PowerPlus Energy Eco P Series User manual
Installation and
Operation Manual
Your complete installation guide
for Eco4840P batteries
Eco P Series
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 2 of 20
1. INTRODUCTION 3
2. SAFETY 3
2.1. Transportation
2.2. Basic Safety
2.3. Handling
2.4. Storage of Battery
2.5. LiFe Support
2.6. Damaged Battery
2.7. Fire
2.8.QualiedPerson(Installer)
3. PRODUCT INFORMATION 5
3.1. Weight and Dimensions
3.2.Inclusions
3.3.Specications
3.3.1. Eco P Series
3.4. Charging and Discharging
3.4.1. Primary Charging Source
3.4.2. Secondary Charging Source
3.4.3. Calibration to 100%
3.4.4. Battery Charging Requirements PCE
for P Series
3.4.5. Charging Curves P Series
3.4.6. Discharging Curves P Series
3.4.7. State of Charge Vs Discharge Voltage
P Series
3.4.8. Over Discharged battery
3.4.9. Circuit Breaker Characteristic
4. INSTALLATION 10
4.1. Location and Environment
4.1.1. Extreme Humidity Climates
4.2.BatteryInstallation
4.2.1. Custom Cabinets
4.2.2. Battery Orientation Stationary
Application
4.2.3. Battery Orientation Pre-Assembled
BESS or BS Systems
4.2.4. Battery Orientation Motorhomes,
RV’s, Trailers, Vehicles, Trucks, Buses
4.3. Battery Connections
4.4. Main DC Connections
4.5. Case Earthing
4.6.BatteryAlarmandCommunicationInstallation
4.6.1. Data Logging
4.6.2. PowerLink
4.6.3.PowerLinkInstallation
6. BATTERY OPERATION 14
6.1. Main Status LED
6.2. Battery Power up / Shut Down Procedure
6.2.1. Battery Startup
6.2.2. Battery Shut Down
6.3.FullRechargeUponFirstInstallation
6.4.Calibrationto100%(Weeklyrechargeto100%)
6.5.SoC(StateofCharge)Drift
7. TROUBLESHOOTING 16
7.1. Over Discharged Battery Recovery
7.1.2. BMS Threshold Soft Shutdown
7.1.3. Soft Shutdown Recovery
7.1.3. BMS Threshold Hard Shutdown
7.1.4. Hard Shutdown Recovery
8. MAINTENANCE 17
9. UPGRADING BATTERY CAPACITY 17
10. CAPACITY TESTING BATTERY 17
11. END OF LIFE 18
12. WARRANTY 18
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 3 of 20
Installersandusersareresponsibleforfamiliarising
themselves with this manual.
The Eco P Series batteries use high grade cylindrical
LithiumFerroPhosphate(LFP)cells.Thesecellsare:
•robust
•reliable in higher ambient temperatures
•have a long service life
•contain no heavy metals
•mostly recyclable
Each Eco P Series battery has an internal Battery
ManagementSystem(BMS)promotingreliable
service life through the management of cell string
balancingwhilstprovidingprotectionagainst:
•over and under voltage
•over current
•over temperature
•short circuit
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.
Installationshouldbecarriedoutbyasuitably
qualiedandexperiencedpersonwhocanspecify
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 LFP Batteries are
classedasDangerousGoods(DG)Class9UN3480.
The batteries are safe for road transport and are shipped
in a partially discharged state with terminal protection
andcircuitbreakero.
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.
2.2 BASIC SAFETY
The following precautions should be observed.
Batterypack:
•is intended to be a 2 person lift when installing
•should not be exposed to pressure, or have objects
placed on top of them
The battery module should not be:
•exposed to temperatures above or below the
temperatureratingsspeciedwithinthismanual
•touched if wet
•installed in direct sunlight
•exposed to strong impacts
•crushed or punctured
•disassembled; it contains no maintainable
components
•opened for repair; it is non-user serviceable
2. Safety
1. Introduction
2. Safety
1. Introduction
TheEcoPSeriesLithiumFerroPhosphate(LFP)
batteries by PowerPlus Energy are designed and
manufactured in Australia for the world’s harshest
conditionstobeasimple,exibleandreliableenergy
storage solution.
