Helios CUBE User manual

HELIOS CUBE
Energy Storage
System
BS4850-SH
User Manual
Lithium-Ion Battery Storage

© Copyright 2020. Helios New Energy Technology (Australia) Pty Ltd.
All rights reserved.
No part of this document may be reproduced or transmitted in any form or by
any means without prior written consent of Helios New Energy Technology
(Australia) Pty Ltd
User Manual
Energy Storage Inverter
H-BL(3600-5000) Series

Helios New Energy Technology (Australia) Pty Ltd
i
Notice
The purchased products, services and features are stipulated by the contract made between
HELIOS and the customer. All or part of the products, services and features described in this
document may not be within the purchase scope or the usage scope. Unless otherwise
specification in the contract, all statements, information, and recommendations in this
document are provided “AS IS” without warranties, guarantees or representations of any
kind, either express or implied.
The information in this document is subject to change without notice. Every effort has been
made in the preparation of this document to ensure accuracy of the contents, but all
statements, information, and recommendations in this document do not constitute a
warranty of any kind, express or implied.
Helios New Energy Technology (Australia) Pty Ltd
Address:
9 Blue Gum Road
Annangrove, NSW 2156
Australia
Telephone:
[phone]
Mobile:
[phone]
Website:
www.heliosenergystorage.com.au
E-mail:
[e-mail]

Foreword
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User Manual
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Helios New Energy Technology (Australia) Pty Ltd
FOREWORD
SUMMARIES
This document describes the mounting, installation, commissioning, configuration,
operation, troubleshooting and decommissioning of the product. The latest version of this
document can also be downloaded in PDF format at www.heliosenergystorage.com.au.
This document is intended for installers and users.
Before installing and operating the product, ensure that you are familiar with the features,
functions, and safety precautions provided in this document.
SYM BOL CONVENTIONS
The symbols in this document are intended to alert installers and users with safety matters
during installation, operation and maintenance and defined as follows.
Symbol
Description
Alerts you to a high risk hazard that could, if not avoided, result in
serious injury or death.
Alerts you to a medium or low risk hazard that could, if not avoided,
result in moderate or minor injury.
Alerts you to a potentially hazardous situation that could, if not
avoided, result in equipment damage, data loss, performance
deterioration, or unanticipated results.
Anti-static prompting.
Electric shock prompting.
Hight temperature prompting
Provides a tip that may help you solve a problem or save time.
Provides additional information to emphasize or supplement important
points in the main text.

HELIOS CUBE BS4850-SH
User Manual
Foreword
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CHANGE HISTORY
Changes between document issues are cumulative. The latest document issue contains all
the changes made in earlier issues.
VER SION 1.0 (MAY 1, 2022)
➢First issue

Contents
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CONTENTS
1. Safety Instructions .......................................................................................................................1
2. Overview........................................................................................................................................8
2.1 Product Description ......................................................................................................................................... 8
2.2 Exterior view .................................................................................................................................................... 9
2.3 Dimensions..................................................................................................................................................... 11
2.4 Technical Specification................................................................................................................................... 11
3. Installation...................................................................................................................................13
3.1 Unpacking and Checking................................................................................................................................ 13
3.2 Tools and Instruments ................................................................................................................................... 13
3.3 Installation Environment Requirements ....................................................................................................... 15
3.4 Installation Clearance .................................................................................................................................... 16
3.5 Installation Procedure.................................................................................................................................... 16
4. Commissioning and Operation...............................................................................................21
4.1 Checking before Commissioning.................................................................................................................... 21
4.2 Battery address setting.................................................................................................................................. 21
4.3 Commissioning ............................................................................................................................................... 23
4.4 Operation ....................................................................................................................................................... 23
5. Maintenance and Troubleshooting ........................................................................................26
5.1 Maintenance .................................................................................................................................................. 26
5.2 Troubleshooting ............................................................................................................................................. 26
6. Emergency Situation..................................................................................................................29

