Sonnen sonnenBackup-Box User manual

Installation instructions | for authorised electricians
sonnenBackup-Box
for sonnenBatterie eco 8.0 and hybrid 8.1
KD-492 • Part no. 22320 • Version X00 [email protected] • sonnen.de

Publisher
sonnen GmbH
Am Riedbach 1
D-87499 Wildpoldsried
Service number [phone]
Email [email protected]
Document
Document number 492
Part number 22320
Version X00
Valid for AU
Publication date 11/06/2018
IMPORTANT
 Read this documentation carefully before installation / operation.
 Retain this document for reference purposes.
EN
Installation instructions sonnenBackup-Box

Table of contents
KD-492 | 22320 | EN | X00 iii
Table of contents
1 Information about this document........................................................................................................ 5
1.1 Target group of this document ................................................................................................... 5
1.2 Designations in this document .................................................................................................... 5
1.3 Explanation of symbols................................................................................................................... 5
2 Safety.............................................................................................................................................................. 6
2.1 Intended use....................................................................................................................................... 6
2.2 Requirements for the electrician................................................................................................6
2.3 Operating the Backup-Box........................................................................................................... 6
2.4 Product modifications or changes to the product environment.................................... 7
2.5 Voltage inside the Backup-Box.................................................................................................... 7
3 Product description...................................................................................................................................8
3.1 Technical data....................................................................................................................................8
3.2 System components........................................................................................................................9
3.2.1 System components of the Backup-Box................................................................... 9
3.2.2 Inverters of the Backup-Box.........................................................................................10
3.2.3 Connections on the Backup-Box..................................................................................11
3.3 Type plate...........................................................................................................................................12
3.4 Symbols on the outside of the Backup-Box...........................................................................12
3.5 Transport and storage....................................................................................................................13
4 Mounting ..................................................................................................................................................... 14
4.1 Scope of delivery............................................................................................................................ 14
4.2 Additional parts required ............................................................................................................. 14
4.3 Selecting the installation location..............................................................................................15
4.3.1 Requirements for the installation location...............................................................15
4.3.2 Observe minimum and maximum distances............................................................15
4.4 Mounting the Backup-Box ...........................................................................................................15
4.4.1 Requirements for mounting material.........................................................................15
4.4.2 Drilling the holes................................................................................................................15
4.4.3 Fastening the Backup-Box.............................................................................................16
5 Electrical installation................................................................................................................................17
5.1 Emergency operation design ..................................................................................................... 18
5.2 Positioning components in the electrical distributor .........................................................19
5.3 Wiring components in the electrical distributor...................................................................19
5.4 Attaching safety label to the distributor .................................................................................21
5.5 Connection to the Backup-Box.................................................................................................22
5.5.1 Connecting earthing cables .........................................................................................22
5.5.2 Routing the battery cables............................................................................................23
5.5.3 Connecting the mains cables.......................................................................................24
5.5.4 Routing the control signal cable.................................................................................25
5.5.5 Using the signalling contact .........................................................................................25
5.6 Connection to the storage system ..........................................................................................26
5.6.1 Routing cables into the storage system................................................................... 27

Table of contents
iv Installation instructions sonnenBackup-Box
5.6.2 Connecting the earthing cable..............................................................................28
5.6.3 Connecting the battery cables..............................................................................29
5.6.4 Connecting the control signal cable .................................................................. 30
6 Commissioning................................................................................................................................... 33
6.1 Commissioning checklist ...................................................................................................... 33
6.2 Switching on the storage system....................................................................................... 33
6.3 Switching on the grid voltage ............................................................................................. 33
6.4 Setting up the Backup-Box.................................................................................................. 33
6.5 Setting the backup buffer ....................................................................................................33
6.6 Testing backup operation .....................................................................................................34
6.7 Filling in the commissioning report...................................................................................34
7 Decommissioning.............................................................................................................................. 35
7.1 Switching off the Backup-Box............................................................................................ 35
7.2 Disconnecting the Backup-Box from the power supply ........................................... 35
8 Uninstallation and disposal ............................................................................................................ 36
8.1 Uninstallation............................................................................................................................. 36
8.2 Disposal ....................................................................................................................................... 36
9 Troubleshooting..................................................................................................................................37
10 Commissioning report sonnenBackup-Box............................................................................. 38