As a result, the Eco P Series batteries can be easily
installed with most inverter and charger combinations,
UPS,rectiers,DCorACcoupledchargingdevices,
on-gridando-gridinsingle,dualorthreephase
applications.
There are 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.
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 4 of 20
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
Ifingested,donotinducevomitingand
contact your local poisons information
centre or doctor.
Inhalation Evacuate area and seek professional
medical attention immediately.
After 6 months of storage the battery may
need cell balancing and should be charged.
Issueschargingafterlongtermstorageshould
be discussed with PowerPlus Energy.
*Refer to product SDS document for more details available
from PowerPlus Energy’s web page or upon request.
2. Safety1. Introduction
Battery connectors should not:
•touch conductive surfaces unless intended
to do so
The battery should be:
•kept dry at all times
•kept away from animals and children
2.3 HANDLING
•use battery only as directed.
•handle battery with care when installing
or transporting
•the batteries are heavy and proper lifting techniques
or equipment should be applied
Do not:
•use the battery if it appears damaged or broken
•use chemicals to clean the battery
•touch the DC terminals
•touch the DC busbar
2.4 STORAGE OF BATTERY
The battery should be:
•stored horizontally and stacked no more than 6
batteries tall without extra support
•kept in a dry environment away from moisture
•stored away from incompatible substances
•stored between 0°C to 45°C, however close to
25°C should be considered for long term storage
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
lifesupportequipmentoreectoperationofsuch
equipment.
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.
2.7 FIRE*
Shouldthebatterypackcatchonreorstartstoemit
smoke,(forsmallreorsmallemissionsofsmoke)use
water spray, dry chemical, carbon dioxide or chemical
reextinguisher.
Evacuate the area and call emergency services.
Toxicgasesmaybeproducedifthebatterycatchesre.
The battery needs to be rapidly cooled to prevent any
heatorrespreading.
2.8 QUALIFIED PERSON (INSTALLER)
This operation manual and task sets within regarding
installationshouldbecarriedourbyasuitablequalied
and skilled person.
The installer needs to be a person with adequate skills,
qualicationsandexperience.
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.
•Holdalllocal,stateandcountrybasequalications
to carry out such work.
•Adhere to all safety and installations requirements
within this manual.
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 5 of 20
Eco4840P
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.
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 other accessories are
sold separately.
The battery does not require communication with the
PowerControlElectronics(PCEs)tooperate.The
EcoPSeriescanoperatewithPCE(PowerControl
Electronics)thatdonotrequirecommunicationsto
operate.
Ifyouareunsure,pleaseconsultyourPowerPlus
Energy expert or the PowerPlus Energy web page for
advice.
3. Product Information
3. Product Information
DC Connector
Positive DC connection 1 x SLPPA16BSR
Negative DC Connection 1 x SLPPA16BSB
25mm to 16mm reducer x2
Eco4840P
Depth 635mm
Width 434mm
Height 88mm
Weight 41kg
63A DC
Circuit
Breaker
Main DC
Isolator
Main
Status
LED
Main DC
Terminals
Alarm Port
Case Earth
Connection
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 6 of 20
3.3 SPECIFICATIONS
3. Product Information
Eco4840P
Nominal DC Voltage 51.2V
Operational Voltage Window 40V to 57.6V
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 LithiumFerroPhosphate(LiFeP04orLFP)
Operating Temperature Range Charge:0°to55°C/Discharge-20°to60°C
Ideal Operating Temperature Range 0 to 45°C
Operating Humidity 85%NonCondensating
Eco4840P
BMS Over-Volt Cell Level Protection 3.9V/Cell
BMS Under-Volt Cell Level Protection 2.0V/Cell
BMS Over-Temp Cut O 65°C
BMS Max Trip Current 200A
Self Discharge 14% Per Annum
Altitude <2000m(seekmanufacturersadviceabove2000m)
Battery Mounting Options Standard 19” Rack Mount / Horizontal / Vertical
Terminal Connections AmphenolSurlok100ANonKeyed
IP Rating IP40
Eciency >96%
Cooling Naturalconvection
Parallel Connection Unlimited - Refer Manufacturer
Series Connection NotPermitted
Alarm Output NormallyClosed.Voltfree,200mA60VMax
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
Certications PendingIEC:62619:2017,UN38.3,EMC
Warranty 10Years(Conditionsapply)
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 7 of 20
3.4 CHARGING AND DISCHARGING
The battery should be charged and discharged within
the operating temperature windows as outlined within
thespecicationsandasindicatedintheCharge
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
APrimaryChargingSourceshouldbeidentiedinthe
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
batteryfor75%ofthetime(chargeenergy)orhigher.
