of the electrolyte temperature that results in less capacity A battery that will deliver 100 of rated capacity at25 C will only deliver approximately 75 of rated capacity at 10 C At temperatures below 7 C the BMS will allow only 0 1C charging Current below 7 C the charge is forbidden As part of the performance Warranty Charge and Discharge shall be in the ran...

Page 5: ...ments information and advice in the documentation shall not constitute any express or implied action in contradiction to local regulations or standards For more information please contact us The official information and the latest datasheet are available on www wecobatteries com It is essential that the battery unit is equipped with the latest firmware version available WeCo will release new firmw...

Page 6: ...d Parts List 5 3 1 Installation Procedure Wall Mount 5 3 2 Installation Procedure Stack Mount 5 4 Communication and Control Panel 5 5 DIP Switch Settings 5 6 Parallel Battery Wiring Convention BATTERY ACTIVATION AND SHUTDOWN 6 1 Panel Button and LEDs Explanation 6 2 Stand Alone Battery Front Panel Control 6 2 1 Start Battery 6 2 2 Shut Down Battery 6 2 3 Low battery Forced Charge Function 6 3 Para...

Page 7: ...red in its original carton box in a dry and cool place WeCo carton box are marked as below ü The transportation and Storage SoC shall not exceed 50 ü The Shelf period without recharging is 6 months it is required a quick charge up to 70 DoD and discharge back to 50 at 0 5C 25 C ü To preserve the performance the shelf life of this battery store at 25 C 70 Humidity ü Optimal Storage temperature of t...

Page 8: ...rect operation and maintenance of the product 2 2 Use Range This installation guidance applies only to the HeSU 4K4 PRO Low Voltage Universal Stackable Model 2 3 Additional Information Specification of the product can be changed without any notice to customers 2 4 Symbols Used Symbol meanings CAUTION represents hazardous situations which can cause light injuries if not avoided NOTICE represents th...

Page 9: ...esult in health and safety risks such as overheating or electrolyte smoke potential All personnel must comply with the safety precautions and observe all warnings as detailed in this document If any of the safety precautions or procedures detailed in this manual is not fully understood by the reader the reader must not perform any operation on the battery until they have contacted WECO the custome...

Page 10: ...itution or installation of any components of this battery will nullify the product guarantee The use of any components contained within or connected to this battery other than the products sold as part of this product or recommended by the manufacturer will nullify the product guarantee Connecting more than five individual HeSU 4K4 PRO battery units in parallel will nullify the product guarantee 4...

Page 11: ...roduct parameters including model type and serial number Installers must always check that the specifications displayed on the nameplate of the battery module relates to the installation manual that is being referred to for guidance Only qualified personnel with a comprehensive understanding of this manual are permitted to install this product RUN BUTTON OPERATOR PORT ...

Page 12: ...cking and preliminary checking of the battery is conducted by carried out by a minimum of two people 5 1 Installation Notice a Before installation check the battery open circuit voltage b Battery installation location should be at least 20m away from sources of heat sparks or other source of potential danger c Battery connecting cables should be as short as possible to prevent excessive voltage dr...

Page 13: ...luded within the carton The following list of components can be used as a check list when unpacking the individual battery and battery kits 5 2 1 Parts list Included Accessories Number Name Quantity Description Image 1 Battery 1 Lithium battery module RAL 7016 GREY 2 Wall mounting plate 1 Support Plate 3 Wall screws 4 Wall Plate Fixing Screws Plug 4 CAN cable RJ45 RJ 45 RJ9 1 1 5m 5 RJ45 parallel ...

Page 14: ...g 1 4 M8 Screws 4 rubber pads 3 Parallel Bus Bar 1 1 1 Red Bus Bar 1 Black Bus Bar 5 2 3 Recommended Installation Tools To remove the terminal cover it is required an Allan Key 2 5mm Multimeter Current clamp Screw Driver Set Allen Key Set Drill Hammer Electrician Scissors Wrench set Lifting strap mechanical lifter RS 232 USB screw terminal insulated 5 2 3 Personal Protective Equipment ...