HELIOS CUBE BS4850-SH
User Manual
1. Safety Instructions
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1. SAFETY INSTRUCTIONS
This chapter contains safety instructions that must be observed at all time when working on or with the product.
To prevent personal injury and property damage and to ensure long-term operation of the product, read this
chapter carefully prior to performing installation, operations and maintenance etc.
General Safety
Only qualified persons are allowed to install, connect cables for, commission, maintain, and troubleshoot the
product, who are required to:
⚫Obtain adequate professional training.
⚫Read through this document and follow all the instructions.
⚫Be familiar with the safety specifications about the electrical system.
⚫Understand the components and working principles of the grid-tied PV system and local regulations.
⚫Wear proper personal protective equipment (PPE).
⚫If the batteries are stored for a long time, it is required to charge them every six months, and the SOC
should be no less than 10%.
⚫The batteries should be recharged within 12 hours, after fully discharged.
⚫All the batteries must be disconnected by pulling out them from the cabinet for maintenance.
⚫Do not expose the batteries to flammable or harsh chemicals or vapors.
⚫Do not connect the batteries with PV solar wiring directly.
⚫Do not paint any part of the batteries including any internal or external components.
HELIOS will not be liable for any consequence caused by the violation of the safety operation regulations and
design, production, and usage standards.
The "DANGER", "WARNING", "CAUTION", “TIP” and "NOTE" marks in this document do not represent all the
safety instructions. They are only supplements to the safety instructions.
Danger to life due to electric shock. The product operates at high voltages with multiple channel power
suppliers. Prior to performing any work on the product, disconnect the product from voltage sources. All work
on the product must be carried out by qualified persons only.

1. Safety Instructions
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⚫Some parts of the enclosure can get hot (up to 60℃) during operation.
⚫Mount the product in such a way that it cannot be touched inadvertently during operation.
⚫No liquid or other objects are allowed to enter the product.
⚫If the product is dirty, clean the enclosure, the enclosure lid, the type label and the LEDs using only clean
water and a cloth. The use of cleaning agent may cause damage to the product.
⚫Prior to performing any work on the product, please turn off the battery DC breaker and then wait for 5
minutes.
⚫Before installing or operating the product, please check that there is no damage or other potential danger
in the product visually.
⚫Check the connections with other external devices are in order and safe.
⚫Do not touch non-insulated cable ends.
⚫Do not touch any live components.
⚫Have the product mounted, installed and commissioned only by qualified persons with the appropriate
skills.
⚫If an error occurs, have it rectified by qualified persons only.
⚫In case of fire, please use dry power fire extinguisher. A liquid fire extinguisher may cause electric shock.
⚫Short-circuit currents in the batteries can cause heat build-up and electric arcs which may result in burns
or eye injuries.
⚫Remove watches, rings and other metal objects.
⚫Use insulated tools.
⚫Wear proper personal protective equipment (PPE)
⚫Do not place tools or metal parts on the product

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User Manual
1. Safety Instructions
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Device Labels
⚫The labels on the device contain important information about safety operation. Don't tear them off or
damage them.
Pay attention to the labels on the device which are explained in Table 1-1.
Table 1-1 Explanation of the device labels
Label
Explanation
CE marking. The product complies with the requirements of the applicable
EU directives.
Intertek marking. The product has passed the Intertek test.
SAA marking. The product has obtained the SAA approval.
Australian Compliance marking.
Don't dispose with general garbage. Recycle them by special method.
Read the user manual when using the device.
Wait for 5 minutes to discharge completely after powering the device off.
Hot surface. Don't touch!
Caution!
Be careful of electric shock.

1. Safety Instructions
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Label
Explanation
External grounding label.
⚫There exists dangerous voltage between the positive and negative ports of the batteries.
⚫When installing the product, it must be disconnected from any AC or DC sources completely. Place a
warning mark here to avoid reconnecting.
Electrostatic Damage Protection
⚫To prevent human electrostatic damage (ESD), make sure that you wear an anti-static wrist strap before
touching sensitive components and the other end is well grounded.
Grounding Requirements
⚫The device must be grounded before performing electrical connection. The grounding terminal must be
connected to the ground.
⚫When installing the product, it must be grounded first. When dismantling the product, the grounding wire
must be removed at last.
⚫Don't damage the grounding conductor;
⚫The product should be connected to PE (protection earth) permanently. Before operation, the electrical
connection should be checked to ensure the product is grounded reliably
.

