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Hoppecke Sun Powerpack Premium Operating Manual

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Operating Manual
HOPPECKE sun | powerpack premium

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  • Page 1 Operating Manual HOPPECKE sun | powerpack premium...
  • Page 2 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.

  • Page 3: Table Of Contents

    Table of contents TARGET GROUP MEANS OF REPRESENTATION SAFETY INSTRUCTIONS 3.1. General Safety Instructions 3.2. Intended Use 3.3. Directives, Legislation and Standards 3.4. Obligations of the Operator 3.5. Occupational safety 3.5.1. Personnel and Qualification 3.5.2. Personal Protective Equipment 3.6. Special information on Li-Ion batteries 3.6.1.
  • Page 4 Target Group REGISTERING THE BATTERY SYSTEM OPERATING THE BATTERY SYSTEM 9.1. Safety Functions 9.2. Display Unit 9.3. Operating states MAINTENANCE AND CARE 10.1. Cleaning 10.2. Repair Work 10.3. BMS software update END OF SERVICE LIFE WARNING AND ERORR MESSAGES SYSTEM EXPANSION DISASSEMBLY TECHNICAL SPECIFICATIONS 15.1.

  • Page 5: Target Group

    Target Group 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. Note: Proper installation and commissioning must be certified by the respective electrician with his signature in this operating manual (see chapter 19).

  • Page 6: Means Of Representation

    Means of Representation 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.

  • Page 7: Safety Instructions

    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.

  • Page 8: Intended Use

    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.

  • Page 9: Obligations Of The Operator

    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.

  • Page 10: Personal Protective Equipment

    Safety Instructions 3.5.2. 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.

  • Page 11: First-Aid Measures If Cell Contents Leak Out

    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.

  • Page 12: 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.

  • Page 13: Intact, Undamaged Batteries And Batteries At The End Of Their Service Life

    Safety Instructions Note: "Transport of Lithium-Ion batteries, electrical tools and electrical garden appliances in connection with the main activity of the transporter (regulation for craftsmen - ADR 1.1.3.1c): 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).

  • Page 14: Defective Batteries

    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.
  • Page 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.

  • Page 16: Sun|Powerpack Premium Battery System

    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.
  • Page 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 6011302980 for 5kWh variant / 6011302981 for 7.5kWh variant) ...

  • Page 18: Hints For Sizing Of The System

    Sun|powerpack premium battery system Figure 3: Nameplate and safety instructions on the battery stack Note: 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).

  • Page 19: Storage

    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.

  • Page 20: Preparing For Installation

    Preparing for installation 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). 6.1. Installation site The sun|powerpack premium must be installed and operated in a dry and frost-free indoor room (e.g.

  • Page 21: Tools And Equipment

    Preparing for installation Note: 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. Note: A smoke detector must be installed on the ceiling at the installation site and above the battery system.

  • Page 22: Installation

    Installation Installation The following sections of this chapter describe the installation and commissioning of the battery store system. 7.1. 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.
  • Page 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 Wall mounting Fastening rail Rear side of the housing Housing cover Figure 6: Suspended housing 4.

  • Page 24: Grounding The Housing

    Installation 7.1.1. Grounding the housing 1. The grounding point is located on the top of the housing (see Figure 8). No. Description Grounding point Figure 8: Grounding point 2. Fix the protective ground conductor with a ring cable lug to the grounding point on the housing.

  • Page 25: Installing The Battery Stacks

    Installation 7.2. Installing the battery stacks Note: The system can be operated only when it is completely equipped, i.e. with the two battery stacks supplied / fix assigned (identical capacity and nominal voltage). Check this based on the information on the nameplate of the battery stacks. 1.
  • Page 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.
  • Page 27 Installation No. Description Lower level Upper level Figure 11: Upper and lower levels in the housing Description Carry grip of the battery stack (see the left and right side on the battery stack) Figure 12: Battery stack – Carry grip BA_sun_power_pack_LiOn_en_V1.05.docx V1.05 (20/07/2017) 6140203036...
  • Page 28 Installation No. Description Lower level with battery stack 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 Fastening screw Figure 14: Fixing the battery stack BA_sun_power_pack_LiOn_en_V1.05.docx V1.05 (20/07/2017) 6140203036...
  • Page 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 BA_sun_power_pack_LiOn_en_V1.05.docx V1.05 (20/07/2017) 6140203036...

