PowerPlus Energy LiFe Premium P Series User manual

Installation and Operation
Manual
LiFe Premium P Series Installation
Manual
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LiFe Premium P Series Lithium Battery
[phone] | [e-mail] | Building 21-25, 885 Mountain Hwy, Bayswater Vic 3153 | powerplus-energy.com.au
Residential
Commercial
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Utilities and
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Introduction
The LiFe Premium 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 LiFe Premium 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 Life Premium P Series battery. Currently the LiFe Premium P Series
battery is available in 24V and 48V and 120V version.
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Introduction!2"
Safety!4"
Transportation!4"
Basic Safety!5"
Handling!5"
Damaged Battery!6"
Fire!6"
Qualified Person (Installer)!6"
Product Information!7"
Weight and Dimensions!7"
Specifications!8"
Charging and Discharging!9"
Charging Curves!10"
Discharging Curves!11"
State of Charge Vs Voltage!12"
Circuit Breaker Characteristic!13"
Installation!14"
Location and Environment!14"
Extreme Humidity Climates!14"
Battery Installation!15"
Battery Connections!16"
Main DC Connections!16"
Case Earthing!17"
Battery Alarm and Communication Installation!18"
Data Logging LiFe 12033P!19"
PowerLink!19"
PowerLink Installation!19"
PowerPlus Energy Battery Enclosures!20"
Rack Series Enclosures!20"
Rack Series Specification!20"
Rack Series Enclosure Installation!21"
SlimLine Series Enclosures!22"
SlimLine Series Specification!22"
PEW3 & PEW4 Installation!23"
PEF6W-250B Installation!24"
PEF9W-250 Installation!25"
Battery Operation!26"
Main Status LED!26"
BMS Status LED!26"
Full Recharge Upon First Installation!27"
Trouble Shooting!28"
Maintenance!28"
Upgrading Battery Capacity!28"
Capacity Testing Battery!29"
End of Life!29"
Warranty!30
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Safety
Installers and users are responsible for familiarising themselves with this manual.
The LiFe Premium 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 with no heavy metals
and are fully recyclable.
Each LiFe Premium 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 to all necessary standards
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.
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Basic Safety
The following precautions should be observed:
•Battery should not be exposed to temperatures above or below the temperature ratings 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 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
LiFe2433P
LiFe4833P
LiFe12033P
LiFe4822P
Depth
635mm
635mm
635mm
420mm
Width
434mm
434mm
434mm
434mm
Height
88mm
88mm
88mm
88mm
Weight
41kg
41kg
41kg
30kg
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Specifications
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LiFe2433P
LiFe4833P
LiFe4822P
LiFe12033P
Terminal Connections
Amphenol Surlok 100A Non Keyed
Module Weight
41kg
30kg
41kg
Operational Voltage Window
20V to 29.2V
40V to 58.4V
40V to 58.4V
100V to 146V
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 (k Curve)
2-Pole 63A 360VDC
2-Pole 25A 360VDC
Self Discharge
14% Per Annum
Lithium Composition
Lithium Ferro Phosphate (LiFeP04 or LFP)
IP Rating
IP40
Efficiency
>96%
Expected Life @25°C
Greater than 10 years when used as per warranty terms
Cooling
Natural convection
Parallel Connection
Unlimited - Refer Manufacturer
Serial Connection
N/A
Alarm Output
Normally closed, Volt free, 1A maximum
Communications
N/A - See ‘PS’ range
Battery Performance
data via PowerLink Data
device.
Certifications
Pending IEC:
62619:2017, UN38.3,
EMC
IEC: 62619:2017,
UN38.3, EMC
Pending IEC:
62619:2017, UN38.3,
EMC
Pending IEC:
62619:2017, UN38.3,
EMC
LiFe2433P
LiFe4833P
LiFe4822P
LiFe12033P
Nominal DC Voltage
25.6V
51.2V
128.0V
Nominal Capacity
3.3kWhr (3.277) / 128Ah
3.3kWh (3.277) / 64Ah
2.2kWh (2,211) / 43Ah
3.3kWh (3.277) / 25.6Ah
Continuous Discharge Current
63A
63A
43A
25A
Continuous Charge Current
63A
32A
21.5A
12.8A
Maximum Current
63A (Limited by circuit breaker)
25A (Limited by circuit
breaker)
Continuous Discharge C-Rate
0.5C (C2)
1C (C1)
Battery Fault Current (1ms)
250A
110A
Arc Flash Incident Energy
IEm in Cal/cm (45cm)
0.25
0.36
0.36
0.54
Arc Flash Incident Energy
AFB in cm2
20.45
24.45
24.45
30.19
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 60°C
Operating Humidity
(Non condensating)
85%
Altitude
Below 2000m
Battery Dimensions
635mm D x 434mm W x 88mm H
420mm D x 434mm W x
88mm H
635mm D x 434mm W x
88mm H
Battery Mounting Options
Standard 19” Rack Mount / Horizontal / Vertical

