Duracell D-HUB User manual

Model: D-HUB
INSTALLATION MANUAL
For use with the DURACELL PO ER CENTER 5KW

Revision History
Revision
Date
Status
Author
Comments
08/30/2022 Ian Grover
Released
01
05/01/2022 Initial
n/a
Ian Grover
02 04/05/2023 Released Ian Grover Removed TP-Link Kit

IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions for the DURACELL HUB as part of a complete home energy
storage system. The DURACELL Hub is a peripheral of the DURACELL PO ER CENTER 5K energy storage
system. The energy storage system will be referred to as the ESS throughout this manual.
CAUTION: Hazardous Voltages! This product contains hazardous voltage and energy that may be lethal. It
may only be installed by qualified personnel who have read this manual and are familiar with its operation and
hazards. The following safety procedures should be followed:
Only connect the DURACELL HUB to a compatible electrical service as defined in the model specifications.
Ensure proper electrical grounding in accordance with code requirements.
Ensure proper airflow path for active cooling.
Never operate system in a manner not described by this manual.
Only qualified personnel should service this product.
Ensure cover is securely fastened after installation is complete.
Do not attempt to operate this product if there is any physical evidence of damage to the enclosure or internal
components.
CAUTION! This product contains an AGM lead acid battery. This product must be stored indoors in an
environmentally conditioned location prior to installation, protected from rain and exposure to any hazardous
chemicals. Inspect the battery case prior to installation. Do not install and power the product if there appears
to be damage to the battery and contact your local product distributor.
Do not dispose of the system or any of the components within the cabinet. Batteries, electronics, cables, and
metal parts are recyclable. Consult your municipal waste management authority to determine required
methods of component recycling.
California Proposition 65
WARNIN ! This product can expose you to chemicals including bis (2-ethylhex-yl)phthalate, which is known to
the State of California to cause birth defects or other reproductive harm. For more information go to
https://www.p65warnings.ca.gov/.

Contents
1 INTRODUCTION .................................................................................................................... 1
1.1 ABOUT THIS MANUAL –SUPPORTING DOCUMENTS........................................................................................................1
1.2 GLOSSARY..............................................................................................................................................................1
1.3 INITIAL INSPECTION OF MATERIAL LIST .......................................................................................................................1
1.4 SPECIAL TOOLS &HARDWARE ..................................................................................................................................2
1.5 FUNCTIONAL OVERVIEW ...........................................................................................................................................2
1.5.1 Grid Connected Solar plus Storage ........................................................................................ 2
1.5.2 Backup Solar plus Storage ................................................................................................... 3
1.5.3 Backup Solar PV curtailment method: Frequency Shift Power Control (FSPC)............................... 3
1.5.4 Circuit and system sizing for 100 / 125 / 150 Amp electrical panels ............................................. 3
1.5.5 Circuit and system sizing for 200+ Amp electrical panels .......................................................... 3
1.5.6 Over-sized PV systems ....................................................................................................... 3
1.6 INTERNAL COMPONENT OVERVIEW ............................................................................................................................4
1.6.1: Energy management controller (EMC) ................................................................................. 4
2 INSTALLATION PLANNIN ....................................................................................................... 5
2.1 INSTALLATION CLEARANCES BETWEEN THE DURACELL HUB AND THE BATTERY SYSTEM ..............................................5
2.2 INSTALLATION CONDUIT PLAN –POWER AND COMMUNICATION CIRCUITS.........................................................................6
2.3 SLD -AC COUPLED PV SYSTEM WITH BACK-UP POWER OPERATION...........................................................................7
3 INSTALLATION INSTRUCTIONS ................................................................................................ 8
4 ELECTRICAL WIRIN INSTRUCTIONS ......................................................................................... 8
4.1 EMC CABLE CONNECTION .......................................................................................................................................8
4.2 AK1 CABLE CONNECTION.........................................................................................................................................8
4.3 AC POWER CONNECTIONS .......................................................................................................................................8
4.3.1 Phase Orientation in Split Phase 120/240 Systems ................................................................... 9
4.3.2 Main Electrical Panel Connection ......................................................................................... 9
4.3.3 Backup Panel Connection .................................................................................................. 10
4.3.4 ESS: PCS Grid Port Connection ........................................................................................... 10
4.3.5 ESS: PCS Load Port Connection .......................................................................................... 10
4.4 CTCONNECTIONS .................................................................................................................................................11
4.4.1 Main Electrical Panel CT Connections .................................................................................. 11
4.4.2 Solar PV CT Connection ..................................................................................................... 11
4.4.3 PCS CT Connections ......................................................................................................... 11
4.5 12V BACKUP BATTERY CONNECTION.......................................................................................................................11
5 OPERATION ........................................................................................................................ 12
5.1 EMC SELECTOR SWITCH ........................................................................................................................................12
5.2 PRE-STARTUP CHECKLIST....................................................................................................................................... 12
5.3 STARTUP ..............................................................................................................................................................12
5.4 POST-STARTUP CHECKLIST .....................................................................................................................................12
5.5 PERMISSION TO OPERATE CHECKLIST....................................................................................................................... 13
6 MAINTENANCE .................................................................................................................... 13
7 TROUBLESHOOTIN ............................................................................................................. 13
8 TECHNICAL DATA ............................................................................................................... 14
8.1 ELECTRICAL SPECIFICATIONS ..................................................................................................................................14
8.2WIRE AND TORQUE RATINGS ...................................................................................................................................14
APPENDIX A: ELECTRICAL BLOCK DIA RAM OF INTERNAL COMPONENTS ............................................ 15
APPENDIX B: MULTI-MODE TRANSFER / BYPASS RELAY OPERATION ................................................... 16
KX:DURACELL HUB BYPASS /TRANSFER RELAY......................................................................................................... 16
K3: PCS TRANSFER RELAY ..........................................................................................................................................16
K1: PCS ISLANDING RELAY .......................................................................................................................................... 17
PCS AND HUB RELAY STATE MAP..................................................................................................................................17
BACKUP SUPPLY INTERRUPTION PERIOD DURING GRID OUTAGE /RETURN TO GRID ..............................................................17
APPENDIX C: INTERNET CONNECTION OPTIONS ...........................................................................18
C.
1HARD-WIRED ETHERNET........................................................................................................................................18