  • Page 30: Connecting The Battery Stacks Electrically

    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.
  • Page 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.
  • Page 32 Installation No. Description 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).
  • Page 33 Installation Description Connecting the battery plus terminal to the upper battery stack Figure 20: Connecting the plus terminal to the upper battery stack Note: The voltages and temperatures of the individual battery cells are acquired via the cables in the cable harness.

  • Page 34: Connecting The Battery Inverter

    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...
  • Page 35 Installation No. Description Opening for routing the battery connecting cable 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) Note: The connector has to be pushed into the connection jack up to the stop.

  • Page 36: Commissioning

    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).

  • Page 37: Final Work

    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 Left opening for fastening the cover Right opening for fastening the cover Figure 26: Openings for fastening the cover 2.
  • Page 38 Installation 3. Stick the supplied sealing sticker on the cover and housing (see Figure 28) No. Description 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).

  • Page 39: Registering The Battery System

    275), the battery system must be registered immediately, but latest within two weeks after commissioning. For this purpose, you may choose between on-line registration (https://register.hoppecke-batterien.de/) and registration via telephone at 02963 61-526 (Mon.-Fri. 09:00 AM - 4:00 PM). You may download the current terms and conditions for warranty from the homepage of HOPPECKE at www.hoppecke.com.

  • Page 40: Operating The Battery System

    Operating the battery system 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.
  • Page 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 flammable substances. Warning against toxic substances. With proper assembly and installation, and during regular operation, no liquids or gases are released.

  • Page 42: Safety Functions

    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 Shutting down the charging current with impending...

  • Page 43: Operating States

    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...
  • Page 44 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. BA_sun_power_pack_LiOn_en_V1.05.docx V1.05 (20/07/2017) 6140203036...

  • Page 45: Maintenance And Care

    Repair of the battery system is not allowed. Depending on the defect it might be necessary to replace the battery management. This must only be carried out by an electrician or HOPPECKE Service personnel (refer to extra documentation). 10.3. BMS software update The software in the BMS can be updated, if needed, by the installation engineer or HOPPECKE Service.

  • Page 46: End Of Service Life

    SOH is at 0%. In this condition the battery storage system has left 70% of its initial capacity. Note: In case of shut-down on account of end of service life identified, contact HOPPECKE Service. BA_sun_power_pack_LiOn_en_V1.05.docx V1.05 (20/07/2017) 6140203036...

  • Page 47: Warning And Erorr Messages

    Electronic error 512, 1024, Do not make use of the battery any longer. 8 to 13 Hardware error 8192, Contact HOPPECKE Service, the BMS 16384 must be replaced. Do not make use of the battery any longer. 32768 Cell error Contact HOPPECKE Service.
  • Page 48 Note the hints in column “Remarks / Measure” Code Meaning Remarks / Measures Warning internal BMS monitoring Watchdog Contact HOPPECKE Service Charge battery immediately; do not shut Deep discharge down, otherwise error code 64 Data memory Contact HOPPECKE Service. Hardware warning Contact HOPPECKE Service.

  • Page 49: System Expansion

    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.

  • Page 50: Technical Specifications

    Technical Specifications Technical Specifications 15.1. 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)

  • Page 51: Ce Declaration Of Conformity

    CE Declaration of Conformity CE Declaration of Conformity BA_sun_power_pack_LiOn_en_V1.05.docx V1.05 (20/07/2017) 6140203036...

  • Page 52: Abbreviations

    Abbreviations Abbreviations Battery Management System Controller Area Network Direct Current Depth of Discharge Li-Ion Lithium-Ion State of Charge State of Health (Available capacity with full charge related to the nominal capacity) BA_sun_power_pack_LiOn_en_V1.05.docx V1.05 (20/07/2017) 6140203036...

  • Page 53: Further Information

    Further information Further information "Operation in stationary lithium solar energy stores - Notes on fire-fighting and technical assistance", issued by: Federal Association for Solar Industry - Bundesverband Solarwirtschaft (1st Edition, December 2014). See also under: http://www.solarwirtschaft.de/ BA_sun_power_pack_LiOn_en_V1.05.docx V1.05 (20/07/2017) 6140203036...

  • Page 54: Appendix

    The original of this certification must remain with the operator of the HOPPECKE sun|powerpack premium system and kept in safe custody. Place:_______________________________ , Date: _______________________...

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