HELIOS CUBE BS4850-SH
User Manual
1. Safety Instructions
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Moisture Proof Protection
⚫Moisture invasion may cause damage to the product.
⚫In the wet or damp weather or when the air humidity is more than 95%, don't open the facade of the
product.
Warning Sign Setting
In order to prevent unwanted persons from getting close to the product or carrying out improper operation, you
should observe the following requirements when performing installation, maintenance or repair.
⚫Place “NO TURN ON” warning signs where the switches are located.
⚫Place safety warning signs or safety warning ribbons in the operation area.
Electrical Connection
1) Electrical connection must be performed according to the description and the electrical circuit schematic in
this document.
2) After unpacking, please check product and packing list first, if product is damaged or lack of parts, please
contact with the local retailer.
3) Before installation, be sure to cut off the grid power and make sure the batteries are turned off.
4) Wiring must be correct, do not mistake the positive and negative cables, and ensure no short circuit with the
external device.
5) It is prohibited to connect the battery and AC power directly.
6) It is prohibited to connect the batteries with different type of batteries.
7) It is prohibited to put the batteries working with faulty or incompatible inverter.
8) The embedded BMS in the batteries is designed for 48VDC, please DO NOT connect battery in series.
9) Battery system must be well grounded and the resistance must be less than 1Ω.

1. Safety Instructions
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10) Please ensured the electrical parameters of the battery system are compatible to related equipment.
11) Keep the batteries away from water and fire.
Operation
⚫High voltage may cause an electric shock, which results in serious injury, death, or serious property
damage from the product in operation.
⚫Strictly comply with the safety instructions in this document and associated documents when
operating the product.
⚫When the product is powered on for the first time, only qualified persons are allowed to perform quick
setting. Incorrect settings may affect the normal operation and cause conflicts with the country
certification.
⚫When the product is operating, do not disconnect under load.
⚫Follow local laws and regulations when operating the product. It is prohibited to disassemble the
batteries.
⚫Please do not open, repair or disassemble the batteries except staff from HELIOS or authorized by
HELIOS.
Maintenance and replacement
⚫High voltage may cause an electric shock, which results in serious injury, death, or serious property
damage from the product in operation. Prior to maintenance, power off the inverter and strictly
comply with the safety precautions in this document and associated documents to operate the
product.
⚫Maintain the product with sufficient knowledge of this document, proper tools, and testing equipment.

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User Manual
1. Safety Instructions
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⚫Before performing maintenance tasks, power off the product and wait at least 5 minutes.
⚫Temporary warning signs or fences must be placed to prevent unauthorized people from entering the
site.
⚫If the product is faulty, contact your supplier.
⚫The product can be powered on only after all faults are rectified. Failing to do so may escalate faults or
damage the product.
⚫Observe ESD precautions and wear ESD gloves during maintenance
Operation Environment
The operation environment may influence the life span and reliability of the product. Please don’t use the
product in the following environment:
⚫Places where temperature and humidity are beyond the technical specifications.
⚫Moving places.

2. Overview
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2. OVERVIEW
2.1 PRO DUCT DESCRI PTIO N
The HELIOS CUBE BS4850-SH is a low voltage (48V) battery storage system (BS). As shown in Figure 2-1, the
system consists of battery modules (2.56 kWh of capacity each) and an IP65 cabinet which also incorporate a
large space for installing inverters or AC chargers at the upper partition. At maximum 7 battery modules can be
installed to provide 17.92 kWh capacity in total. The hot-swap feature of the system makes installation very easy
and safe (plug-and-play). The lithium iron phosphate batteries feature a long-life cycle, safety and reliability. The
built-in BMS battery management system can manage and monitor the operations of the battery cells including
voltage, current and temperature and prevent the battery cells from over-charging or -discharging to extend the
battery life cycle.
Figure 2-1 Picture of the battery storage system.
Features
⚫Hot-swap (plug-and-play): easy to install and safe to operate by avoiding complex wiring which may cause
mis-connections.
⚫Built-in DC breaker.

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User Manual
2. Overview
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⚫The IP65 cabinet allows to install the batteries and inverters outdoor.
⚫Multiple outlets at back and both sides are designed for flexible installation.
⚫The battery management system (BMS) has protection functions including over-discharge, over-charge,
under-voltage, over-current and high/low temperature.
⚫The BMS can automatically manage charge and discharge state and balance the current and voltage of each
cells.
⚫The 10A current limitation function prevents current circulation between the battery modules.
⚫Flexible configuration, multiple battery modules can be in parallel for expanding capacity and power.
⚫The natural cooling design reduces the system overall noise.
⚫The module has less self-discharge, up to 6 months without charging it on shelf, no memory effect,
excellent performance of shallow charge and discharge.
⚫Wide operating temperature range between 0 to 45oC.
⚫Excellent discharge performance and cycle life.
2.2 EXT ERI O R VIEW
The exterior view of the HELIOS BS4850-SH battery module is shown in Figure 2-2.
Figure 2-2 Exterior view of the HELIOS BS4850-SH battery module
Figure 2-3 shows the front view of the HELIOS BS4850-SH battery module with an explanation of the functions of
various indicators and connection ports Table 2-1.
Handle