Page 15: ...capable of supporting the battery weight Wall Installation Procedure Step 1 Install the fixing screws on the appropriate height of the wall The scheme is as following When installing the screws please check the wall plug size WeCo provides 4x φ10 60mm but it may be that a different size or type will be required depending on the actual installation surface Step 2 Make sure that the mounting screws ...

Page 16: ...e on the wall Step 4 Interlock the battery module with the wall bracket For wall and floor installation it is always required to secure the battery module with the vertical structure by using the provided bracket Free standing installations are strictly forbidden Wall Mounted Floor Mounted When installing the battery please work with appropriate lifting devices managed by at least two people to av...

Page 17: ...om the ceiling The bottom side of the battery is suggested to be at 100cm from the floor for an easiest maintenance Wall Stack Installation Vertical Tower Kit Maximum Three Batteries per Stack Up to three batteries can be installed vertically one on top of the other against a wall with the bottom battery resting on the floor This installation will require the vertical installation kit Vertical Kit...

Page 18: ...WeCo Srl Italia www wecobatteries com weco wecobatteries com 4K4 PRO V 1 11 28 9 2021 ...

Page 19: ... the accessories in a stack of five batteries Make sure the support surface is adequate to support the overall battery load Preparation of the modules The battery is delivered as standard in a WALL MOUNTED CONFIGURATION and it is therefore necessary that the installer make simple external changes to install into a STACKABLE CONFIGURATION STACK MOUNT INSTALLATION PROCEDURE Step 1 When the batteries...

Page 20: ...tch v kzxuK2jWPK8 t 296s Positioning the first module on a support in accordance with the local regulation and in accordance with the site specifications Step 3 To lift and position the battery on top of the first one use the temporary handles provided with the stack kit and align the second battery with the first and lay down the second module Step 3 a Lay the first module on a support in accorda...

Page 21: ...and installed across the modules to interlock the modules with each other Step 5 Continue installation of the modules considering the floor admitted load WeCo suggests to install a max of 5 modules and 4 4 to compose a cluster of eight modules Each battery weights more than 55kg and must be installed with the help of a mechanical lift and or with at least two people equipped with suitable suction ...

Page 22: ...de on the battery using the M8 Screw removed before from the original position Step 2 It will be necessary to remove the feet from the second battery and install them on the right side of the first battery following the same instructions Step 3 Lay the first module on the ground on its final position Step 4 Stick the 4 rubber pads on the back side of the second module From the screw bag of the Sta...

Page 23: ...e modules and secure it by using the bottom feet INSTALL THE BUS BAS AND THE RS 485 RJ45 COMMUNICATION CABLE INTERLOCK THE MODULES USING THE SUPPORT FEET INSTALLED ON EACH BATTERY FIRST MODULE Floor Mounted RUBBER FEET RUBBER FEET SECOND MODULE Stack 1 INSTALL THE BUS BAR ON THE LV TERMINAL BLOCK ...

Page 24: ...f the cables as shown in the diagram below Power Connection by using the STACKABLE KIT BUS BAR EXAMPLE ONE CLUSTER COMPOSED BY 2 TOWERS 4 4 After all cables and bus bars have been connected and the inverter is correctly set up try to start up the system by turning ON the master module and proceed toward the last module installed If the installation is properly set up all the modules will turn on i...

Page 25: ...r 1 2 M4 3 8 External Covers 3 M5 7 5 Isolators and Contactor Supports 7 M6 13 Fuses Cables and Cable Lungs Connection to Terminals Feet Brackets Wall Plugs 10 M8 14 Plastic to steel and Cables on Terminal Block Feet Brackets Wall plugs 14 M8 32 Steel on Steel Connection Steel to copper Contactor terminal to Bus bar 16 M10 62 External Bus Bar Aluminium and Copper steel on steel connection 40 M12 1...

Page 26: ...Generator Start Stop CAN1 CAN Line External Communications Line IN OUT CAN2 CAN Line Inner Communication Line IN OUT DIP DIP BLOCK 1 8 ID addressing for Master and Slave configuration RS485A Parallel Line RS485 Parallel Input from Upper Module when in master Slave config RS485B Parallel Line RS485 Parallel Output from Upper Module when in master Slave config POLE Screw terminal 2 X Positive POLE S...