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%ofthecharging(energy)ofthebattery.
3.4.4. BATTERY CHARGING REQUIREMENTS PCE FOR P SERIES
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
specicchargingvoltagesasspeciedinthetable
“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%
Calibrationto100%every7days(minimum)isrequired
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:
Chargebatteriesatspecied“ContinuousCharge
Voltage”andnogreaterthanthespeciedMaximum
Charge Current.
Battery is considered full after battery is absorbing less
than 1% of maximum charge current after being held at
speciedchargevoltagefor30minutesminimum.
IfPowerPlusEnergyhasreleasedCustomCharge
Settings for your connected PCE, then these
instructions can be followed instead.
3. Product Information
Connected PCE Programming Requirements
Shutdown DC Voltage @0.5C 48.0V
Shutdown Voltage Recommended 50.2V
Recovery / Restart Voltage 52V
Continuous Charge Voltage 57.6V
Continuous Charge Transition Battery is considered full after battery is absorbing less than 1% of maximum
chargecurrentafterbeingheldatspeciedchargevoltagefor30minutesminimum.
Float Voltage Cyclic (Short Term Float) (Example
Solar Application) 57.6V
Float Voltage Standby (Long Term Float) (Example
UPS Application) 54.4V to 56V
Charge Current 39A
Peukert Exponent 1.02
Shutdown SoC Recommended 20%
Calibration to 100% Every 7 days or more frequent where possible.
(Ensurescellbalancingisperformed&keepsexternalSoCcountermoreaccurate)
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 8 of 20
3.4.5. CHARGING CURVES P SERIES
3. Product Information
3.4.6. DISCHARGING CURVES P SERIES
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 9 of 20
3. Product Information3. Product Information
3.4.7. STATE OF CHARGE VS DISCHARGE VOLTAGE
P SERIES
The table to the right can be used a guide for referencing
voltageagainstenergyinthebattery.Theguresinthe
table are taken at 25°C and with a 0.5C load applied.
3.4.8. OVER DISCHARGED BATTERY
Intheeventthatthebatterieslowvoltageprotection
circuit has operated to protect the battery from
excessive discharge, it is important that the battery is
charge to 100% within 7 days. Leaving the battery in a
discharged can cause irreversible damage to the battery
or battery capacity.
3.4.9. CIRCUIT BREAKER CHARACTERISTIC
The integrated non-polarised DC circuit breaker is dual
pole and a K curve type. The table below outlines the
trip times based on current.
Eco4840P
100% >53.00V
99% 52.50V
98% 52.00V
97% 51.75V
96% 51.72V
95% 51.70V
90% 51.65V
80% 51.50V
70% 51.32V
60% 51.15V
50% 51.00V
40% 50.75V
30% 50.50V
20% 50.20V
10% 49.50V
0% 48.00V
Multiple of circuit breaker rated current
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 10 of 20
Installationshouldbecarefullyconsideredandall
aspectsofthespecicationsshouldbeunderstoodto
determine a suitable location and way of installing the
battery.
4.1 LOCATION AND ENVIRONMENT
The location of the battery should be in accordance with
theIPratingandoperatingtemperaturerangespecied
inthespecicationsectionofthismanual.
The location of the batteries should meet the below
conditions:
•The battery should not be installed where direct
contactofsaltairmaybepossible.Ifunavoidable,
appropriateairltrationmustusedtopreventsaltair
contacting the battery, and the battery installation
shouldbeindoorsoranIP66orgreaterenclosure.
•Theoorislevelandfreefromobstructions.
