Operating Manual HOPPECKE sun powerpack premium

Transcription

1 Operating Manual HOPPECKE sun powerpack premium

2 Foreword Dear Customer, Thank you very much for having decided in favour of a product bearing our brand name. Before working on the battery system or its components, please read this documentation carefully. It contains important information on secure and professional unpacking, storing, installing, operating and maintaining the sun powerpack premium battery system. Amendments to this documentation are subject to change without prior notice. Our products undergo continuous advanced development. As a result, there may be deviations between 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: International service hotline: +49 (0) Internet: info@hoppecke.com Copyright HOPPECKE Batterien GmbH & Co. KG All rights reserved including those of patent and utility model applications. Disclosure of as well as copying this documentation and using or revealing its contents are not permissible unless this has been expressly approved in writing by HOPPECKE Batterien GmbH. Infringements will lead to liability for damages. sun_powerpack_premium_en V1.00 (06/07/2015)

3 Table of contents 1. TARGET GROUP 5 2. MEANS OF REPRESENTATION 6 3. SAFETY INSTRUCTIONS General Safety Instructions Intended Use Directives, Legislation and Standards Obligations of the Operator Occupational safety Personnel and Qualification Personal Protective Equipment Special information on Li-Ion batteries First-aid measures if cell contents leak out Fire-fighting procedures Disposal instructions Transport Intact, undamaged batteries and batteries at the end of their service life Defective batteries Check the delivery SUN POWERPACK PREMIUM BATTERY SYSTEM STORAGE Intact, undamaged batteries and batteries at the end of their service life Defective batteries PREPARING FOR INSTALLATION Installation site Tools and Equipment INSTALLATION Assembling and installing the housing Grounding the housing Installing the battery stacks Connecting the battery stacks electrically Connecting the battery inverter Commissioning Final work REGISTERING THE BATTERY SYSTEM 39 sun_powerpack_premium_en V1.00 (06/07/2015)

4 Target Group 9. OPERATING THE BATTERY SYSTEM Safety Functions Display Unit Operating states MAINTENANCE AND CARE Cleaning BMS software update END OF SERVICE LIFE WARNING AND FAULT MESSAGES SYSTEM EXPANSION DISASSEMBLY TECHNICAL SPECIFICATIONS System Battery cell Norms and Standards CE DECLARATION OF CONFORMITY ABBREVIATIONS FURTHER INFORMATION APPENDIX Certification of the function of the smoke detector Certification of installation and commissioning 54 sun_powerpack_premium_en V1.00 (06/07/2015)

5 Target Group 1. Target Group This Operating Manual is meant for dealers, electricians and end users. It describes the transport, storage, installation, operation, maintenance and disassembly of the sun powerpack premium battery system. The work of installation, maintenance and disassembly should be done only by electricians. 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 system. sun_powerpack_premium_en V1.00 (06/07/2015)

6 Means of Representation 2. Means of Representation The following icons and signal words have been used in this operating and maintenance manual: DANGER! Denotes an immediate hazard with a high level of risk that could lead to death or severe physical injury 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 not prevented. Denotes first-aid measures. Denotes instructions that are important for optimal utilisation of the product. sun_powerpack_premium_en V1.00 (06/07/2015)

7 Safety Instructions 3. Safety Instructions Observe and follow the safety instructions given below when handling the sun powerpack premium battery system as well as its components General Safety Instructions DANGER! Metallic parts of the batteries are always live. Do not short-circuit the batteries! Very high values of current may flow and cause burn injuries in case of a short-circuit. Touching electrically conducting parts may cause cardiac arrhythmia and shock. Please be very careful when doing any work on the battery system in order to prevent severe injuries caused by electrical shocks or burns. Never place tools or other metallic objects on a battery. Be sure to remove watches and jewellery before doing any work on the batteries. Do not touch any exposed battery parts, jumpers, terminals or poles! Just 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 electrolyte and gases. DANGER! At temperatures above 80 C there is danger of the Li-Ion batteries bursting and the discharge of liquid electrolyte and gases. There is danger of the escaping materials igniting. Reactions of the electrolytes and the electrodes with water and humidity are possible. Use only those battery chargers that have been approved by HOPPECKE for use with sun powerpack premium. ATTENTION! The use of an automatic smoke alarm system is necessary at the place of installation. ATTENTION! Children must be kept away from the battery system. Observe and follow this operating manual and keep it such that it is easily visible at the installation site of the battery system. sun_powerpack_premium_en V1.00 (06/07/2015)

