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Related Manuals for DISCOVER HELIOS 52-48-16000
Summary of Contents for DISCOVER HELIOS 52-48-16000
- Page 1 HELIOS ESS INSTALLATION AND OPERATION MANUAL BATTERY MODEL 52-48-16000 | 900-0077 805-0090 REV A...
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Page 2: Table Of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 1 . -
Page 3: Introduction
Introduction A battery from Discover Energy Systems (Discover), the HELIOS ESS is a high-capacity, low-voltage battery that can operate independently or in a battery bank configuration where multiple batteries are connected in parallel . AUDIENCE, MESSAGES, WARNINGS, GENERAL SAFETY, PERSONAL PROTECTIVE EQUIPMENT 1.1 Audience Configuration, installation, service, and operating tasks should only be performed by qualified personnel in consultation with local authorities having jurisdiction and authorized dealers. Qualified personnel should have training, knowledge, and experience • Installing electrical equipment •... -
Page 4: General Warnings
1.3 General Warnings Do not crush, disassemble or dispose of the battery in fire or the garbage. This product is made of recyclable materials and must be recycled . WARNING ELECTRIC SHOCK AND FIRE HAZARD • This equipment must only be installed as specified. • Connect the battery to isolated Power Conversion Systems (PCS) only . • Do not install the battery in series . •... -
Page 5: Electric Shock Hazard
CAUTION ELECTRIC SHOCK HAZARD • Do not touch the energized surfaces of any electrical component in the battery system . • Before servicing the battery, follow all procedures to fully de-energize the battery system . • Follow the Safe Handling Procedures below when working with the battery . -
Page 6: Personal Protective Equipment
• If there is an emergency STOP button, press it to shut down the system . • Do not attempt to put out the fire. • Do not spray water or other fire retardants. ITEMS SHIPPED IN THE BOX Confirm the contents of the box. Discover does its best to maintain quality and accuracy in the shipment of its products . If anything is damaged or missing, please contact customer support immediately . Table 2-1, HELIOS ESS Box Contents... -
Page 7: Specifications
SPECIFICATIONS All specifications in this document are published @25ºC / 77ºF. 3.1 Electrical Specifications Table 3-1, HELIOS ESS Electrical Specifications Electrical Specifications 52-48-16000 | 900-0077 Nominal Voltage 51 . 2 V Energy 16,080 Wh Nominal Capacity 314 Ah Charge Bulk Voltage - Bulk Vdc 55 . 2 – 56 . 8 V Charge Absorption Voltage - U1 MAX 55 . -
Page 8: Mechanical Specifications
3.2 Mechanical Specifications Table 3-2, HELIOS ESS Mechanical Specifications Mechanical Specifications 52-48-16000 | 900-0077 Chemistry LiFePO Height 900 mm (35 . 4 3 in) Width 465 mm (18 . 3 1 in) Depth (body only) 247 mm (9 . 7 2 in) Depth (including Wall-Mount bracket) 271 mm (10 . -
Page 9: Environmental Specifications
Table 3-3, HELIOS ESS Wall-Mount Bracket Specifications Specifications Wall-Mount Bracket Height 497 mm (19 . 5 7 in) Width 363 mm (14 . 2 9 in) Depth 22 mm (0 . 8 7 in) Weight 3 . 8 kg (8 . 4 lb) Material Galvanized Steel Sheet 363 mm (14.29in) -
Page 10: Protection Specifications
3.4 Protection Specifications Table 3-5, HELIOS ESS Protection Specifications Protection 52-48-16000 | 900-0077 Specifications Overvoltage Protection Above 58 . 0 8 V for 3 seconds Recovery Recovery after 120 seconds and less than 55 . 2 V Undervoltage Protection Less than 43 . 2 V for 5 seconds Recovery No automatic recovery . - Page 11 Protection 52-48-16000 | 900-0077 Specifications Overvoltage protection monitors individual cell voltages . Protection is triggered when any cell is over 3 . 6 3 VPC and recovers when all cells are below 3 . 4 5 VPC for 120 seconds . Voltages are provided for guidance only . Undervoltage protection monitors the voltage of individual cells .