Page 27: ...h Settings Version 8 DIP SWITCHES Always configure the DIP switch settings BEFORE connecting any power cables to the battery terminals B and B The battery module must be restarted for DIP switch settings to take effect When connecting to an inverter which has BMS CAN communication switch 5 on the Master battery module must always be set to ON 8 1 Pin 8 7 6 5 4 3 2 1 Definition GND CAN_L CAN_H ...

Page 28: ...WeCo Srl Italia www wecobatteries com weco wecobatteries com 4K4 PRO V 1 11 28 9 2021 ...

Page 29: ...ub 1 5 5 3 Master Sub 1 Sub 2 5 5 4 Master Sub 1 Sub 2 Sub 3 5 5 5 Master Sub 1 Sub 2 Sub 3 Sub 4 5 5 5 Master Sub 1 Sub 2 Sub 3 Sub 4 Sub 5 5 5 6 Master Sub 1 Sub 2 Sub 3 Sub 4 Sub 5 Sub 6 5 5 7 Master Sub 1 Sub 2 Sub 3 Sub 4 Sub 5 Sub 6 Sub 7 Always configure the DIP switch settings BEFORE connecting any power cables to the battery terminals B and B ...

Page 30: ...r Plus Sub 1 Sub 2 Sub 3 Sub 4 5 6 5 Master Plus Sub 1 Sub 2 Sub 3 Sub 4 Sub 5 5 6 6 Master Plus Sub 1 Sub 2 Sub 3 Sub 4 Sub 5 Sub 6 5 6 7 Master Plus Sub 1 Sub 2 Sub 3 Sub 4 Sub 5 Sub 6 Sub 7 Up to 8 batteries can be connected in parallel even if they have two different types of DIP SWITCH Hubs Batteries with 5 DIP and with 8 DIP can be connected in parallel following the addressing in sequence T...

Page 31: ...Plus S1 Sn MAX 8 MODULES 5 6 3 MULTICLUSTER via ON BOARD CAN COMM 8 X 3 CLUSTERS Available only in some Countries RS485 from B to A To Inverter CAN BMS RS485 from B to A CAN BMS To Inverter MASTER SUB1 MASTER SUB1 SUB n LAST MASTER SUB1 SUB8 CLUSTER 01 CLUSTER 02 CLUSTER 03 CAN TO HUB CAN B CAN A CAN B CAN A CAN TO HUB ...

Page 32: ...n 13 of this manual BATTERY SCREWS FIXING TORQUE All Power Cable Connectors with the battery terminal connector should be tightened to 14Nm All cables and Bus Bar connected with the battery terminals must be checked every three months EXTERNAL BUS BAR CABLES SCREWS FIXING TORQUE All power cables connected with external parallel bus bar shall be fixed with 40Nmtorque M8 Bolt or above The drawings i...

Page 33: ...rt press the power button for one second The GREEN RUN light should come on blinking The battery has been activated normally 6 2 2 Shut Down Battery Long press the power button for five seconds The GREEN RUN light should go off The battery has been shut down normally 6 2 3 Low Battery Force Charge Prerequisite The VOLTAGE between the battery B and B terminals is ZERO and the PANEL LIGHTS ARE OFF B...

Page 34: ...6 3 1 Activation of Parallel Batteries From Master to Sub 4 Short press the Master power button for one second The GREEN RUN light should come on The battery has been activated normally Short press the Sub 1 power button for one second The GREEN RUN light should come on The battery has been activated normally Short press the Sub 2 power button for one second The GREEN RUN light should come on The ...

Page 35: ...onnected when charging and the battery fault light is flashing Stop charging and review and reset properly the inverter settings WeCo suggests to use Closed Loop CAN BMS inverters 5 LOW VOLTAGE ALARM The battery relay is disconnected when discharging and the battery fault light is flashing Stop discharging from battery Charge the battery in accordance with the correct charging procedure 6 RELAY DA...