•Therearenoexplosiveorammablematerials
nearby.
•The ideal temperature around the battery is between
0°C and 45°C.
•Operation of charge and discharge outside of the
ideal temperature should be limited to 0.2C and still
remain within the operating temperature range as
detailedinthespecication.
•The temperature and humidity should remain 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 P Series battery is designed to be installed in a
19 inch data rack assembly or an electrical enclosure of
yourchoice.Ifthebatteryistobeinstalledoutdoorsa
suitableIP54orgreatenclosureshouldbeused.
4.1.1. EXTREME HUMIDITY CLIMATES
When our batteries are being installed in climates of
extreme humidity, extra precaution should be taken.
•Ahumiditycontrolagent(i.e.chemicalwhich
absorbshumidity)mayberequiredinsidethe
enclosure,withcontrolledairowtoexpelmoistair.
•And or, the battery system to be installed in a
moistureandclimatecontrolledroom(example,
reversecycleair-conditionercooled).
•The temperature of the cabinet should be held at
a temperature above dew point at all times.
4. Installation
4. Installation
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 11 of 20
4.2. BATTERY INSTALLATION
PowerPlus Energy highly recommends our range of
Rack or Slimline Series indoor and outdoor cabinets.
FullspecicationdetailsareavailableonthePowerPlus
Energywebpage,howeverspecicinstallationsdetails
are further along in this manual.
4.2.1. CUSTOM CABINETS
Thebatteryhasbeendesignedtotintoastandard
800mm deep 19inch rack enclosure.
•Ifyouarebuildingyourownenclosure,ensurethe
below is considered in your design.
•Ifthebatteryisinstalledintoenclosureswithout
rails, please ensure that they are securely seated
to prevent accidental damage or tampering.
•Ifacustomenclosureormountingmethodisused
please ensure the batteries are not stacked more
than 6 high unless battery support rails are used to
distribute weight.
•Pleaseensurethereisadequateairowaroundthe
battery stack within the cabinet. 15mm minimum
around 4 side of the stack is required as minimum.
•PleaseensuretheselectedIPratingiscorrectas
per your location selection.
•All interconnecting battery cables for parallel
connection shall be the same length and cable size.
•A busbar is recommended for connection of all
parallel battery connections.
•An appropriate way of connecting the cabinet to the
PCE should be considered.
•Please follow PCE instructions for fuse, cable and
connection requirements. These will vary depending
on brand and product selected.
4.2.2. BATTERY ORIENTATION STATIONARY
APPLICATION
The Eco batteries can be mounted in 4 orientations,
excluding on its face or upside down.
4.2.3. BATTERY ORIENTATION PRE-ASSEMBLED
BESS OR BS SYSTEMS
•Batteries should be shipped horizontally and
secured in place to limit movement.
•Ifbatteriesaretobesubjecttoprolongedvibrations
during transportations, they should be removed
and shipped in original manufacturers packaging
orasucientnon-ammableshockmountsystem
(likehighdensityfoamorsimilar)shouldbeinstalled
within the BESS/BS under each battery.
4.2.4. BATTERY ORIENTATION MOTORHOMES, RV’S,
TRAILERS, VEHICLES, TRUCKS, BUSES OR SIMILAR
•Batteries should be shipped horizontally and
secured in place to limit movement.
•Batteriesshouldbepositionedinanon-ammable
section and be easily accessible and removable
form the outside of the vehicle.
•Sucientnon-ammableshockmountsystem(like
highdensityfoamorsimilar)shouldbeinstalled
within the BESS/BS under each battery.
Upside down on lid
Upside down on lid
Battery can be only mounted as shown
Maximum of 6 batteries stacked
without additional support
Battery can be only mounted as shown
On face of battery
On face of battery
4. Installation
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 12 of 20
4.3 BATTERY CONNECTIONS
Each battery has a positive and negative Amphenol
SurLok(nonkeyed)connectorforeasysnapon
connection. A range of cables and mating connectors
are available from any PowerPlus Energy place of
purchase.
Ifmultiplebatteriesarebeingusedinparallel,thebattery
cables shall all be of the same length to retain equal
impedance of each battery and cable set.