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Page 12: Internal Heating Specifications
. Table 3-9, HELIOS ESS DC Capacity Values for Sample Battery Systems (@25°C, 77°F) (a) provides DC capacity values for sample Discover systems . NOTICE • Exceeding the Max Continuous Current of all the batteries in the system will lead to triggering the battery BMS over-temperature protection quicker, resulting in disconnection of all batteries in the system . -
Page 13: Regulatory
NOTE The maximum number of batteries installed in a closed-loop configuration with a LYNK Gateway device is 36 . Table 3-9, HELIOS ESS DC Capacity Values for Sample Battery Systems (@25°C, 77°F) Parallel Continuous Continuous Usable Peak Current System Discharge Charge Capacity Current Current 1 battery 300 A 200 A 200 A 16 kWh 2 batteries 600 A... -
Page 14: Features
6. FEATURES 6.1 Battery Features Left Right ① ② ⑬ ⑩ ⑭ ⑪ ⑮ ⑨ ③ ④ ⑫ ⑥ ⑤ ⑦ ⑧ Figure 4. HELIOS ESS Battery Components Item Description Breather valves 4 x Battery negative terminals (-) black (with quick connects) LCD display (SOC, fault/warning, voltage level, amperes) ON/OFF key Wall-mount bracket... -
Page 15: Conduit Box (Optional Accessory)
6.2 Conduit Box (Optional Accessory) Available as an option, conduit boxes provide seamless connections between an inverter and the HELIOS ESS battery . Figure 5. Conduit Box Table 6-1, Conduit Boxes Description Part Number HELIOS ESS Sol-Ark 15K 2P-N Conduit Box 950-0067 6.3 Battery Breaker The battery breaker protects the electronic components of the battery’s internal BMS... -
Page 16: Lcd Display
6.4.1 Battery ON/OFF Key LED States Description Battery is OFF . Battery is ON . Pulse Battery breaker is either open or the battery is warning of an approaching protection limit . Flash Battery has faulted . Use LYNK Access software to identify and diagnose the issue . - Page 17 Icon State Description State of State of charge of all the batteries in the battery bank . A Charge full charge is indicated when all the bars are displayed . Remaining The remaining time is an estimate of how much time Time remains until: •...
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Page 18: Com 2 (Can Port)
Number Fault/Warning Recovery Under-temperature in charge Leave the charger connected to engage the internal heater . Charging will continue after the battery cell temperature reaches 4°C (39 . 2 °F) or higher . Over-temperature in charge The battery stops charging and will continue charging only after the battery temperature is below the recovery threshold . - Page 19 LYNK Inverter Closed Loop without Closed LYNK CLOUD LYNK II Loop with ACCESS with with LYNK II Straight Create your LYNK II LYNK II cable own cable Schneider Electric (Legacy) Conext XW+ 5 . 5 /6 . 8 Conext XW+ 7 . 0 /8 . 5 Conext MPPT 60-150 Conext MPPT 80-600 Conext MPPT 100-600...
- Page 20 6.6.2 Closed-Loop Communication Without LYNK II (Straight Cable) The HELIOS ESS supports closed-loop communication with the following inverters through a CAT6 or higher cable . Refer to Table 6-4, Closed-Loop Communication with Inverters . • Sol-Ark 5K to 15K-P (Outdoor) and 12K to 15K-2P (Outdoor) •...
