PowerPlus Energy Eco P Series User manual

Installation and Operation
Manual
Eco P Series Installation Manual
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Eco P Series Lithium Battery
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Introduction
The Eco P Series Lithium Ferro Phosphate (LFP) battery by PowerPlus Energy is designed and
manufactured in Australia for the worlds harshest conditions to be a simple, flexible and reliable energy
storage solution. As a result, the Eco 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. Currently the Eco P Series battery is available in a 48V
version.
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Introduction 2
Safety 4
Transportation 4
Basic Safety 4
Handling 4
Damaged Battery 5
Fire 5
Qualified Person (Installer) 5
Product Information 6
Weight and Dimensions 6
Specifications 7
Charging and Discharging 8
Charging Curves Eco 4840P 9
Discharging Curves Eco 4840P 9
State of Charge Vs Voltage 10
Circuit Breaker Characteristic 11
Installation 12
Location and Environment 12
Extreme Humidity Climates 12
Battery Installation 13
Battery Connections 14
Main DC Connections 14
Case Earthing 15
Battery Alarm and Communication Installation 16
PowerPlus Energy Battery Enclosures 17
Rack Series Enclosures 17
Rack Series Specification 17
Rack Series Enclosure Installation 18
SlimLine Series Enclosures 19
SlimLine Series Specification 19
PEW3 & PEW4 Installation 20
PEF6W-250B Installation 21
PEF9W-250 Installation 22
Battery Operation and Commissioning 23
Main Status LED 23
Full Recharge Upon First Installation 23
Trouble Shooting 24
Maintenance 24
Upgrading Battery Capacity 24
Capacity Testing Battery 25
End of Life 25
Warranty 26
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Safety
Installers and users are responsible for familiarising themselves with this manual.
The Eco P Series batteries use a high grade cylindrical Lithium Ferro Phosphate (LFP) cells which are
robust and reliable in higher ambient temperatures, have a long service life and with no heavy metals and
are fully 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 and Short Circuit as well extended
service life through managing cell string balancing.
Each battery has a 2 pole non polarised circuit breaker, status indicator light, volt free alarm contact and
high quality Amphenol SurLok DC connections for safe and easy installation.
Installation should be by qualified and experienced installers who can specify the correct cables and DC
bus arrangement, external circuit protection, polarity checking and suitability of the design for the
installation.
Transportation
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.
Basic Safety
The following precautions should be observed:
•Battery should not be exposed to temperatures above or below the ambient temperature rating specified
within in 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 should not be disassembled unless qualified to do so.
•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.
Handling
•Use battery only as directed.
•The battery is non user serviceable and should not be opened for repair.
•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.
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Damaged Battery
A damaged battery should not be used and should be returned to the PowerPlus Energy or disposed of via
a recycling facility. Leaking electrolyte can cause skin irruption 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, however an inhalation
is not expected due product form and nature of use.
Fire
Should the battery pack catch on fire a dry agent fire extinguisher should be readily available and used.
DO NOT use water. Evacuate the area and call emergency services. Toxic gas may be produced if the
battery catches fire.
Note: Refer MSDS document for more details which is available from PowerPlus Energy’s web page or upon
request.
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 on and off-grid
electrical system.
•Have a thorough understanding of all dangers associated with installing and using electrical devices as
well as all risks.
•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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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.
Weight and Dimensions
Eco4840P
Depth
635mm
Width
434mm
Height
88mm
Weight
43kg
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Specifications
Eco4840P
Nominal Capacity DC Voltage
51.2V
Nominal Capacity
4.0kWh (3.994) / 78Ah
Continuous Charge / Discharge C-Rate
0.5C (C2)
Continuous Charge / Discharge Current
39A (Refer to Eco 2RU Warranty Statement)
Maximum Current
63A (Limited by circuit breaker)
Battery Fault Current (1ms)
250A
Arc Flash Incident Energy
IEm in Cal/cm (45cm)
0.36
Arc Flash Incident Energy
AFB in cm2
24.45
Charge/Discharge Cycles approx.
2700@100% DoD / 5000@75% DoD / 10,000@50% DoD @25°C op. temp.