1
1 Introduction
Throughout this manual, the following symbols will be used to highlight important information and procedures:
Symbol
Definition
Symbol
Definition
WARNIN ! A dangerous voltage or other
condition exists. Use extreme caution when
performing these tasks.
Function performed by energy
management system / controller.
CAUTION! This information is critical to the safe
installation and or operation of the product.
Follow these instructions closely.
NOTE: This statement is important.
Follow instructions closely.
1.1 About this manual – supporting documents
This manual is intended to be used by qualified service and installation personnel for the purposes of installation
and startup only. The DURACELL HUB energy management system & gateway requires installer administration and
device commissioning prior to operation of the ESS. Refer to the Fleet Installer Administration Guide and the
DURACELL HUB Install & Commission Quick Guide for further details.
This product is permanently wired to the home electrical service, and must be installed by a licensed electrician
only. This product is a power distribution peripheral intended to be operated with the ESS. Refer to the DURACELL
PO ER CENTER 5K Installation & Startup Manual for installation of the ESS.
Go to www.duracellpowercenter.com for a complete list of installer resource materials.
1.2 Glossary
1.3 Initial Inspection of Material List
The system components supplied with the
DURACELL HUB are shown below. Each
component should be inspected visually for any
damage that may have been caused by
shipment. If parts are missing or damaged,
please contact your local distributor.
Term Definition Term Definition
AC / DC Alternating Current / Direct Current NC/NO Normally Closed / Normally Open
AHJ Authority Having Jurisdiction NEC/CEC National (USA) Electric Code / Canadian Electric Code
ARC Auto Recovery Control PCS Power Control System (Inverter)
DC Direct Current PE (GND) Protective Earth
EMC Energy Management Controller PV Photo-Voltaic
EMS Energy Management System RF Radio Frequency
ESS Energy Storage System SOC State Of Charge (Battery)
LED Light Emitting Diode SOH State of Health (Battery)
Item Description
1 EMS-A DURACELL HUB
2 Current transformer – 200 Amp
3 Current transformer – 50 Amp
4 EMS to PCS RJ-45 cable
5 AK1 DURACELL HUB control cable
6 USB to Mini-USB service cable
(x2)
(x3)
2
3
4
6
5
1
EMS
Figure
1
: DURACELL HUB materials list.