4.4. MAIN DC CONNECTIONS
ThebatterycomesttedwithAmphenolSurlok
connectors(nonkeyed)connectors.Thetablebelow
outlines the battery connections and the mating cable
connectors required. Each battery when ordered
separately(withoutacabinet)willcomesuppliedwith
mating connectors.
Each Amphenol SurLok connector supplied by
PowerPlus Energy can adequately seat 25mm single
insulated or 16mm double insulated cable. A 16mm
reducing sleeve is provided. Crimping of SurLok to the
stripped end of the cable is performed using a standard
25mm hex crimp tool.
Before connecting the DC cable to the battery you will
need to remove the safety insulating cap on the battery
DC connectors and dispose of appropriately.
Case Earth
Connection
Main DC
Terminals
Main Status
LED
4.5. CASE EARTHING
The Eco battery case is designed to be electrically
oatingandisolatedfromallinternalbatteryconnections
and in most installations will not require earthing.
However should your application require the case to be
grounded a 5mm M6 bolt should be used.
Battery Cable
Positive
connection SLPRATPSR SLPPA16BSR
Negative
Connection SLPRATPSB SLPPA16BSB
4.6. BATTERY ALARM INSTALLATION
The battery provides the ability to alarm the system
manager that the battery’s BMS or circuit breaker has
tripped. The BMS trip will self reset once fault has been
resolved or removed, however if the battery circuit
breaker has tripped, it will need manual intervention.
The connectors are an RJ45 style connector. The alarm
output uses pins 5 and 6 and provide a volt free contact.
This volt free contact can be used to signal an external
PLC or alarm circuit.
The alarm output is normally closed when energised by
thebattery(batteryisONandLEDilluminated).When
the BMS or circuit breaker trips the battery turns OFF
(circuitbreakerorBMStripandLEDo)andthecontact
will open.
The alarm outputs are designed to be daisy chained
(usingP/NCOM003Acommscable),connectingthe
bottom RJ45 from one battery to the top RJ45 of the
next and so on. The battery at the end of the chain
(generallythebottombattery)willneedtothehavepins
1 and 2 bridged on the bottom RJ45 terminals using
bridgingconnectorP/NCOMLBA.Thetopconnector
on the last battery in the chain can be connected to an
appropriate alarming circuit using one of our battery
comms cables.
4. Installation
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4. Installation
Communication Accessories
Description PartNumber
Battery Bridge connector COMLBA
Battery daisy chain
connector lead (30cm) COM003A
Battery Comms Cable
(2 Metre) COM020A
Battery Comms Cable
(5 Metre) COM050A
Battery Comms Cable
(10 Metre) COM100A
Battery Comms Cable
(15 Metre) COM150A
Description PartNumber
PowerLink data logger PL001
4.6.1. DATA LOGGING
Eco batteries do not come equipped with a data output.
Battery performance is monitored by the connected PCE and
data presented will vary based on each product’s capabilities
or monitoring options.
Diagrams below: Specic examples on how to use alarm contacts
4.6. BATTERY ALARM AND COMMUNICATION INSTALLATION CONTINUED
DIGITAL
CTRL IN
Max Input
60V 100mA
12V 0.8A power
supply from
comms board
Ethernet
Cable
Loopback
connector
COMLBA
DIGITAL
INPUT
Max Input
60V 100mA
Ethernet
Cable
Loopback
connector
COMLBA
VICTRON
CEBRO GX
SELECTRONIC
SP PRO
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 14 of 20
Nowyouhaveinstalledthebatteriesyouarealmost
ready to energise the system. First you need to inspect
yourinstallationchecking:
•polarity of all battery connections is correct
•there is no damage to cables
•all system breakers are in the OFF position
•foradequateairowasperinstallation
requirements
•for local installation compliance if applicable
6.1 MAIN STATUS LED
The Main LED Status indicator is used to understand the
operation of the battery and the state of the BMS.
63A DC
Circuit
Breaker
Main DC
Isolator
Main
Status
LED
Main DC
Terminals
Alarm Port
Case Earth
Connection
Starting up the battery system should be done
in conjunction with the PCE manufacturer’s
recommendations as well as this manual and any
local or government safety requirements.