8 Safety Instructions 3.2. Intended Use The sun powerpack premium battery system serves to store electrical energy. It is set up and wired at the installation site. The battery system should be operated only with approved battery inverters / battery chargers. A list of approved battery inverters / battery chargers can be downloaded from (see also chapter 7.4). DANGER! Unintended use of the batteries may lead to personal injuries or damage to property. In case of unintended use, HOPPECKE Batterien GmbH & Co. KG shall not assume any liability for personal injuries or damage to property that result directly or indirectly from handling the batteries. The operator shall be solely responsible for the risks arising from unintended use. ATTENTION! The sun powerpack premium should not be used as an emergency power supply system, if the failure of the loads connected may lead to personal injuries (e.g. for power supply to medical devices with life-sustaining functions). ATTENTION! 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 Directives, Legislation and Standards Observe and follow the rules and regulations applicable to the installation and operation of stationary battery installations. Please observe the latest edition of each of the following rules and regulations: Accident prevention regulations, especially DGUV rule 3 (formerly BGV-A3): Electrical systems and equipment DIN EN ISO ("Personal safety gear Safety boots") DIN VDE 100/IEC ("Erection of low-voltage installations") DIN EN 50110/VDE 0105 ("Operation of electrical installations") DIN EN 50272/VDE 0510 ("Safety requirements for secondary batteries and battery installations") DIN VDE ("Requirements for persons working near electrical equipment") VDE-AR-E ( Stationary energy storage systems with lithium batteries ) Please note that different and further rules and regulations may be required outside Germany. Please observe local rules and regulations accordingly. sun_powerpack_premium_en V1.00 (06/07/2015)

9 Safety Instructions 3.4. Obligations of the Operator Please keep the documentation in such a manner that it is available immediately to all persons who need to carry out work in connection with the batteries or their components. WARNING! The requirements for safe operation of the battery installation must be complied with for subsequent modifications at the installation site. Otherwise, any claims for warranty become null and void Occupational safety This section contains important information that needs to be observed and followed while working on the sun powerpack premium and its components. Prohibit all work methods that endanger the safety of human beings and impair the working of the batteries in any manner. Maintain the work sequence described in the documentation while installing, dismantling or connecting the battery terminals to the battery inverter / battery charger. Pay attention to the polarity of the battery stacks. Ensure that the battery connection cables are fitted tightly. Use only the battery connecting cables supplied along with the battery. Battery stack connections should not be made or removed 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 Personnel and Qualification Work on the battery system, especially its installation, maintenance and disassembly should be done only by electricians. Two persons are necessary for the installation and subsequent disassembly. The personnel must be well-versed with handling the batteries, be aware of the precautionary measures that are necessary, be trained in accordance with DIN VDE and DGUV regulation 3 (formerly BGV A3) and if applicable local rules and regulations containing requirements for persons working near electrical equipment. Please read the documentation carefully before you do any work on the sun powerpack premium or its components. It contains important information on secure and professional unpacking, storing, installing, operating and maintaining the battery system safely and properly. Please make sure to contact your local authorised dealer if: you have any queries on this documentation. there are local regulations or provisions that are not covered by this documentation or are contrary to its contents. sun_powerpack_premium_en V1.00 (06/07/2015)

10 Safety Instructions Personal Protective Equipment While working on the sun powerpack premium or its components, always wear the following protective equipment in order to prevent injuries or at least to mitigate them: Safety goggles Safety gloves 3.6. Special information on Li-Ion batteries Lithium-Ion batteries are safe if used properly. However, incorrect or improper handling may lead to leakages and thus, the discharge of the battery constituents. There is the risk of considerable reactions endangering health and the environment. DANGER! Defective batteries may reach conditions that are critical to safety. As a consequence of this, the batteries may burst or catch fire and hazardous decomposition products may be formed. In case liquid or gaseous substances are leaking, leave the room immediately and alert the fire brigade. DANGER! Basically, coming into contact with battery constituents that have leaked out may pose hazard for health and the environment. This is why adequate physical protection is necessary and adequate ventilation must be provided when coming into 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 this, pull out the connector of the battery connecting cable at the top of the battery system. The following measures are applicable only if the battery system is damaged causing damage to the battery cells and the cell contents start leaking: Do not inhale vapours that get discharged. Leave the room immediately in case of smoke development or gas release. Instructions for specialists: Damaged batteries must be surrounded with dry sand, chalk powder (CaCO3) or Vermiculite. If possible, they should be stored outside the buildings. They should best be stored in a sealed, shock-proof and fire-proof external packaging. The storage place should be marked and safeguarded with warning signs; in case the battery causes smoke development the storage place must also be monitored. Make sure to maintain a safe distance to combustible materials with Li-Ion batteries in any case. CAUTION! Do not allow leakage to get into sewer system/surface water/ground water. sun_powerpack_premium_en V1.00 (06/07/2015)