Operating Temperature Range
Charge: 0° to 55°C / Discharge -20° to 55°C
Operating Humidity (Non condensating)
85%
Altitude
Below 2000m
Battery Dimensions
635mm D x 434mm W x 88mm H
Battery Mounting Options
Standard 19” Rack Mounting / Horizontal or Vertical
Terminal Connections
Amphenol Surlok 100A Non Keyed
Module Weight
43kg
Operational Voltage Window
40V to 58.4V
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
Max Trip Current
200A
Circuit Breaker
2-Pole 63A 360VDC (K Curve)
Self Discharge
14% Per Annum
Lithium Composition
Lithium Ferro Phosphate (LiFeP04 or LFP)
IP Rating
IP40
Round Trip Efficiency
>96%
Expected Life @25oC
Greater than 10 years when used as per warranty terms
Cooling
Natural convection
Parallel Stacking
Unlimited - Refer Manufacturer
Serial Stacking
N/A
Alarm Output
Normally closed, volt free, 1A maximum
Certifications
Pending IEC:62619:2017, UN38.3, EMC
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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. All currents are maximum for
each battery, and should be taken into consideration when multiple devices are charging the battery.
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 (or higher).
Secondary charging sources can also be used, the preference is to also have these devices programmed to
the charging settings in the table below. 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 Continuous Charge Current, and does not account for more than 25% of the charging 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 the table,
however will not exceed the Operational Voltage Window or Continuous Charge Current of the battery (as
outlined in the table below).
SoC control should be used when maintaining charging and discharging of the battery.
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Connected PCE Programming Requirements
Eco4840P
Shut Down SoC (Recommended)
20%
DC Volts Shut Down 0% Load
48.0V
DC Volts Shut Down 100% Load
46.0V
Recovery / Restart Voltage
52V
Continuous Charge Voltage (Per Warranty)
57.6V
Float Voltage Cyclic (Short Term Float)
(Example Solar Application)
57.6V
Float Voltage Standby (Long Term Float)
(Example UPS Application)
54.4V to 56V
Peukert Exponent
1.02
100% recharge (Recommended)
7 to 14 days to keep External SoC counter accurate
Operational Voltage Window
40V to 58.4V
Continuous Discharge Current
39A
Continuous Charge Current
39A
Cable Size
Refer relevant manual or cable sizing standard
Warranty
Refer Warranty document for warranty duration, installation, usage and
maintenance requirements
Note
In our efforts towards constant product enhancement this specification is subject
to change at anytime without notice

Charging Curves Eco 4840P
!
Discharging Curves Eco 4840P
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State of Charge Vs Voltage
The below table can be used a guide for referencing voltage against energy in the battery.
The below figures are taken at 25°C and with a 0.5C load applied.
SoC
Eco4840P
100%
>53.00
99%
52.50
98%
52.00
97%
51.75
96%
51.72
90%
51.70
80%
51.65
70%
51.50
60%
51.32
50%
51.15
40%
51.00
40%
50.75
30%
50.50
20%
50.20
10%
49.50
0
48.00
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Circuit Breaker Characteristic
The integrated double pole DC is dual pole and a K curve type. The table below outlines the trip times based on
current.
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Installation
Installation should be carefully considered and all aspects of the specifications should be understood to
determine a suitable location and way of installing the battery.
Location and Environment
The location of the battery should be in accordance with the IP rating and operating temperature range
specified in the Specification section of this manual. Even though the batteries operate at a low
temperature, it is preferred that adequate airflow around the batteries is provided.
The location of the batteries should meet the below conditions:
•The location if far way from the ocean/sea. If unavoidable, appropriate air filtration is used to prevent or
limit salt air contacting the battery, and the battery installation should be indoors.
•The floor is level and free from obstructions.
•There are no explosive or flammable materials nearby.
•The optimal ambient temperature is between 0 and 45°C (battery is OK to operate outside this range
however, not for sustained periods).
•Operation of charge and discharge outside of the optimal ambient temperature should be limited to C5
and still remain between the max and min operation temperature range as specified in this manual.
•The temperature and humidity remains as constant as possible.
•The area is of a clean environment with minimal dust.
•The area or enclosure is vermin proof to suit your environmental locations.
•The batteries and battery cabinets/housings are not exposed to direct sunlight.
The Eco battery is designed to be installed in a 19 inch data rack assembly or an electrical enclosure of
your choice. If the battery is to be installed outdoors a suitable IP54 or above enclosure shall be used.
Extreme Humidity Climates
When our batteries are being installed in climates of extreme humidity, extra precaution should be taken.
•A humidity control agent (ie chemical which absorbs humidity) is required inside the enclosure, with
controlled airflow to expel moist air.