Each battery in the system is powered up separately
byturningthedoublepolecircuitbreakertotheON
position. Once powered up, voltage will be present at
the DC terminals and the Main Status LED light will
glow blue.
6. Battery Operation
Status Operational State
ON Battery is ON and allowing charge and
discharge.
OFF Battery circuit breaker is in the OFF position.
OFF
Low Voltage Protection Mode [Battery
BMS]: Charge will still be accepted, however
discharge will not be permitted until battery
cell voltage is sufcient.
OFF
High Voltage Protection Mode [Battery
BMS]: Charge will not be accepted, however
discharge will continue.
OFF
Temperature Protection Mode [Battery
BMS]: BMS has detected cell temperature
outside of our operation window of MAX
55°C. Charge or discharge will be disabled
until cell temperature reduces.
6. Battery Operation
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6.2.2 BATTERY SHUT DOWN
The battery system should be shutdown following the
shutdown procedure supplied with the system.
The Eco batteries will provide an isolated output when
theyareturnedo.Inmostcasespoweringothe
battery will be one of the last steps of shutting down
your power system.
63A DC Circuit
Breaker
63A DC Circuit
Breaker
6.2 BATTERY POWER UP / SHUT DOWN
PROCEDURE
Each battery has an integrated DC circuit breaker to
protect the battery in the event of a system fault and is
alsousedtopowerthebatteryONandOFF.
The below procedures should be used in conjunction
with the system start up/shut down procedure.
6.2.1 BATTERY POWER UP
The battery system should be started following the
startup procedure supplied with the system.
The Eco batteries do not provide an output voltage
untiltheyareturnedon.Inmostcasespoweringon
thebatterywillbeoneoftherststepsofstartingyour
power system.
1. LocateandensureyourmainsystemIsolation
point is OFF
2. Check all battery connections are correctly
installed
3. individually(workinginasystematicalapproach),
turn each battery circuit breaker to the ON position
(cycletotherightwhenlookingatthefrontfaceof
thebatteryfaceon)
4. Main Status LED will illuminate indicating voltage is
present at the battery terminals
LiFe4833P
LiFe4833P
LED Indicator Light
will illuminate when
circuit breaker is on
LED Indicator Light
will turn off
CIRCUIT BREAKER ON
Flip the switch on circuit breaker to the right
CIRCUIT BREAKER OFF
Flip the switch on circuit breaker to the left
Important: Ifthepowersystemhasbeenshutdown
or charging source removed, the battery must
have its circuit breaker cycled to the OFF position
within 48hrs to alleviate battery discharge from self
discharge or system standby discharge.
Important: The Eco batteries should be shutdown
as soon as possible or within 6 hours of a system
shutdown, system fault or charging source being
removed.
1. LocateandensureyourmainsystemIsolation
point is OFF
2. Individually(workinginasystematicalapproach),
turn battery circuit breakers to the OFF position
(cycletotheleftwhenlookingatthefrontfaceof
thebatteryfaceon).
3. MainStatusLEDwillturnoindicatingvoltageis
no longer present at the battery terminals.
6. Battery Operation
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 16 of 20
6.3. FULL RECHARGE UPON FIRST INSTALLATION
Batteries are delivered and shipped in a partial state of
charge. Prior to discharging the battery it should be fully
chargedtotheoatstage.
6. Battery Operation
Important: Thisstinitialchargewillallowthe
battery BMS to perform a cell balancing process and
ensure all cells are at the same state before regular
cycling.ItalsoallowstheexternalSoCcountertoset
itselftoknownbatterySoC(someSoCcountersmay
takeafewcyclestolearntheSoC).
6.4. CALIBRATION TO 100% (WEEKLY RECHARGE
TO 100%)
InternalcellbalancingoftheEcoSeriesbatteryhappens
duringtheendofthechargingprocess.Itisimportant
for the health of the battery and to ensure the battery
capacity does not slip over time that the batteries
are charged to 100% at least once every 7 days as a
minimum.
6.5. SOC (STATE OF CHARGE) DRIFT
State of Charge drift happens when the product that
is calculating SoC builds up an accumulative error.