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Page 21: Com3/Com4 (Lynk Port)
Figure 9. Create Your Own Cable (Victron Energy) 6.7 COM3/COM4 (LYNK Port) The COM3 and COM4 ports enable multiple Discover batteries to communicate and interact in a closed-loop network . The COM3/COM4 ports enable multiple HELIOS ESS batteries to work together in a closed-loop communication system with other networked devices, such as inverter-chargers . -
Page 22: Theory Of Operation
NOTICE • Use a straight-through cable . Do not use a cross-over cable . • Isolate unused pins . Crossing pin functions may cause system damage . • Do not terminate unused wires to ground, power, or other functions . •... -
Page 23: Battery Management System
7.3 Battery Management System 7.3.1 Battery Management System Protections The Battery Management System’s (BMS) primary function is to monitor cell module voltage, temperature, and battery current . The BMS uses this information to maintain cell operation within operating specifications. If a parameter falls outside of operating specifications, the BMS will disconnect and protect the battery from: 1 . Overvoltage: Charge voltages that are too high . 2 . -
Page 24: Lynk Network Communication
The battery has intelligent CAN termination . Terminating resistors are not required when deploying the battery in a LYNK Network . 7.4.1 LYNK Network Power A Discover battery provides the LYNK network power through the LYNK port (COM3/ COM4). Discover documentation specifies how many batteries are required to provide sufficient power for the LYNK network and compatible accessories. Some accessories... -
Page 25: Optional Accessories
NOTICE Do not use an external power source to power devices over the LYNK Network . NOTE The LYNK II Communication Gateway is required for diagnosis of the batteries and to use the LYNK Cloud web service . 7.4.2 LYNK Network Size One LYNK Network can support up to 36 HELIOS ESS Batteries . -
Page 26: Installation
9. INSTALLATION The following instructions describe how to connect single or multiple batteries in parallel to an inverter . WARNING ELECTRIC SHOCK AND FIRE HAZARD • This equipment must only be installed as specified. • Do not disassemble or modify the battery . • Do not touch exposed contents if the battery case has been damaged . •... - Page 27 304.8 mm 304.8 mm (12 in) (12 in) Figure 11. Battery spacing 3 . Do not install in direct sunlight. Avoid installing the battery in an area with high ambient temperature . NOTICE Damage to the LCD display due to sunlight exposure is not covered by the warranty . 4 .
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Page 28: Attaching The Battery Onto A Wall
9.3 Attaching the Battery onto a Wall CAUTION HEAVY OBJECT Two-person or three-person lift is recommended for the battery . Failure to follow these instructions may result in injury. The following instructions are based on installing the battery onto a wall . Instructions on installing the inverter itself are provided in the inverter manufacturer’s documentation . - Page 29 152.4 mm 152.4 mm (6.0 in) (6.0 in) 649 mm (25.55 in) 391 mm (15.4 in) Figure 13. Wall-Mount Bracket Drill Holes 6 . Drill the holes for the Wall-Mount Bracket . 7 . Secure the Wall-Mount Bracket to the wall using appropriate fasteners that can support the battery’s weight and are compatible with the material of the wall or studs .
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Page 30: Wiring
Figure 15. Secure Battery to Wall-Mount Adapter 9 . Install the inverter near the battery . Refer to the inverter manual for instructions . 10 . Next, wire the batteries and the inverter . NOTE The cover plate protecting the battery terminals and COM ports is installed inside out for shipping purposes . - Page 31 inverter, and use the quick connect on the other side of the cable for the positive or negative battery terminal . 2 . Minimum and equal cable lengths. Select a location that minimizes the length of battery cables to reduce voltage drop from the impedance leading to reduced performance .
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Page 32: Single Battery Installation
9.4.3 Terminal Connections and Hardware Plug and pull quick connects are used to mate with the plug and pull terminals on the HELIOS ESS battery . Push Release Figure 16. Plug and Pull Quick Connect 1 . Plug the connector into the plug and pull terminal . 2 . - Page 33 1 . Prepare the inverter and battery for wiring . a . If the inverter is wired to a power source, open the disconnect and set the inverter OFF . b . Use a DMM or other voltage measuring device to confirm the circuit is de-energized. c . If the circuit in which the battery is installed has a disconnect, open the disconnect to isolate the battery .