2
1.4 Special Tools & Hardware
In addition to the standard tools required for enclosure mounting, the following tools should be readily available to
complete the installation.
•Drill and hole saw kit
•RJ-45 crimp tool and RJ-45 connectors
•all mounting hardware.
•#0 flat screwdriver.
•
1.5 Functional Overview
The DURACELL HUB is equipped to support an AC coupled solar plus storage installation with backup power to a
dedicated backup electrical panel. The DURACELL HUB is a power distribution center for the ESS, routing all AC power
between the main and backup electrical panels. In the event of a grid outage, the DURACELL HUB will be energized
by the ESS, which will island off the main electrical panel. As shown below, the PV inverter’s AC output is connected
to the backup panel to support solar charging of the battery during a grid outage.
Figure 2: DURACELL HUB with DURACELL PO ER CENTER 5K .
1.5.1 Grid Connected Solar plus
Storage
The DURACELL HUB routes power from the main
electrical panel to the backup panel through the ESS
Grid/Load transfer circuit when the grid is live and
the battery system is in service (normal operation).
The EMC commands the battery system to charge or
discharge the battery as demanded by the energy
management algorithm. In a self-consumption
algorithm, for example, the EMC calculates the
difference in total load vs. solar PV, and routes the
balance of power to/from the battery as needed.
hen the battery is full, PV power bypasses the
battery to grid/loads. hen the battery is at
minimum reserve, all home loads are supplied
entirely by the grid. The following diagram
outlines the power flow possibilities while grid
connected.
Note: The DURACELL HUB is equipped with an internal automatic bypass switch which provides uninterrupted
service to the backup electrical panel when the ESS is either not powered (installed but pending permission to
operate) or out of service.
PV
Inverter
PV panels
Grid
Load
power
Home
Internet
Service
CT
Main
Panel
Backup
Panel
Home loads
Home loads
to grid
PV
Inverter
PV panels
Grid
Load
Main
Panel
Backup
Panel
H
ome
loads
Home loads
Figure
3
: Grid connected solar plus storage.
communication
ethernet

3
1.5.2 Backup Solar plus Storage
During a grid outage, the DURACELL HUB isolates the battery
system and backup electrical panel from the grid. In this mode, the
EMC is in a monitoring state, with most control handed over to the
ESS. The ESS curtails PV when the battery is either full or exceeds
the charge limit of the battery. On low SOC, the battery system
goes into a standby state until either the solar resource or the grid
returns.
IMPORTANT! Shutting off the DURACELL HUB circuit breaker at the
main electrical panel will place the ESS into backup mode and
continue to energize the backup panel.
1.5.3 Backup Solar PV curtailment method:
Frequency Shift Power Control (FSPC)
During backup power operation of the ESS, PV curtailment is achieved by shifting the frequency up or down to trip
the PV inverter. This curtailment method, defined as frequency shift power control (FSPC), is required to prevent
solar from over-charging the battery. By default, the ESS will ramp up frequency to a PV trip range of 62.1 Hz, but
this is adjustable depending on the regulatory frequency trip limits within the jurisdiction.
IMPORTANT! PV inverters connected to the backup panel must have frequency trip settings programmed within the
following ranges: PV low frequency trip range: 57.0 to 59.3 Hz, PV high frequency trip range: 60.5 to 62.0 Hz.
If the PV inverter cannot be adjusted within the range specified, the PV inverter must not be connected to the backup
panel.
NOTE: The DURACELL HUB is not suitable for use in applications where the electric utility prohibits PV power export
to the grid. For non-export applications, consult your DURACELL PO ER CENTER 5K dealer for alternate EMS
panel solutions.
1.5.4 Circuit and system sizing for 100 / 125 / 150 Amp electrical panels
Line side tapping the main electrical panel is required for ESS installations where the electrical service rating is under
200 Amp. Refer to section 2.3, figure 11.
1.5.5 Circuit and system sizing for 200+ Amp electrical panels
The DURACELL HUB may be connected to a 200+ Amp electrical panel using a single 40A breaker. For this
configuration, the total solar PV output connected to the backup electrical panel will depend on the curtailment
features of the solar PV inverter. If the PV inverter is equipped with its own curtailment controls that can limit PV
output to 5k or less in backup mode, the maximum rating of the PV inverter connected to the DURACELL HUB is 7.6
k AC. For PV inverters without internal curtailment methods, the 5 k PV restriction applies. Regardless of PV
size, this configuration permits the DURACELL HUB EMS to limit continuous combined solar plus storage output to 7.6
k AC (32 Amp).
1.5.6 Over-sized PV systems
For installations with PV systems that are
larger than the DURACELL HUB and ESS can
accommodate, the PV inverters must be split
up such that the balance of PV is wired directly
to the main electrical panel.
NOTE: An additional CT must be added to the
main panel connected PV inverter.
PV
Inverter
Load
Home
loads
Backup
Panel
PV
Inverter
PV panels
Grid
Load
Main
Panel
Backup
Panel
Home
loads
Home loads
PV
Inverter
Excess
PV
PV panels
Figure 4: Backup solar plus storage.
Figure 5: Over-sized PV systems connected to main panel.
PV panels