11 Safety Instructions Method for cleaning by specialists: Pick up residues mechanically with liquid-binding material (e.g. sand, sawdust, universal binding agents and diatomite). Dispose of picked up material in accordance with regulations. Avoid direct contact with the skin and eyes by wearing protective clothing First-aid measures if cell contents leak out If vapours are inhaled: Take the affected persons to open air and have them rest quietly. Consult a physician. In case of contact with skin: In case of contact with skin, rinse with plenty of water immediately and thoroughly for at least 15 minutes. If skin irritation persists, consult a physician. In case of contact with eyes: In case of contact with eyes, rinse immediately and thoroughly with water for at least 15 minutes and consult a physician. Protect uninjured eyes. If swallowed: Consult a physician immediately 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 up to 800 C occur on the surface of the cell, the cell opens up and blows off its contents under excessive pressure. In this process, a white / grey mist is formed in most cases that contains the electrolytes and other cell constituents. This may also ignite and thus cause a jet of flame (see also /1/). WARNING! Leaking gases are harmful to health and inflammable. Without appropriate protective equipment you must leave the place of fire immediately. This white mist formed is toxic and corrosive! It can dissolve on the moist surface of the skin and lead to chemical burns. ATTENTION! Alert the fire brigade immediately in case of fire. Inform the disaster relief force that there is a Lithium-Ion (Li-Ion) battery system located in the building. sun_powerpack_premium_en V1.00 (06/07/2015)

12 Safety Instructions Disposal instructions Disposal should be done in accordance with the European Batteries Directive and the German Batteries Act (2006/66/EC). Coordinate the disposal of apparently damaged batteries with the manufacturer HOPPECKE. Used batteries that bear the recycling symbol are renewable products. According to the label with the crossed-out garbage can, these batteries must not be set out with the household rubbish. Returning and recycling the batteries must be agreed upon with the manufacturer and ensured Transport To prepare lithium-ion batteries for transport, they should be packed in the original packaging such that they are safeguarded against short-circuit. The 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 pallet, one carton for each of the battery stacks and the accessories. ATTENTION! There are two so-called battery stacks available as slide-in modules in the sun powerpack premium battery system (see also chapter 4). During transport the battery stacks must be packed separately. It is not permissible to transport the complete battery system with the battery stacks installed! CAUTION! The battery stacks must be transported upright and put down. Basically, road transport of Li-Ion batteries is subject to the ADR Directive. The currently valid version must be applied. sun_powerpack_premium_en V1.00 (06/07/2015)

13 Safety Instructions "Transport of Lithium-Ion batteries, electrical tools and electrical garden appliances in connection with the main activity of the transporter (regulation for craftsmen - ADR c): For companies that undertake transport in connection with their main activity (e.g. delivery or return delivery in connection with measurements, repair and maintenance work or demonstration purposes) there are exceptions and special regulations (waiver or exemption). For Lithium-Ion batteries or devices that are operated with Lithium-Ion batteries > 100 Wh power, the weight limit applicable for the application of this waiver or exemption is 333 kg (Battery weight). Measures have to be taken in order to ensure a safe transportation (load securing)." Intact, undamaged batteries 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. If at least one of the following criteria is met, the regulations for packaging and transport of defective batteries shall apply: Battery cells have a damaged or highly deformed housing Liquid is leaking out (and with it severe development of odour) Peculiar smell of gas occurs Measurable increase in temperature in the switched off condition (more than lukewarm) Melted or deformed plastic parts Melted connecting cables The Battery Management System (BMS) identifies defective cells (message in display unit) 1 See also "Guidelines for the transport of Lithium-Ion batteries for electrical tools and electrical garden appliances: Implementation of the hazardous goods regulations", issued by: EPTA - The European Power Tool Association, Version: April: 2014 sun_powerpack_premium_en V1.00 (06/07/2015)