Page 36: ...tput Measure the positive and negative voltage of each battery if the voltage difference between the batteries is greater than 2V please reduce the voltage difference to less than 2V to try parallel connection 10 MASTER SLAVE MACHINE COMMUNICATION EXCEPTIONS Slave battery fault light flashes the master machine cannot control slave battery Check that the communication cables between the master batt...

Page 37: ...Y 8 SOFTWARE QUICK GUIDE WECO OLP RS232 USB RS232 converter is necessary to communicate with the battery need to be ordered separately PC Battery communication and set up for 232 USB device is available for auth Installers 8 1 Download ad Launch the EXE file WeCo Monitor and wait for the self installation to complete ...

Page 38: ...ACCESS windows and follow the Authorized Installer Guide If in possession of a valid password the Authorized installer will be able to access more detailed windows within the software 8 3 Connect the RS232 converter between the battery and the PC and search the relative com on the PC settings device manager of Windows Select the COM port from the Main page of the WeCo Monitor then press CONNECT Fo...

Page 39: ... 4K4 PRO V 1 11 28 9 2021 8 4 If more than one module is connected select Parallel Overview and check the single unit data information Note Make sure to select the exact number of modules that composing your cluster in order to have the proper DIP switch setting ...

Page 40: ...the Software available on https wecobatteries com download area 8 5 The normal mode for equalization is Auto mode however in the unlikely event of a failure it is possible to perform a manual equalization If it is necessary to perform a manual equalization please contact WeCo support for further advice Reference to the CELL EQUALIZATION MANUAL not public will be necessary to activate the manual pr...

Page 41: ... Dry contact setting page 8 7 Factory reset This must be authorized from the WECO Tech Department follow the instruction of the FACTORY RESET PROCEDURE A factory reset made outside WeCo facility or without a prior written approval will void the warranty and may cause severe battery damages ...

Page 42: ...in the warranty is not covered by the performance warranty Description Inverter Low Voltage CUT OFF Inverter High Voltage CUT OFF STD Charging Current Max 110A STD Discharging current Max 110A Single Battery 49 5 SOC 0 Suggested 50 5 SOC 5 if ON grid Suggested 51 0 SOC 10 if OFF GRID 54 5 98 65A max 110A 70A max 110A Master Slave1 Master SL1 SL2 Master SL1 SL2 SL3 Master SL1 SL2 SL3 SL4 CHARGE Tem...

Page 43: ...OMMUNICATION are not allowed 10 SINGLE CLUSTER CONFIGURATION WITH BUS BAR No HUB is required for a single cluster 4K4 PRO has a specific bus bar size Do not use 4K4 R type BUS BAR SPECIAL BUS BAR FOR PARALLEL CONNECTION UP TO MAX 400A ATTENTION Bus Bar is mandatory for systems above 100A Fixing Torque 14Nm Fixing Torque 14Nm ...

Page 44: ... discharging Current 86Adc DC Voltage Range limited by contactor 46 to 58 9 do not use as settings Depth of Discharge 100 Up to 100 49 5V to 54 5V from 90 to 100 10A charge current to be set Depth of Discharge 90 51 5V to 54 0V 0 9C Depth of Discharge 80 51V to 53 5V Operating Efficiency 97 8 Operating Temp 25 to 65 C Charging Temp 5 to 55 C Self Discharge Rate 2 loss per month Dimensions 46x50x15...

Page 45: ...fore pressing the RUN button again A reduction of the charging current at the end of charge and end of discharge in addition to a new set up of the voltage range is mandatory if the installation faces faults as described above Single Cell Curve 25 C Degrees 0 5C Charge Discharge The charge and discharge current of the inverter MUST be limited according with the maximum current allowed by each batt...

Page 46: ...t for a response BEFORE making any connection USING THE BATTERY OUTSIDE OF THE WORKING RANGE AS DEFINED IN THIS MANUAL WILL DAMAGE THE BATTERY AND WILL VOID THE WARRANTY NOTE This manual is subjected to continuous implementation Before install your WeCo batteries please contact our assistance team in order to have the latest manual and any additional support Safety improvement is our priority plea...

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