•And or, the battery system to be installed in a moisture and climate controlled room (example, reverse
cycle cooled).
•The temperature of the cabinet should be held at a temperature above dew point at all times.
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Battery Installation
The battery has been designed to fit into a standard 800mm deep 9 inch rack enclosure. The enclosure
should be fitted with PowerPlus Energy’s battery rails or similar to ensure stability and correct installation.
Battery rails can be sourced from you normal PowerPlus Energy place of purchase.
•If the battery is installed in to enclosures without rails, please ensure that they are securely seated to
prevent accidental damage or tampering.
•If a custom enclosure or mounting method is used please ensure the batteries are not stacked more than
6 high unless battery support rails are used to disperse weight.
Description
Part Number
Rack Mount battery rails Rack M (pair)
PIR Shelf
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Battery Connections
Each battery has a positive and negative Amphenol SurLok non keyed male connector for easy snap on
connection. A range of cable and mating connectors are available from you normal PowerPlus Energy
place of purchase.
If multiple batteries are being used in parallel, the battery cables shall all be of the same length to retain
equal impedance of each battery and cable set.
Main DC Connections
The battery comes fitted with Amphenol Surlok connectors (non keyed) male connectors. The table below
outlines the battery connections and the mating cable connectors required. Before connecting the DC
cable you will need to remove the safety insulating cap on the connectors and dispose of appropriately.
Each Amphenol SurLok connector supplied by PowerPlusEnergy can adequately seat 25mm single
insulated or 16mm dual insulated battery cables. A 16mm reducing sleeve is provided. Crimping of
SurLok to the stripped end of the cable cables is using a standard 25mm hex crimp tool.
Battery
Cable
Positive connection
SLPRATPSR
SLPPA16BSR
Negative Connection
SLPRATPSB
SLPPA16BSB
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Case Earthing
The Eco battery has an M6 nut-set to allow case earthing should your application require grounding of case
to the same potential across the application. A 5mm M6 bolts should be used.
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Battery Alarm and Communication Installation
The battery provides the ability to alarm the system manager or user that there has been a loss of power to
a battery or batteries. Loss of power to the battery or batteries could be either a circuit breaker or BMS trip.
BMS trip will self rest, however a battery circuit breaker will need manual intervention.
The alarm contacts can be daisy chained to produce one alarm output or can be wired individually.
The connectors are an RJ45 style female connector. The alarm output uses pin 5 and 6 and provide and
Volt free contact.
The alarm output is normally closed when energised by the battery (battery is ON and LED illuminated).
When or if the battery turns OFF (circuit breaker or BMS trip and LED off) the contact will open.
The alarm outputs are designed to be daisy chained connecting the top RJ45 from one battery to the
bottom RJ45 of the next and so on. The battery at the beginning of the chain will need to the have pins 5
and 6 bridged on the bottom RJ45 terminals, and battery at the end of the chain can be connected to an
appropriate alarming circuit.
A range of cables to connect the battery alarm contacts are available for purchase.
CABLE
Battery daisy chain connector lead (30cm)
COM0030A
Battery Bridge connector
COMLBA
Battery Comms Cable (2Metre)
COM020A
Battery Comms Cable (5Metre)
COM050A
Battery Comms Cable (10Metre)
COM100A
Battery Comms Cable (15Metre)
COM150A
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PowerPlus Energy Battery Enclosures
PowerPlus Energy provides a range of mounting options to make your installation simple and easy. They
have been design to suit indoor and outdoor applications and to secure a rage of different battery
capacities.
Rack Series Enclosures
The Rack Series enclosure for domestic, commercial and utility installations, allows quick and easy
visualisation of battery operation.
The cabinets come pre configured with all interconnecting battery cables and DC busbar (accessible via
the rear door) for a speedy and easy indoor installation of our batteries.
Rack Series Specification!
PIR8C
PIR10C
PIR12C
PIR18C
PIR20C
Dimensions (H x W x D)mm
990 x 600 x 800
1166 x 600 x 800
1400 x 600 x 800
1800 x 600 x 800
1950 x 600 x 800
Colour
Black with glass front door (powder coated)
Mounting
Floor
Securing
4 x Caster rollers for positioning and 4 x locking feet.