14 Safety Instructions Even intact, undamaged Lithium-Ion batteries are classified as "hazardous goods" in international transport law. Classification according to ADR (Road transport): 1 UN3480 Lithium batteries class 9 packaging group II, classification code: M4 Lithium battery Hazard label: UN3480 LITHIUM-ION BATTERIES Defective batteries WARNING! Defective batteries may reach conditions that are critical to safety. As a consequence of this, the batteries may burst or catch fire and hazardous gases may be formed by decomposition. WARNING! Transporting or collecting defective or damaged batteries should be done only in coordination with HOPPECKE. In case of queries, please contact the HOPPECKE Service hotline (Germany: / International: +49 (0) ) 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 appointed by HOPPECKE for this purpose. WARNING! Defective batteries may reach conditions that are critical to safety. As a consequence of this, the batteries may burst or catch fire and hazardous decomposition products may be formed. In case liquid or gaseous substances are leaking, leave the room immediately and alert the fire brigade. Observe and follow the safety instructions (see chapter 3). If you notify apparent defects or incomplete deliveries to the freight forwarder too late, this may lead to your claims becoming null and void. sun_powerpack_premium_en V1.00 (06/07/2015)

15 Safety Instructions HOPPECKE packs all supplies with the maximum possible care and diligence, so that the goods are received by you in undamaged condition. Check the delivery immediately on receipt for completeness 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 out the check. Write a defect report and send this to the suppliers within 7 days. sun_powerpack_premium_en V1.00 (06/07/2015)

16 Sun powerpack premium battery system 4. Sun powerpack premium battery system The sun powerpack premium battery system serves to store electrical energy. The major components of the system are illustrated in Figure 1. No. Description 1 Housing 2 Lower battery stack 3 Upper battery stack 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 utilisation of the battery system, the capacity selected must be compatible with the application. In case of queries, please contact your local HOPPECKE partner. sun_powerpack_premium_en V1.00 (06/07/2015)

17 Sun powerpack premium battery system The system consists of the following components: 1 x housing with cover 2 x battery stacks (with individual battery cells connected in series and parallel respectively) (Mat.-No for 5kWh variant / for 7.5kWh variant) 1 x Battery Management System (BMS) with display unit and installed in the housing Further: 1 x wall mount for installation (Mat.-No.: ) 1 x battery connecting cable for connection to the inverter (included in the scope of supply) 1 x battery connection cable incl. data cable (Mat.-No.: ) 1 x operation manual (Mat.-No.: ) 4 x Washer (DIN A2) (Mat.-No.: ) 4 x Toothed washer M6 Type M-A4 (Mat.-No.: ) 4 x Hexagon nut ISO M6-05 ZN (Mat.-No.: ) 1 x Sticker for sealing of housing (Mat.-No.: ) 1 x Protective foil for nameplate (Mat.-No.: ) The battery stacks consist of individually connected lithium iron phosphate battery cells (see also nameplate for the system and battery stack in Figure 2 and Figure 3). The two battery stacks are connected in series. This yields a storage capacity of approx. 5 kwh or 7.5 kwh at a nominal voltage of 51.2 V. sun_powerpack_premium_en V1.00 (06/07/2015)

18 Sun powerpack premium battery system Figure 2: Example of a battery system nameplate Figure 3: Nameplate and safety instructions on the battery stack The battery system should be operated only with approved battery inverters / battery chargers. The nominal battery voltage is 51.2 V, and communication between the battery inverter / battery charger and the battery system takes place via a data interface (CANOpen). sun_powerpack_premium_en V1.00 (06/07/2015)

19 Storage 5. Storage This chapter pertains to the storage of the battery system components at the premises of wholesale dealers, installation agencies or end customers. For installation agencies or end users, the individual system components should be stored only temporarily until the installation of the battery system Intact, undamaged batteries and batteries at the end of their service life Do not store the battery system together with inflammable substances. It is recommended to have a smoke detector at the place of installation. Protect from exposure to sunlight, sources of radiation and heat sources. Store it in a dry and cool place. HOPPECKE recommends storage in the original packaging. ATTENTION! A maximum of up to two battery stacks in original packaging may be kept or stored such that they are stacked on one another. Instructions for wholesale dealers and 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 Defective batteries WARNING! Defective batteries may reach conditions that are critical to safety. As a consequence of this, the batteries may burst, ignite and hazardous decomposition products may be formed (see also chapter 3). Instructions for specialists: Damaged batteries must be surrounded with dry sand, chalk powder (CaCO3) or Vermiculite. If possible, they should be stored outside the buildings. They should best be stored in a sealed, shock-proof and fire-proof external packaging. The storage place should be marked and safeguarded with warning signs; in case the battery causes smoke development the storage place must also be monitored. Make sure to maintain a safe distance to combustible materials with Li-Ion batteries in any case. sun_powerpack_premium_en V1.00 (06/07/2015)