- Page 34 Figure 18. Connect Cables to Battery Terminals 4 . Connect the negative battery cables to the receiving pins of the negative battery terminals and push down to enable the connection . 5 . Connect the CAN communication cable . Closed-Loop Communication with the LYNK II Communication Gateway If you are using the LYNK II Communication Gateway, connect the CAT6 communication cable from the inverter to the LYNK device and then to the battery .
- Page 35 Closed-Loop Communication Without the LYNK II Communication Gateway Legend CANbus LYNK bus Figure 20. Closed-Loop Communication Without LYNK II Closed-loop communication without the LYNK II Communication Gateway is available with select inverters . Refer to 6 . 6 COM 2 (CAN Port) for the list of supported inverters and the specifications on the cable required to communicate with the inverter .
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Page 36: Parallel Battery Installation
9.6 Parallel Battery Installation CAUTION FIRE HAZARD Use cables that meet specifications. Undersized cables can become hot and may potentially catch fire. Failure to follow these instructions may result in injury. Batteries used in a parallel system must meet the following requirements: a . Same model. Batteries must be the same model . b . - Page 37 Install equipment following the standards set by the local authority having jurisdiction. 1 . Prepare the inverter and battery for wiring . a . If the inverter is wired to a power source, open the disconnect and set the inverter OFF . b . Use a DMM or other voltage measuring device to confirm the circuit is de-energized. c . If the circuit in which the battery is installed has a disconnect, open the disconnect to isolate the battery .
- Page 38 LEGEND Positive Negative Figure 22. Two Batteries in Parallel (One Parallel Wire Kit 950-0068) 3 . Connect the positive (+) battery cable in the HELIOS ESS Parallel Wire Kit (950- 0068) to a receiving pin of the positive battery terminals on a battery at one end of the battery bank .
- Page 39 When using TWO Sets of Battery to Inverter cables LEGEND Positive Negative Figure 24. Three Batteries in Parallel (Two Parallel Wire Kits 950-0068) LEGEND Positive Negative Figure 25. Two Batteries in Parallel (One Parallel Wire Kit 950-0068) 3 . Connect one of the positive battery cables from the inverter to a battery on one end of the battery bank, and connect the other cable to the battery on the other end of the battery bank .
- Page 40 Figure 26. Connect Cables to Battery Terminals 4 . Connect one of the negative battery cables from the inverter to a battery on one end of the battery bank, and connect the other cable to the battery on the other end of the battery bank .
- Page 41 Legend CANbus LYNK bus Figure 27. Closed-Loop Communication with LYNK II Closed-Loop Communication without the LYNK II Communication Gateway Closed-loop communication without the LYNK II Communication Gateway is available with select inverters . Refer to 6 . 6 COM 2 (CAN Port) for the list of supported inverters and the specifications on the communication cable required to communicate with the inverter .
- Page 42 8 . Set all battery BMS to ON (ON/OFF key) . 9 . Energize the system by setting all battery breakers to ON (close) . 10 . Close the circuit disconnect if it is open . NOTICE Failure to securely lock the ends of battery cables to the receiving pins on the battery will increase resistance and lower voltage, leading to burnout of the terminals and voiding of the warranty .
- Page 43 2 . Wire the batteries . You can use the Battery to Inverter Power Cables 2/0 AWG (950-0070) or 1/0 AWG (950-0071) to wire the batteries to the busbar . a . Ensure the cable connections are clean and in working order . b .
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Page 44: Grounding
9.7 Grounding At the top of the HELIOS ESS battery is a grounding screw . Grounding screw Figure 31. Grounding Screw at Top of HELIOS ESS Battery 9.7.1 Grounding a Single Battery ② ① Figure 32. Grounding a Single Battery 1 . - Page 45 9.7.2 Grounding Multiple Batteries ④ ③ ② ① Figure 33. Grounding Multiple Batteries 1 . Grounding the first battery. Secure an appropriately sized grounding wire to the grounding screw on the farthest battery . Refer to your applicable code and check with the authority having jurisdiction to confirm local requirements.