2. Overview
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Figure 2-3 Front and back views of the HELIOS BS4850-SH battery module
Table 2-1 Explanation of the connection port symbols
No.
Indicator/Port
Function
1
SOC (status of charge)
Green light showing status of charge of the battery
2
Alarm
Red light indicates there is a fault in the battery
3
Run
Green light indicates the battery is in normal operation.
4
Reset
Keep pushing this button for 3 seconds to reset the BMS
Keep pushing this button for 6 seconds to switch on/off the
battery
5
ADD
4ADD switches (Dip1, 2, 3, 4) to define a mater battery and slave
batteries. A master battery can manage up to 15 slave batteries.
To set a correct address for each battery module, please refer to
chapter XX.
6
RG45
Communication port to connect with external devices e.g. PC for
upgrading the BMS software
7
Switch
To turn on/off the battery
8
RS485
Communication terminal to connect the battery modules and
BMS
9
48V port
DC input/output terminal

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User Manual
2. Overview
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2.3 DIM ENSI ONS
Figure 2-4 Dimension of the battery module
Figure 2-5 Dimension of the battery cabinet
2.4 TEC HNICAL SPEC I FICATION
The technical specification of the HELIOS BS4850-SH battery storage system is shown in Table 2-2.

2. Overview
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Table 2-2 Technical specification
HELIOS CUBE Pre-assembled Battery System MODEL
BS4850-SH
Rated voltage Vdc 51.2
Recommended charge voltage Vdc 56-57
Maximum charge voltage Vdc 58.4
Under-voltage protection Vdc 40
Maximum charge current A50
Recommended charge current A10-20
Maximum discharge current A60
Recommended discharge current A10-25
Depth of discharge %>90
Chemistry Lithium
Rated voltage Vdc 51.2
Rated capacity (@25°C and >0.1C C/D power) kWh 2.56
Usable capacity (@25°C and >0.1C C/D power) kWh 2.3
Life cycle @DOD=90% >4000
Operating temperature range
°C0 - 45
Dimension (LxWxH) mm 450x443.5x132.5
Weigth kg 32
Communication protocol RS485, RS232
Number of battery modules 7
Max. rated capacity (@25°C and >0.1C C/D power) kWh 17.92
Max. usable capacity (@25°C and >0.1C C/D power) kWh 16.13
Dimension (WxDxH) mm 600/670/1380
Weight (excluding batteries) kg 70
IP grade IP65
Cooling Natural air cooling
Limited warranty 5 years
WARRANTY
CHARGE AND DISCHARGE DATA
IEC/AS62040.1:2019, IEC 62619: 2017, IEC 60730-1:2013, IEC 60730-1:2013/AMD1:2015
BATTERY MODULE
BATTERY CABIN
STANDARDS AND COMPLIANCE

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3. Installation
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3. INS TAL LAT ION
3.1 UNPACKI NG AND CHECKIN G
Before unpacking the HELIOS CUBE BS4850-SH product, check the outer packing materials for damage, such as
holes and cracks, and check the model sticker. If any damage is found or the model is not what you requested, do
not unpack the package and contact your supplier as soon as possible.
After unpacking the product, check the packing list provided with the product to see if the types of accessories
are complete and correct. In case of any discrepancy, contact your supplier immediately.
3.2 TOO LS AND INSTR U MENTS
Table 3-1 Tools and Instrument for Installation
Tool
Appearance
Description
Clamp-on
ammeter
Measure current
Multimeter
Used to check cabinet insulation and cable
connection, and measure electronic
performance specifications of a device, such
as voltage, current, and resistance.
Label paper
Used to prepare labels.
Phillips
screwdriver
Used to tighten screws and bolts.
Slotted
screwdriver
Connect cable, fasten screw
Socket wrench
Used to tighten bolts and nuts.
Adjustable
spanner
Fasten bolt
Torque wrench
Fasten bolt