20 Preparing for installation 6. Preparing for installation Before you begin with installation, check whether the installation site meets the requirements (see chapter 6.1). Keep all necessary tools ready at hand (see chapter 6.2) Installation site The sun powerpack premium must be installed and operated in a dry and frost-free indoor room (e.g. utility room or cellar). The installation site must be vibration-free. WARNING! The battery system should not be stored, installed or operated in rooms endangered by floods. CAUTION! At the installation site maintain a minimum distance of 2 m to inflammable items. The battery system should not be installed on combustible surfaces. Operation in explosive zones is not permissible. CAUTION! The battery system must be installed in such a manner that the battery 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 walls or floors. Observe and follow the manufacturer's specifications for the minimum distances to the battery inverter or other equipment installed in the room. ATTENTION! In order to dissipate waste heat optimally, the battery system should not be covered up or concealed. While installing batteries, the respective national building regulations must be observed and followed. The max. installation height of the battery system is 1.20 m (distance between the floor and the bottom edge of the battery system). The battery system is fixed to a wall at the installation site. Only the wall mount supplied along with the battery should be used for this purpose. sun_powerpack_premium_en V1.00 (06/07/2015)

21 Preparing for installation It must be possible to lock with a door the room in which the battery system is located. The door must be kept closed. HOPPECKE recommends an automatically closing door or an automatic door closer. A smoke detector must be installed on the ceiling at the installation site and above the battery system 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 wrench 10 mm for connecting the terminal nuts with screws to the battery stacks. Drilling machine (with drill bits for appropriate subsurface of the mounting wall) Spirit level sun_powerpack_premium_en V1.00 (06/07/2015)

22 Installation 7. Installation The following sections of this chapter describe the installation and commissioning of the battery store system Assembling and installing the housing 1. Transfer the position of the boreholes with a pencil to the intended 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 the mounting wall (see also Figure 5). No. Description 1 Mounting wall 2 Wall mounting Figure 5: Installing the wall mount sun_powerpack_premium_en V1.00 (06/07/2015)

23 Installation 3. Hook the empty housing with the fastening rail fixed on the rear side 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 sun_powerpack_premium_en V1.00 (06/07/2015)

24 Installation Grounding the housing 1. The grounding point is located on the top of the housing (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). sun_powerpack_premium_en V1.00 (06/07/2015)

25 Installation 7.2. Installing the battery stacks 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 sun_powerpack_premium_en V1.00 (06/07/2015)

26 Installation 2. Check the battery stacks for visible signs of damage. WARNING! The battery stacks with apparent signs of damage must not be installed or connected to the BMS! CAUTION! The battery stacks and the battery cells that they contain should not be disassembled or opened under any circumstances. 3. Remove the cover of the housing. To do this, loosen the Allen screws at the bottom 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). Each battery stack is marked on the front side, among others, with a serial number. Each of the housing levels is also marked with the serial number of the battery stack assigned to it (see the inside of the housing) to know which battery stack needs to be installed in each level of the housing. sun_powerpack_premium_en V1.00 (06/07/2015)

27 Installation 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 sun_powerpack_premium_en V1.00 (06/07/2015)

28 Installation 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 sun_powerpack_premium_en V1.00 (06/07/2015)

29 Installation 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 sun_powerpack_premium_en V1.00 (06/07/2015)

30 Installation 7.3. Connecting the battery stacks electrically DANGER! The battery stacks with apparent signs of damage should not be connected to the BMS (see also chapter 3.7.1)! Defective batteries may reach conditions that are critical to safety. As a consequence of this, the batteries may burst or catch fire and hazardous decomposition products may be formed. In case liquid or gaseous 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 the battery stack must be folded up. 3. Fasten the connector with a flat washer and M6 nut to the screw terminals of the battery stack. The tightening torque is 5 Nm (see Figure 16). Figure 16: Screw connection of the minus terminal at the lower battery stack sun_powerpack_premium_en V1.00 (06/07/2015)

31 Installation 4. Connect the cable of the battery management system with the connection at the upper battery stack. The associated cable harness is prepared accordingly (see Figure 17) ATTENTION! The cable harnesses for the battery management system are prepared and kept ready, and based on their length, they fit only to the upper or lower battery stack. These cables should not be 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 black colour). To install the connector, the respective plastic covers of the battery stack must be folded up. 6. Fasten the connector with a flat washer and M6 nuts to the screw terminals of the battery stacks (see Figure 18). The tightening torque is 5Nm. sun_powerpack_premium_en V1.00 (06/07/2015)