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
LiFe2433P
LiFe4833P
LiFe4822P
LiFe12033P
Shut Down SoC
(Recommended)
20%
DC Volts Shut Down 0% Load
24.0V
48.0V
120.0V
DC Volts Shut Down 100%
Load
23.0V
46.0V
115.0V
Recovery / Restart Voltage
26V
52V
130V
Continuous Charge Voltage
(Per Warranty)
28.8V
57.6V
142V
Float Voltage Cyclic
(Short Term Float)
(Example Solar Application)
28.8V
57.6V
142V
Float Voltage Standby
(Long Term Float)
(Example UPS Application)
27.2V to 28V
54.4V to 56V
140V
Peukert Exponent
1.02
100% recharge
(Recommended)
7 to 14 days to keep External SoC counter accurate
Continuous Discharge Current
63A
63A
43A
25A
Continuous Charge Current
63A
32A
21.5A
12.8A
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 to at
anytime without notice

Charging Curves"
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Discharging Curves
"
"
"
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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
LiFe2433P
LiFe4833P
LiFe12033P
100%
>26.50V
>53.00
>132.50
99%
26.25V
52.50
131.25
98%
26.00V
52.00
130.00
97%
25.88V
51.75
129.38
96%
25.86V
51.72
129.30
90%
25.85V
51.70
129.25
80%
25.83V
51.65
129.13
70%
25.75V
51.50
128.75
60%
25.66V
51.32
128.30
50%
25.58V
51.15
127.88
40%
25.50V
51.00
127.50
40%
25.38V
50.75
126.88
30%
25.25V
50.50
126.25
20%
25.10V
50.20
125.50
10%
24.75V
49.50
123.75
0
24.00V
48.00
120.00
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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 LiFe Premium 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 (i.e. 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 9inch 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 railsRack 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 LiFe battery case is floating and in most installations will not require earthing. However should your
application require the case to be grounded an 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.
The BMS trip will self reset once trip fault has been resolved or removed, 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.
Description
Part Number
Battery Bridge connector
COMLBA
Battery daisy chain connector lead (30cm)
COM003A
Battery Comms Cable (2Metre)
COM020A
Battery Comms Cable (5Metre)
COM050A
Battery Comms Cable (10Metre)
COM100A
Battery Comms Cable (15Metre)
COM150A
Description
Part Number
LiFe 120 data logger
SmartLink
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Data Logging LiFe 12033P
Each 120V LiFe Series battery has the ability to report battery information when connected via the RJ45
alarm contact output to a PowerLink data logger.
PowerLink
Each PowerLink can connect up to 20 batteries and multiple PowerLink’s can be connected to the one
system portal.
PowerLink Installation
Refer PowerLink Installation Guide.
Battery Measurements
Battery Current"
Battery Voltage"
Battery Temperature
Pack Measurements
Pack Current"
Pack Voltage
Coming Soon (implementation pending)"
Sate of Charge, State of Health, Throughput Energy, SNMP, CANBus,"
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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
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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