This error is generally due to tolerance of components
thatmeasurevoltage¤tandalgorithmsusedto
calculate how full the battery is. Most products will reset
its accumulative error when the system gets to100%
SoCoroat.
Itisimportantthatawelldesignedbatterystorage
systemreachesoatstageor100%asregularlyas
possible, preferably every 1 to 2 days to reset SoC drift,
however can be extended if required.
SoC drift can be addressed in many ways, and some
examples are below.
1. Sucientsolarsizedtochargebatteriestooator
100% on the winter Solstice
2. Backupsourceinstalled(gridorgenerator)toallow
charging of batteries during extended bad weather
or high load events.
3. Ascertain from PCE manufacture the accuracy of
theSoCcalculator.Ifahighermoreaccurateshunt
can be used with the PCE to monitor system SoC,
then this should considered.
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 17 of 20
7.1. OVER DISCHARGED BATTERY RECOVERY
7.1.2. BMS THRESHOLD SOFT SHUTDOWN
Soft shutdown occurs if the voltage in the battery
reachesadesignatedLOWlevel.Inthesoftshutdown
state, the battery will not provide a DC voltage at its
terminal(voltagewillbe<4V)untilthesystemhasbeen
reset.
The time you have to recover the battery when it has
performed a soft shutdown will vary depending on
model. The battery will not deliver power to a load from
its DC terminals until the battery module reaches a
designated recovery voltage.
7.1.3. SOFT SHUTDOWN RECOVERY
This procedure is a guide and should be performed by
suitablyqualiedperson.
Eco4840P
1. Shutdown system following your shutdown
procedure.
2. Ensureallloadsareswitchedo.
3. Turnobattery/sviaDCcircuitbreakerandwait
30 seconds.
4. Turn on battery via DC circuit breaker.
5. Wait for battery Main Status LED to illuminate.
6. Connect and turn on site PCE.
7. Troubleshooting
The BMS only enters alarm state when the operation
of the battery is outside of the limits of the battery to
operate safely.
During normal operation there will be a voltage
acrosstheterminalsofthebatteries.IftheBMS
activates its protection circuit, once the fault is
cleared the battery should restart without external
assistance.
The scenario where this may not occur is on low volt
disconnect(batterycellvoltagelow).Inthisinstance
the battery will keep its discharge circuit open and
will only allow a charge. The battery output will read
<4V.
Note:YourinstallerorPowerPlusEnergyshouldbe
consulted if your battery will not activate.
7. IfthePCEstartsup,pleaseactionafullcharge
cycle to occur.
8. Ifbatterywillnotturnonorremainonlongenough
start a PCE charge. Please follow Hard Shutdown
Recovery.
7.1.3. BMS THRESHOLD HARD SHUTDOWN
Hard shutdown occurs if the voltage in the battery is too
LOW to activate the internal BMS. This is a hardware
triggered response.
7.1.4. HARD SHUTDOWN RECOVERY
RequiredEquipment:
1. External DC Charger/Current Limited Power
Supply(availablefromPowerPlusEnergy).
•50V Charger/Current Limited Power Supply for
LiFe4833P
Eco4840P:
1. TurnobatteryviaonboardDCbreaker.
2. Connect DC Charger/Current Limited Power
Supply to battery, one battery at a time.
3. CheckDCChargerissettobatteryNominal
Voltagespeciedinthethismanual(See
Specication).
4. Turn on battery/s via DC breaker.
5. Turn on external charger.
6. Wait for at least 30 minutes, the main status LED
should turn on.
7. Turnobatteryanddisconnectstartupcharger.
8. Reconnect on site PCE to the recovered battery
and action a full charging cycle enabling the
battery to balance at Continuous Charge Voltage
(seespecication)untiloatreached.
Important: Itisrecommendedthatthebatterystatus
is checked once a month for 3 months after battery
recovery has occurred to ensure reliable operation of the
battery module.
7. Troubleshooting
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 18 of 20
The battery does not require maintenance itself, however
as part of your overall system maintenance schedule it is
recommended that the following checks are carried out.