Feet
Adjustable
Number of Battery Slots
8
10
12
18
20
Battery Connection Main
Isolator
Busbar with M8 Stud 1000A Continuous rated (M8 Nut, bolting and washer not supplied)
Battery Interconnection
Amphenol Surlok connector, 16mm double insulated cable (supplied and installed in cabinet for easy plug and play
assembly)
DC Circuit Breaker
None
Cable Entry
Top or bottom entry
IP Rating
IP21
Weight Kg
95
110
132
174
187
Note
In our efforts towards constant product enhancement this specification is subject to change at anytime without notice
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Rack Series Enclosure Installation
•Move cabinet into position.
•Choose cable entry position to suit your application. Multiple cable entry trays are positioned on and
around the enclosure.
•Ensure suitable glands or similar are used to protect the cables after forming cable entry hole. Glands
are not supplied and should be of the same or higher IP rating of the cabinet.
•Ensure all filings from forming holes are removed from cabinet.
•Connect main DC cable from main DC isolator to the PIR enclosure DC bus bar with M8 nut, washer and
locking washer and tighten.
•Close rear door and move cabinet into final position.
•Secure locking feet and wind down until firm against the ground, transferring the cabinet weight from the
caster wheels.
•Using a 2 person lift, slide the batteries into the cabinet starting from the bottom and working your way to
the top.
•Connect corresponding Amphenol cables to batteries.
Note: The Caster wheels are not designed to take the weight of the cabinet and batteries. The locking feet
supplied must be used.
Note: Batteries should be loaded from the bottom of the cabinet working your way to the top. This ensures
the cabinet remains stable.
Note: The cabinets have fans installed for cooling. These fans are 240V powered and are aways on when
powered. If your installation requires to the use fans (not compulsory) for cooling, an ambient temperature
controlled switch may be required to turn the on and off as necessary. These are available from you normal
PowerPlus Energy place of purchase.
Note: When paralleling multiple battery cabinets, battery cables from each cabinet must be the same length
and cable size to ensure cabinet impedances remain the same. The use of an external busbar is highly
recommended.
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SlimLine Series Enclosures
PowerPlus Energy SlimLine series battery enclosures are designed to provide low profile options for
mounting the LiFe and Eco batteries. Each style is available at 300 to 400mm deep making them suitable
for installation in walkways, sides of buildings and alongside industrial equipment.
The cabinets come pre configured with all interconnecting battery cables and DC busbar for a speedy and
easy indoor or outdoor installation of our LiFe and Eco batteries.
SlimLine Series Specification
PEW3
PEW4
PEF6W - B250
PEF9W - 250
Dimensions (H x W x D)
800 x 600 x 300mm
800 x 600 x 400mm
2002 x 802 x 304mm
1477 x 849 x 300mm
Mounting
Wall
Floor
Feet
N/A
Adjustable
Number of Battery Slots
3
4
6
9
Battery Connection
Busbar with M8 Stud
Cooling
Natural convection
Temperature controlled
(adjustable) fan forced
Natural convection
DC Circuit Breaker
N/A
2Pole Non Polarised 250A 1000VDC
IP Rating
IP66
IP54
Weight
33kg
37kg
95kg
72kg
Note
In our efforts towards constant product enhancement this specification is subject to change at any time
without notice
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PEW3 & PEW4 Installation
The PEW3 and PEW4 are a small wall mount battery enclosure for use in smaller storage solutions. The
cabinets are suitable to be installed indoor or outdoor.
•Securely mount the battery enclosure to the wall using appropriate fastening. Your fastening types will
vary depending on wall surface and sub-strait.
•The wall should be rated to carry all equipment, including up to 210kg for a PEW4 with 4 batteries
installed.
•Choose cable entry position to suit your application.
•Ensure suitable glands or similar are used to protect the cables after forming cable entry hole. Glands
are not supplied and should be of the same or higher IP rating of the cabinet.
•Ensure all filings from forming holes are removed from cabinet.
•Connect main DC cable from main DC isolator to enclosure DC busbar with M8 nut, washer and locking
washer.
•Using a 2 person lift, Insert batteries into cabinet standing them up vertically with battery terminals facing
upwards.
•Securely fasten batteries in places using provided strap. Ensure strap is tight and and secure.
•Connect corresponding Amphenol cables to batteries.
Note: Batteries should be loaded from the rear of the cabinet working your way to the front. This ensures
the cabinet remains stable and weight is distributed closet to the wall.
Note: When paralleling multiple battery cabinets, battery cables from each cabinet must be the same length
and cable size to ensure cabinet impedances remain the same. The use of an external busbar is highly
recommended.
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