32 Installation No. Description 1 Serial connection of the lower and upper battery stacks Figure 18: Serial connection of the batteries 7. Connect the cables of the battery 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 red colour (see Figure 20 and Figure 21). sun_powerpack_premium_en V1.00 (06/07/2015)

33 Installation No. Description 1 Connecting the battery plus terminal to the upper battery stack Figure 20: Connecting the plus terminal to the upper battery stack 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 sun_powerpack_premium_en V1.00 (06/07/2015)

34 Installation 7.4. Connecting the battery inverter ATTENTION! The battery system must be connected only to battery inverters that have been approved by HOPPECKE. For connection to the battery inverter approved for the HOPPECKE sun powerpack premium (see Table 1). These inverters meet among others the requirements of galvanic isolation necessary: Manufacturer Device Additional information: SMA Sunny Island 6.0H / 8.0H When using the Sunny Island 8.0 in off-grid applications, HOPPECKE recommends the sun powerpack premium 7.5/48 battery store system or larger. SMA Sunny Island 3.0M / 4.4M --- Table 1: Overview of compatible battery inverters ATTENTION! Observe and follow the sequence of the electrical connection strictly! 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. 2. Connect the communication cable to the appropriate connection on the inverter. Follow the information provided in the manufacturer's documentation. 3. Route the battery connecting cable and the communication cable to the battery system. If the battery inverter is placed below or beside the battery system, the cables may be routed in the left or right opening (see Figure 22) to the top of the battery system (connecting cable up to 50mm2 cross section for plus and minus). sun_powerpack_premium_en V1.00 (06/07/2015)

35 Installation No. Description 1 Opening for routing the battery connecting cable 2 Opening for routing the battery connecting cable Figure 22: Openings for the battery connecting cable 4. Insert the connector of the battery connecting cable in the connection jack on the top of the battery system (see Figure 23). 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 jack Figure 23: Battery connection jack sun_powerpack_premium_en V1.00 (06/07/2015)

36 Installation 7.5. Commissioning Switch the battery inverter on. With successful assembly and installation and correct connection to the battery inverter, the current state of charge is shown in the display unit of the battery system in percent and the instantaneous charging or discharging power is displayed (see Figure 24). In charging mode, the arrow points in the direction of the battery icon. In the discharging mode, the arrow points away from the battery icon. With this, the installation has been completed successfully. Configure the battery inverter according to the manufacturer's specifications. 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. Figure 24: Display unit (Example of standard display) If a warning or error condition is present, this is displayed with an exclamation mark (Warning) or an "X" symbol (Error) in the display unit (see Figure 25). See also chapter 12. No. Description 1 Icon for active warning Figure 25: Display unit (example for symbolising an active warning) sun_powerpack_premium_en V1.00 (06/07/2015)

37 Installation 7.6. Final work 1. Hook the cover of the battery system into the openings at the top of the housing (see Figure 26). No. Component 1 Left opening 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 (seefigure 27). 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: Fastening the cover sun_powerpack_premium_en V1.00 (06/07/2015)

38 Installation 3. Stick the supplied sealing sticker on the cover and housing (see Figure 28) No. Description 1 Sealing sticker Figure 28: Sealing of housing 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 (see chapter 19.2) sun_powerpack_premium_en V1.00 (06/07/2015)

39 Registering the battery system 8. Registering the battery system For battery systems in Germany only: For the fair value replacement warranty in the context of the German KfW sponsorship 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 ( and registration via telephone at (Mon.-Fri. 09:00 AM - 4:00 PM). You may download the current terms and conditions for warranty from the homepage of HOPPECKE at sun_powerpack_premium_en V1.00 (06/07/2015)

40 Operating the battery system 9. Operating the battery system Please make sure to observe and follow the warning and safety instructions given on the nameplate. The meaning of these instructions is explained in the following: Avoid open flames, embers or sparks near the battery system. Do not disassemble or open the battery system (with the exception 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 manufacturer and ensured. Warning against substances harmful to health (with release of gases or liquid electrolyte). With proper assembly and installation, and during regular operation, no liquids or gases are released. sun_powerpack_premium_en V1.00 (06/07/2015)

41 Operating the battery system General hazard information on batteries Warning against oxidising substances. In case of fire, the constituents of the battery (cells) get oxidised. Warning against inflammable 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 the instructions for transport. sun_powerpack_premium_en V1.00 (06/07/2015)