•Check for any obstruction placed around the battery
or battery enclosure.
•Check for animals, insects or creatures nesting in or
around the battery solution.
•Check for build up of any foreign objects in or
around the cabinet.
•Check battery connections and cables for secure
ttingordamage.
•Checkbatterybreakerbyturningitoandonagain.
•Check LED indicators.
8. Maintenance
8. Maintenance
Itispossibletoaddadditionalbatteriestoanexisting
EcoPSeriesinstallationatalaterdate.Ifyouare
adding extra capacity, the battery must be of the same
type,partnumber,andspecication,unlessadvisedby
PowerPlus Energy.
Before adding the new battery the original battery
bank and the new battery must be bought up to within
~0.2VDC of each other.
This is achieved by:
Insertthenewbattery/stoapartiallydischargedbattery
bank ensuring the new battery and the battery bank
are within 0.2V of each other. Charge complete battery
up and maintain our recommended continuous charge
voltageuntilbatteryhasreachedoat.
Ensure all connected PCE has had relevant charge
current and battery capacities revised to suit new
increased storage solution.
Itisimportanttoensurethebatteryisfullycharged
before discharging.
Thebatterycapacitycanbemeasuredandveried
by following the below test procedure. This should
be performed using calibrated test equipment and
performedbyasuitablyqualiedperson.
To determine the battery capacity, the below process
shouldbeconductedbyasuitablyqualiedprofessional
andperformedatanambienttemperatureof25°C:
•Discharge the battery at 0.5C until the low voltage
cut-oisreached,thiswillbedeterminedbythe
BMS going open circuit.
•Charge the battery at the recommended continuous
charge voltage and 0.5C rate and hold at that
voltage for 6 hours.
•Discharge the battery with a constant load at 0.5C
untilthelowvoltagecut-oisreached.Thiswillbe
determined by the BMS going open circuit.
•Record the number of hours it takes to reach low
voltagecut-opoint.
•Charge the battery at the recommended continuous
charge voltage and 0.5C rate for 6 hours.
The State of Health of the rated capacity can now be
calculated as below and as a % of original capacity:
(((Ah*0.5)*Dischargehrs)/Ah)*100=
Ah = Amp Hour Capacity.
0.5 = 0.5C constant load discharge.
100 = Conversion to %.
Example:
Eco4840P Ah Capacity = 78Ah
Battery time to discharge under test = 1.85hrs
=(((78*0.5)*1.85)/78)*100
= 92.5%
9. Upgrading Battery Capacity
10. Capacity Testing Battery
9. Upgrading Capacity 10. Capacity Testing
PowerPlus Energy Pty Ltd 12/05/2023 | V3.6 page 19 of 20
11. End of Life
12. Warranty
When a PowerPlus Energy battery is removed from
service it can be returned to PowerPlus Energy for
recycling.
Due to the stability and longevity of LFP cylindrical cells,
returned batteries will be refurbished and checked so
they can be repurposed for low power applications and
made available for community, education and charity
projects.
Any lithium cells not suitable for repurposing will be sent
to a licensed recycling facility, where all ferrous and non
ferrous metals are separated and then forwarded to our
metals recycling partner.
PowerPlus Energy will protect this product under
warranty when it is installed as written in this manual
and used as set out in the warranty documents. Any
product not being used or installed as outlined will be in
violation of the terms and will render the product void of
any warranty.
PowerPlus Energy does not cover warranty or any
liability for damages or defects caused or from the
following:
•Incorrectstorageortransportation.
•Incorrectinstallationandwiring.
•Installednotaccordingtothismanual.
•Incorrectoperation.
•Inappropriateenvironmentalconditionswhen
operating the battery.
•Failure to follow safety requirements.
•Tampering of or opening the battery.
•Unauthorisedrepairsormodications.
•Externalinuencessuchasphysicaldamage,over
charging or electrical damage.
•Used outside of warranty terms and conditions.
11. End of Life 12. Warranty
PowerPlus Energy Pty Ltd
2 Koornang Road
Scoresby, Vic, 3179
Australia
+61 3 8797 5557
info@powerplus-energy.com.au
powerplus-energy.com.au
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