PowerPlus Energy Eco P Series User manual

Installation and Operation
Manual
Eco P Series Installation Manual V3.0
21/10/2021 Page of1 37
Eco P Series Lithium Battery
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1. Introduction
The Eco P Series Lithium Ferro Phosphate (LFP) battery by PowerPlus Energy is designed and
manufactured in Australia for the world’s harshest conditions to be a simple, flexible and reliable energy
storage solution.
As a result, the Eco P Series batteries can be easily installed with most Inverter and charger combinations,
UPS, rectifiers, DC or AC coupled charging devices, on-grid and off-grid in single, dual or three phase
applications.
There is almost no limitations in applications and suitable devices that can charge or discharge the Eco P
Series battery.
The Eco P Series battery is available in 48V.
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1. Introduction 2
2. Safety 5
2.1. Transportation 5
2.2. Basic Safety 6
2.3. Handling 6
2.4. Storage of Battery 6
2.5. LiFe Support 6
2.6. Damaged Battery 7
2.7. Fire 7
2.8. Qualified Person (Installer) 7
3. Product Information 8
3.1. Weight and Dimensions 8
3.2. Inclusions 8
3.3. Specifications 9
3.3.1. Eco P Series 9
3.4. Charging and Discharging 10
3.4.1. Primary Charging Source 10
3.4.2. Secondary Charging Source 10
3.4.3. Calibration to 100% 10
3.4.4. Battery Charging Requirements PCE for P Series 11
3.4.5. Charging Curves P Series 12
3.4.6. Discharging Curves P Series 13
3.4.7. State of Charge Vs Discharge Voltage P Series 14
3.4.8. Over Discharged battery 14
3.4.9. Circuit Breaker Characteristic 15
4. Installation 16
4.1. Location and Environment 16
4.1.1. Extreme Humidity Climates 16
4.2. Battery Installation 17
4.2.1. Custom Cabinets 17
4.2.2. Battery Orientation Stationary Application 18
4.2.3. Battery Orientation Pre-Assembled BESS or BS Systems 18
4.2.4. Battery Orientation Motorhomes, RV’s, Trailers, Vehicles, Trucks, Buses or Similar 18
4.3. Battery Connections 19
4.4. Main DC Connections 19
4.5. Case Earthing 20
4.6. Battery Alarm and Communication Installation 21
4.6.1. Data Logging 22
5. PowerPlus Energy Battery Enclosures 23
5.1. Rack Series Enclosures 23
5.1.1. Rack Series Specification 23
5.1.2. Rack Series Enclosure Installation 24
5.2. SlimLine Series Enclosures 25
5.2.1. SlimLine Series Specification 25
5.2.2. PEW3 & PEW4 Installation 26
5.2.3. PEF6W-250B Installation 27
5.2.4. PEF9W-250 Installation 28
6. Battery Operation 29
6.1. Main Status LED 29
6.2. Battery Power up / Shut Down Procedure 30
6.2.1. Battery Startup 30
6.2.2. Battery Shut Down 31
6.3. Full Recharge Upon First Installation 32
6.4. Calibration to 100% (Weekly recharge to 100%) 32
6.5. SoC (State of Charge) Drift 32
7. Troubleshooting 33
7.1. Over Discharged Battery Recovery 33
7.1.2. BMS Threshold Soft Shutdown 33
7.1.3. Soft Shutdown Recovery 33
7.1.3. BMS Threshold Hard Shutdown 34
7.1.4. Hard Shutdown Recovery 34
8. Maintenance 35
9. Upgrading Battery Capacity 35
10. Capacity Testing Battery 36
11. End of Life 37
12. Warranty 37
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2. Safety
Installers and users are responsible for familiarising themselves with this manual.
The Eco P Series batteries use high grade cylindrical Lithium Ferro Phosphate (LFP) cells which are robust
and reliable in higher ambient temperatures, have a long service life and contain no heavy metals and are
mostly recyclable.
Each Eco P Series battery has an internal Battery Management System (BMS) that provides protection
against over and under voltage, over current, over temperature, short circuit and provides reliable service
life through managing cell string balancing.
Each battery has a 2 pole non polarised K Curve circuit breaker, status indicator light, volt free alarm
contact and high quality Amphenol SurLok DC connections for safe and easy installation.
Installation should carried out by a suitably qualified and experienced person who can specify the correct
cables, DC bus arrangement, external circuit protection, polarity checking and suitability of the design for
the installation according to all necessary local/international standards and requirements within this manual.