42 Operating the battery system 9.1. Safety Functions The battery management system offers various safety functions in order to ensure safe and high-performance operation over the specified service life. Safety functions in accordance with EN62108 are listed in the following (see Table 2). Name Function Classification SF1 Shutting down the charging current with impending overcharging of one or more cells SIL1 Table 2: Safety function The Battery Management System (BMS) controls the battery charging and discharging process automatically. For this purpose, the BMS communicates with the battery inverter via a data interface (CAN bus). The maximum permissible values of the charging and discharging current and the current state of charge are communicated to the battery inverter via this data interface. The battery inverter is responsible for managing the operation based on the load or consumption situation as well as the energy generation of the PV generator. The BMS controls the battery system automatically. It is not possible for the (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 Display Unit The display unit is switched on using the button at the bottom right corner. Moreover, the information displayed can be switched with the help of this button. In order to conserve battery power, the display unit is switched off after about 60 sec. (after the previous button operation). If there is an active warning or an error present, the display remains switched on. The following information can be output on the display unit by pressing a button: 1. Main screen: State of charge (SOC = State of Charge) in %. Instantaneous battery charging or discharging power in kw Additional icon if there is an active warning or active error 2. Warnings / Errors (only if an active warning or error message is present): Type of message (warning or error) Error description 3. System: Serial number of the battery system Serial number of the BMS Nominal voltage of the systems (48 V) Nominal capacity of the system (e.g. 5 kwh) Hardware version of the BMS Software version of the BMS Inverter configured (e.g. SMA) sun_powerpack_premium_en V1.00 (06/07/2015)

43 Operating the battery system 4. Statistics: Charged energy in kwh (since commissioning) Discharged energy in kwh (since commissioning) Cycles (since commissioning) 5. Info / Instantaneous values: Voltage Current Current battery temperature State of charge (SOC) in % State of health (SOH) in % Current maximum cell temperature present Current minimum cell temperature present Current maximum cell voltage Current minimum cell voltage Error register (F) Warning register (W) 9.3. Operating states The following operating states of the battery are possible: Operation (Active): All functions and data communication with the battery inverter are active. Off (Inactive): The battery store is switched off by pulling the battery connecting cable. The CAN communication is stopped 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. For specialists: By pulling the cable attached to the service interface the battery system is also switched off. Deep Discharge Protection: As soon as a specific battery cell voltage has been reached, the BMS issues a warning. If the BMS is restarted before the expiry of one day during the presence of the warning, the BMS detects the error "Deep discharge" and shuts down. In order to prevent damage to the battery, the BMS shuts down when a certain critical battery cell voltage is undershot. The BMS switched the system automatically to the inactive mode if the batteries are threatened by deep discharge. Thus, the BMS ensures that adequate residual energy remains in the battery in order to initiate the next recharging operation. sun_powerpack_premium_en V1.00 (06/07/2015)

44 Operating the battery system 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. In the case of deeply discharged batteries, the DC link cable must be pulled out and then plugged in again immediately. Over and above this, the battery must be charged 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 are described in chapter 12. in case of critical errors, the battery system is disconnected from the battery inverter via an electromechanical switch. The battery system cannot be operated any longer (see also the appropriate error message in chapter 12). In this case, contact the installation engineer or HOPPECKE Service. sun_powerpack_premium_en V1.00 (06/07/2015)

45 Maintenance and Care 10. Maintenance and Care Since the battery management system (BMS) in the battery system monitors the battery cells continuously and in case of an error, disconnects the battery system from the battery inverter, regular maintenance of the system is restricted to visual inspection. Maintain and check the smoke detector at the installation site in accordance with the manufacturer's specifications Cleaning Wipe off the system occasionally with a cloth slightly moistened with water BMS software update The software in the BMS can be updated, if needed, by the installation engineer or HOPPECKE Service. sun_powerpack_premium_en V1.00 (06/07/2015)

46 End of service life 11. End of service life The BMS determines among others the end of service life of the battery system. In the process, the calendar-based and usage-based ageing (represented by the calculated SOH - state 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. In case of shut-down on account of end of service life identified, contact HOPPECKE Service. sun_powerpack_premium_en V1.00 (06/07/2015)