4
1.6 Internal Component Overview
The DURACELL HUB is equipped the following components as identified in the diagram below:
Figure 6: DURACELL HUB internal component overview.
1.6.1: Energy management controller (EMC)
IMPORTANT! The device unique identifier (UID) & serial number (S/N) tag attached to the front of the EMC is required
to register the device to the cloud so that it may be monitored via the Fleet Installer monitoring system. Record this
information for online registration.
The EMC performs the following functions:
•Commands the battery system to charge and discharge as defined by the selected control algorithm.
•Monitors the home loads, solar PV, and battery power via on-board 8 channel power meter.
•Provides the Internet gateway to customer supplied internet router via wired Ethernet.
A 12V AGM UPS backup battery supplies uninterrupted power to the EMC.
Figure 7: EMC feature overview – rev1 EMC faceplate label.
Web config tool
Service port
(mini-USB)
8 channel
power meter
12V AG
Backup battery
Ethernet to
Internet router
(or to a Wi-Fi
range extender)

5
2 Installation Planning
Before installing the DURACELL HUB, read all instructions and warnings in this manual. The DURACELL HUB can be
installed in an indoor and outdoor non-corrosive environment (not marine environment). all mounting hardware
is not included.
CAUTION! All electrical installation work should be performed in accordance with local building and electrical
codes.
WARNIN ! Isolate the DURACELL HUB from all energy sources prior to electrical installation by means of
disconnects, breakers or connectors. Failure to properly isolate either AC or DC sources may result in serious injury
or death.
NOTE: Communication cables between the DURACELL HUB and the battery system are limited in length. The
DURACELL HUB should be installed within 2 ft of the battery system.
CAUTION! Do not install in direct sunlight.
2.1 Installation clearances between the DURACELL HUB and the battery system
The DURACELL HUB includes a 10 foot communication cable that connects the hub to the battery system. If the
installation is constrained such that the DURACELL HUB must be located greater than 24” from the battery system,
consult the DURACELL PO ER CENTER 5K Installation & Startup Manual for instructions on creating an extended
communication cable.
Figure 8: Installation clearances between the DURACELL HUB and the ESS.
Max: 24”
(600 mm)

6
2.2 Installation conduit plan – power and communication circuits
The following example outlines the conduit plan for power and communication circuits for a complete solar plus
storage system using the DURACELL HUB and the DURACELL PO ER CENTER 5K . (String PV inverter shown –
replace with equivalent AC combined micro-inverter output, where applicable).
Table 1: Circuit summary for a solar plus storage installation.
Conduit
Ref Circuit Definition
Conductor
(recommended) Circuit Protection
P1 ESS grid power 8/3 40 Amp
P2 ESS backup power 8/3 40 Amp
P3 Main panel power 8/3 40 Amp
P4 Backup panel 8/3
40 Amp feeder if total backup ccts exceed 40
Amp/240V rating
P5 Solar PV power 8/3 40 Amp
S1
EMS communication cable
3 meter patch cable included
CAT 5/6 STP -
S2 (x2) CT , 50 Amp 8 ft pigtail 18/2, 300V
-1
-
S3
AK1 Hub Control Signal cable
harness included , 10 ft 18/2, 300V -
S4 (x2) CT, 200 Amp 8ft pigtail 18/2, 300V
-1
-
S5 CT , 50 Amp 8 ft pigtail 18/2, 300V
-1
-
Note 1: Conductor type referenced where Hub is installed greater than 24” from the ESS. Signal wiring routed in
conduit with power must be 300V rated. For runs longer than 10 meters, signal separation from power is
recommended to minimize signal interference.
Disclaimer:
Manufacturer supplied components represented here are limited to the PCS/Battery, DURACELL HUB, and CTs for PV, battery, and
mains. All other materials and components represented are customer supplied. CEC/NEC electrical code compliance is the
responsibility of the designer and/or electrical permit holder. Source circuit disconnects for PV and ESS grid/load ports not shown.
CT home
CT 50A: (2x)
Figure 9: Installation conduit plan for a solar plus storage installation (base model shown).