2.1. Transportation
PowerPlus Energy’s Eco Series Lithium Ferro Phosphate Batteries are classed as Dangerous Goods
(DG) Class 9 UN3480.
They are safe for road transport. The batteries are shipped in a partially discharged state with terminal
protection and the circuit breaker off.
Batteries where possible, should be shipped in the original manufacturer’s packaging, positioned
horizontally and secured to a pallet. Batteries should not be stacked more than 6 batteries tall or shipped
vertically.
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2.2. Basic Safety
The following precautions should be observed:
•Battery should not be exposed to temperatures above or below the temperature ratings specified within
this manual.
•Battery should not be installed in direct sunlight.
•Battery should not be exposed to strong impacts.
•Battery should not be crushed or punctured.
•Battery connectors should not touch conductive surfaces unless intended to do so.
•Battery is non-user serviceable and should not be opened for repair.
•Battery has no maintainable components and is should not be disassembled.
•Battery should not be touched if wet.
•Battery should be kept dry at all times.
•Battery should be kept away from animals and children.
•Battery pack should not be exposed to pressure, or have objects stood on top of them.
•Battery pack is intended to be a 2 person lift when installing.
2.3. Handling
•Use battery only as directed.
•The batteries are heavy and proper lifting techniques or equipment should be applied.
•Do not use the battery if it appears damaged or broken.
•Handle battery with care when installing or transporting.
•Do not use chemicals to clean the battery.
•Do not touch the DC terminals.
•Do not touch the DC Busbar.
2.4. Storage of Battery
•Battery should be stored horizontally and stacked no more than 6 batteries tall without extra support.
•Battery should be kept in a dry environment away from moisture.
•Battery should be stored away from incompatible substances.
•Battery should be stored between 0 to 45°C, however close to 25°C should be considered for long term
storage.
•After 6 months of storage the battery may need cell balancing and should be charged. Any issues with
charging after long term storage should be discussed with PowerPlus Energy.
2.5. LiFe Support
Our batteries should not be used in life support applications where failure of our Eco Batteries can
reasonably be expected to cause failure of the life support equipment or effect operation of such
equipment.
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2.6. Damaged Battery
A damaged battery should not be used and should be returned to PowerPlus Energy or disposed of via a
recycling facility. Leaking electrolyte can cause skin irritation and chemical burns, so contact should be
avoided.
Eye Contact: Rinse gently with running water and seek medical attention if irritation develops.
Skin Contact: Rinse gently with running water and seek medical attention if irritation develops.
Ingestion: If ingested, do not induce vomiting and contact you local poisons information centre or
doctor.
Inhalation: Evacuate area and seek professional medical attention immediately.
Refer to product SDS document for more details which is available from PowerPlus Energy’s web page or
upon request.
2.7. Fire
Should the battery pack catch on fire or start to emit smoke, (for small fire or small emissions of
smoke) use water spray, dry chemical, carbon dioxide or chemical fire extinguisher.
Evacuate the area and call emergency services.
Some toxic gases may be produced if the battery catches fire.
The battery needs to be rapidly cooled to prevent any heat or fire spreading.
Refer to product SDS document for more details which is available from PowerPlus Energy’s web page or
upon request.
2.8. Qualified Person (Installer)
This manual and task sets within regarding installation should be carried our by a suitable qualified and
skilled person.
The installer needs to be a person with adequate skills, qualifications and experience.
They should:
•Have a thorough understanding of operations, design and installation principles of battery energy storage
systems.
•Have a thorough understanding of all dangers and risks associated with installing and using electrical
devices.
•Hold all local, state and country base qualifications to carry out such work.
•Adhere to all safety and installations requirements within this manual.
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3. Product Information
The technical information presented here within, outlines the physical and electrical characteristics of the
battery and what environment they should be installed in.
The Eco P Series batteries are self-managed with an internal BMS within each battery to protect it from over
voltage, under voltage, over temperature and over current.
The Battery does not require communication with the Power Control Electronics (PCEs) to operate. The Eco
P Series can operate with PCE (Power Control Electronics) that do not require communications to operate.
If you are unsure, please consult your PowerPlus Energy expert or the PowerPlus Energy web page for
advice.
3.1. Weight and Dimensions
3.2. Inclusions
Each battery comes supplied in a cardboard box that should be retained in case there is a need to return
the battery to PowerPlus Energy. All batteries except those supplied with as PowerPlus Energy cabinet will
come supplied separately with corresponding DC connectors. All other accessories are sold separately.