47 Warning and Fault messages 12. Warning and Fault messages In case of an active fault, the battery management system interrupts the battery charging / discharging operation (see overview of fault messages in Table 3). Note the hints in column Remarks / Measure. Code Description Remarks / Measure E001 Maximum cell voltage Battery must be discharged. E002 Minimum cell voltage Battery must be charged; E003 E004 E005 E006 E007 E008 E009 E010 E011 E014 E015 Maximum cell temperature Minimum cell temperature Minimum cell temperature, discharging Maximum board temperature Heavy discharge Electronic error Communication error Communication error Electronic error Electronic error Electromechanical switch defective / not available > 60 C: Do not use the battery any longer. To do this, switch the battery inverter off. < 0 C: The battery system must have temperature > 0 C before further use. < -10 C The battery system must have temperature > 0 C before further use. > 90 C: The battery system must cool down to below 60 C. Switch the BMS on by plugging in the connection cable to the battery system and apply the charging current Do not make use of the battery any longer. Contact HOPPECKE Service, the BMS must be replaced. Do not make use of the battery any longer. Contact HOPPECKE Service, the BMS must be replaced. Do not make use of the battery any longer. Contact HOPPECKE Service, the BMS must be replaced. Do not make use of the battery any longer. Contact HOPPECKE Service, the BMS must be replaced. Do not make use of the battery any longer. Contact HOPPECKE Service, the BMS must be replaced. Do not make use of the battery any longer. Contact HOPPECKE Service, the BMS must be replaced. Table 3: Error codes sun_powerpack_premium_en V1.00 (06/07/2015)

48 Warning and Fault messages The following warnings do not lead to the battery system being shut down (see Table 4). Note the hints in column Remarks / Measure Code Description Remarks / Measures W001 Warning internal BMS monitoring Contact HOPPECKE Service W003 Heavy discharge < 2.45 V: charge the battery immediately; do not shut down, otherwise error E007 W004 SD card not present Contact HOPPECKE Service. W005 Blower defective Contact HOPPECKE Service. W008 High cell voltage Battery must be discharged W009 Low cell voltage Battery must be charged W010 W011 W012 High cell temperature Low cell temperature High board temperature > 50 C: The battery system should not heat up any more, otherwise error E003 The battery system should not cool down any more, otherwise error E004, E005 > 80 C: Allow the BMS to cool down (avoid high current flow during charging or discharging) Table 4: Warnings sun_powerpack_premium_en V1.00 (06/07/2015)

49 System expansion 13. System expansion The storage capacity may be enhanced subsequently by connecting individual battery systems in parallel. Only battery systems of identical capacity can be connected in parallel. The age difference (from the date of commissioning) between the individual systems to be connected in parallel should not exceed 24 months. HOPPECKE offers an appropriate accessories kit for connecting individual battery systems in parallel. Parallel operation of multiple battery systems must be done only with the help of original HOPPECKE accessories. Refer to the documentation supplied 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 terminals of the battery stacks (top left plus terminal, top cable to the BMS, top right minus terminal, bottom left plus terminal, bottom cable to the BMS, bottom right minus terminal). 6. Loosen the battery stacks from the mounts (loosen 2 Allen screws of 4 mm each) 7. Remove the battery stacks from the housing and pack them safely in the original packaging. 8. Loosen the housing from the mount (4 mm Allen screw). 9. Lift the housing from the wall. 10. Pack the housing in the delivery packing. sun_powerpack_premium_en V1.00 (06/07/2015)

50 Technical Specifications 15. Technical Specifications System Dimensions: 600 x 500 x 350mm (H x W x D) Total weight per system: 5.0 / 48: Ca. 85 kg or 7.5 / 48: Ca. 100 kg Ambient temperature, operation and storage: +5 C to +45 C Optimal temperature range during operation: +5 C to +35 C Relative atmospheric humidity: 0 to 90% (non-condensing) IP Code: 21 End-of-charge voltage: Power consumption: 56V Approx. 1 W (CAN Bus active). In 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 Battery cell Technologies: Nominal capacity: Nominal voltage: Charging method: Efficiency: Prismatic cells, lithium iron phosphate (LiFePo) 50 Ah (C3) 5 kwh or 78 Ah (C3) 7.5 kwh system 3.2 V/cell (51.2V battery system) IU (constant current / constant voltage) 98% (0.5 C discharge) Norms and Standards DIN EN EN DIN EN 62620: IEC EN EN VDE-AR-N 4105 VDE AR UN38.3 (Area of application: Battery stacks) sun_powerpack_premium_en V1.00 (06/07/2015)

51 CE Declaration of Conformity 16. CE Declaration of Conformity sun_powerpack_premium_en V1.00 (06/07/2015)