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Page 46: Lynk Network
9.8 LYNK Network 9.8.1 Network Layout Legend CANbus LYNK bus Figure 34. Inverter and Batteries Connected Through LYNK II Communication Gateway 9.8.2 Network Installation Networking Guidelines: • Separate data and power cables . Allow for separation between data and power cables . -
Page 47: Operation
A voltage-based battery meter designed for lead-acid batteries will not provide an accurate state-of-charge (SOC) for lithium batteries . The LYNK II Communication Gateway (950-0025), available from Discover, can be used to communicate an accurate state of charge to other devices . -
Page 48: Charging
10.3 Charging Each electrical system will have different characteristics and balance-of-system components. Charger settings may require modifications to optimize system performance . NOTICE • Confirm that the charging device cannot produce transient spikes that exceed the published terminal voltage limits for the battery . • Confirm the charging curve meets the battery’s charging requirement. • Never charge a visibly damaged or frozen battery . • If the battery is stored in a cold environment, it may become frozen and may not accept a charge . -
Page 49: Charging Profile
• Low charge current extends life. Charging at 50% of nominal current or lower helps extend the battery cycle life . • Charge within the proper temperature range. Ensure that charging is within the charge temperatures specified in Table 3-4, HELIOS ESS Environmental Specifications . NOTICE •... -
Page 50: Bulk Charge
Bulk Absorption Float 100%SOC U1 Max Bulk Vdc Absorption & Balancing CURRENT I Max U2 Float Terminate at 2%-3% of I Min 200 milliamps required for battery rated capacity balancing current Figure 35. Charge Graph NOTICE • Charge with a Lithium charge profile matching the specifications of the HELIOS ESS battery . •... -
Page 51: Equalization Charge
10.4.3 Equalization Charge CAUTION FIRE AND BURN HAZARD Do not perform an equalization charge on the HELIOS ESS battery . Failure to follow these instructions may result in injury. Do not equalize charge the HELIOS ESS battery. Equalization charging is intended only for lead-acid batteries . -
Page 52: Storage
Type C port (see Figure 4 . HELIOS ESS Battery Components, Item #13) to update the battery firmware and to download data logs from the battery. LYNK II Communication Gateway devices are available from Discover dealers and distributors . Get the latest LYNK ACCESS software and battery operating firmware from the Discover website at discoverenergysys . c... -
Page 53: Troubleshooting
. If the system includes multiple batteries, download the data logs from each battery, one by one . 15. RELATED INFORMATION For warranty information, refer to 885-0098 Discover HELIOS ESS Battery Warranty Policy, available from the Discover website at discoverenergysys . c om . -
Page 54: Appendix
APPENDIX A.1 HELIOS ESS Commissioning Checklist Use this checklist to confirm the correct installation and function of the HELIOS ESS during the commissioning of the complete energy storage system . This checklist is only for the installation and operation of the HELIOS ESS . Further system-level functionality checks and tests must be performed once the full system is interconnected with the HELIOS ESS to complete commissioning . - Page 55 PROCEDURE CHECK 5 . Equipment is bonded as required per the local installation code . Verify that: ̔ A suitable-sized bonding wire is connected from the ground terminal on the battery to a marked bonding terminal . 6 . Additional disconnects and overcurrent protection required by the installation ...
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Page 56: Decommissioning Checklist
A.2 Decommissioning Checklist This checklist is only for the battery energy storage system; further system-level decommissioning procedures on the full system may be required. Refer to the manuals of connected DC loads, power conversion equipment, and other components in the system . Disassemble, Recycle, and Dispose PROCEDURE CHECK 1 . Open disconnect devices to ensure there is no electrical connection to any ...
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