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Eco4840P
Depth
635mm
Width
434mm
Height
88mm
Weight
43kg
DC Connector
Positive DC connection
1 x SLPPA16BSR
Negative DC Connection
1 x SLPPA16BSB
25mm to 16mm reducer
x 2

3.3. Specifications
3.3.1. Eco P Series
Eco4840P
Nominal DC Voltage
51.2V
Operational Voltage Window
40V to 58.4V
Nominal Capacity
4.0kWh (3.993) / 78Ah
Usable Capacity
4.0kWh (3.993)
Recommended Usable Capacity
3.2kWh (3.194)
Depth of Discharge
Up to 100%
Recommended Depth of Discharge
80% or less
Continuous Discharge C-Rate
0.5C (C2)
Continuous Discharge current
39A
Continuous Discharge Power
2.0kW
Maximum Discharge
(Limited by K-Curve Circuit Breaker)
(Refer manual for circuit breaker characteristics)
63A* (3.22kW)
Maximum Charge Current
63A
Warrantable Charge Current
39A
Warrantable Charge Power
2.0kW
Prospective Fault Current (1ms)
250A
Circuit Breaker (k Curve)
2-Pole 63A 360VDC
Lithium Composition
Lithium Ferro Phosphate (LiFeP04 or LFP)
Operating Temperature Range
Charge: 0° to 55°C / Discharge -20° to 60°C
Ideal Operating Temperature Range
0 to 45°C
Operating Humidity
85% Non Condensating
BMS Over-Volt
Cell Level Protection
3.9V/Cell
BMS Under-Volt
Cell Level Protection
2.0V/Cell
BMS Over-Temp Cut Off
65°C
BMS Max Trip Current
200A
Self Discharge
14% Per Annum
Altitude
< 2000m (seek manufacturers advice above 2000m)
Battery Mounting Options
Standard 19” Rack Mount / Horizontal / Vertical
Terminal Connections
Amphenol Surlok 100A Non Keyed
IP Rating
IP40
Efficiency
>96%
Cooling
Natural convection
Parallel Connection
Unlimited - Refer Manufacturer
Serial Connection
Not Permitted
Alarm Output
Normally closed, Volt free, 1A maximum
Communications
Alarm Output
Module Weight
43kg
Battery Dimensions
635mm D x 434mm W x 88mm H
Arc Flash Incident Energy
IEm in Cal/cm2 (45cm)
0.36
Arc Flash Incident Energy
AFB in cm
24.45
Certifications
Pending IEC: 62619:2017, UN38.3, EMC
Terminal Connections
Amphenol Surlok 100A Non Keyed
Note:
This specification is subject to change at anytime without notice
Warranty
10 Years (Conditions apply)
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3.4. Charging and Discharging
The battery should be charged and discharged within the operating temperature windows as outlined within
the specifications and as indicated in the Charge Discharge table below “Connected PCE Programming
Requirements”. All currents are maximum for each battery, and should be taken into consideration when
multiple devices are charging the battery.
3.4.1. Primary Charging Source
A Primary Charging Source should be identified in the system and programmed to charge the batteries as
outlined in the table below. A primary charging source, is the charging device that will be used to charge
the battery for 75% of the time (charge energy) or higher.
3.4.2. Secondary Charging Source
A Secondary Charging Source can also be used, the preference is to also have these devices programmed
to the charging settings in the table “Connected PCE Programming Requirements”. However if this is not
possible, they can be used as long at the output voltage does not exceed the upper voltage of the
Operational Voltage Window of the battery, does not exceed the Max Charge Current, and does not
account for more than 25% of the charging (energy) of the battery.
Example
Primary Charging Source = Solar PV will be used to perform 75% of charging and will be programmed as
per below table.
Secondary Charging Source = Wind Turbine will be used to supply approximately 25% of the charging,
however can not have the voltage adjusted as per the specific charging voltages as specified in the table
“Connected PCE Programming Requirements”, and will not exceed the Operational Voltage Window or Max
Charge Current/Power of the battery.
3.4.3. Calibration to 100%
Calibration to 100% every 7 days (minimum) is required to perform a cell balance maintenance
charge. Cell balancing allows the BMS to equalise the battery cells to limit battery capacity slip and
ensures battery will accept the charge voltage correctly.
Calibration to 100% is achieved by:
!
Charge batteries at specified “Continuous Charge Voltage” and no greater than the specified Maximum
Charge Current.
!
Battery!is considered full after battery is absorbing less than 1% of maximum charge current after being
held at specified charge voltage for 30minutes minimum.
If PowerPlus Energy has released Custom Charge Settings for your connected PCE,!then these instructions
can be followed instead.
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