Information about this document | 1
KD-492 | 22320 | EN | X00 5 / 40
1 Information about this document
This document describes the installation of the sonnenBackup-Box in connection
with the storage system sonnenBatterie eco 8.0 or hybrid 8.1.
Read this document in its entirety.
Keep this document in the vicinity of the sonnenBatterie.
1.1 Target group of this document
This document is intended for authorised electricians. The actions described here
must only be performed by authorised electricians.
1.2 Designations in this document
The following designations are used in this document:
Complete designation Designation in this document
sonnenBatterie eco 8.0 Storage system
sonnenBatterie hybrid 8.1
sonnenBackup-Box Backup-Box
1.3 Explanation of symbols
DANGER Extremely dangerous situation leading to certain death or serious injury if
the safety information is not observed.
WARNING Dangerous situation leading to potential death or serious injury if the safety
information is not observed.
CAUTION Dangerous situation leading to potential injury if the safety information is
not observed.
NOTICE Indicates actions that may cause material damage.
Important information not associated with any risks to people or property.
Symbol Meaning
►
Work step
1. 2. 3. … Work steps in a defined order
üCondition
• List
Table1: Additional symbols

2 | Safety
6 / 40 Installation instructions sonnenBackup-Box
2 Safety
2.1 Intended use
The sonnenBackup-Box is an emergency power unit designed to supplement the
sonnenBatterie eco 8.0 or hybrid 8.1. The Backup-Box - in conjunction with the
appropriate storage system of the sonnen GmbH - serves to supply power in the
event of a power failure. Any other use is considered improper use.
Improper use poses a risk of death or injury to the user or third parties as well as
damage to the product and other items of value. The following points must there-
fore be observed in order to comply with the intended use of the product:
• Only operate the Backup-Box together with the right storage system.
• The Backup-Box must be installed by an authorised electrician.
• The Backup-Box must only be connected to the storage system as described
here.
• Isolated operation is not possible with the Backup-Box. A generator (e.g. a PV
system) must never be connected after the output of the Backup-Box.
• Intended use includes observing this document as well as all accompanying
product documentation of the appropriate storage system.
• The Backup-Box must only be used at suitable installation location.
• The transport and storage conditions must be observed.
Especially the following uses are not permissible:
• Operation in flammable environments or areas at risk of explosion.
• Operation in locations at risk of flooding.
• Operation outdoors.
Failure to comply with the conditions of the warranty and the information
specified in this document invalidates any warranty claims.
2.2 Requirements for the electrician
Improper installation can result in personal injury and/or damage to components.
For this reason, the Backup-Box must only be installed and commissioned by au-
thorised electricians. Authorised electricians must meet the following criteria:
• The electrician must be a person with a technical knowledge or sufficient ex-
perience to enable him/her to avoid dangers which electricity may create.
• The company for which the electrician works must be certified by sonnen
GmbH.
• The electrician must have successfully complete sonnen GmbH certification
training for the product.
2.3 Operating the Backup-Box
Incorrect operation can lead to injury to yourself or others and cause damage to
property.

Safety | 2
KD-492 | 22320 | EN | X00 7 / 40
• The Backup-Box must only be operated as described in the product document-
ation.
• This device can be used by children from the age of eight (8) years old and in-
dividuals impaired physical, sensory or mental capabilities or individuals with
limited knowledge and/or experience of working with the device, as long as
they are supervised or have been trained to safely use the device and under-
stand the resulting risks of doing so. Children must not play with the device.
Cleaning and user maintenance must not be carried out by children without su-
pervision.
2.4 Product modifications or changes to the product
environment
• The Backup-Box must only be used in its original state without any user modi-
fications and only when in perfect working order.
• Safety devices must never be overridden, blocked or tampered with.
• The interfaces of the Backup-Box and the storage system must be wired in ac-
cordance with the product documentation.
• All repairs on the Backup-Box must be performed by authorised service tech-
nicians only.
2.5 Voltage inside the Backup-Box
5 min
The Backup-Box contains live electrical parts, which poses a risk of electrical
shock. The Backup-Box and storage system inverter also contain capacitors which
carry voltage even after the storage system is switched off.
Therefore:
Disconnect the Backup-Box and the storage system from the power (see
Switching off the Backup-Box [P.35] and the product documentation of
the storage system).
Only then can the Backup-Box be opened.

3 | Product description
8 / 40 Installation instructions sonnenBackup-Box
3 Product description
3.1 Technical data
sonnenBackup-Box
System data
Maximum power (2 sec.) 4,100VA
Overload (30 min.) max. 2,800VA
Nominal power 1,800VA
Nominal frequency 50 Hz
Output voltage 230V +/- 10%
Mains connection three-phase, L1 / L2 / L3 / N / PE
Mains connection fuse Miniature circuit breaker | Type C | 32 A
Operating concept single-phase power supply via phase L1 | The switch
to backup operation takes place automatically
through the storage system.
Switchover time to
backup operation
approx. 3 seconds
Mains topology TN / TN-S / TN-C-S
Threshold power approx. 5 W
Safety / Protective devices
Protection class I (PE conductor)
Degree of protection IP30
Protective functions Overvoltage protection, Overcurrent protection,
Overtemperature protection
Fault-current circuit breaker (RCD) external RCD required
Separation principle Batt. -> AC galvanic isolation
Dimensions / Weight
Dimensions (H/W/D) in cm 70/67/23
Weight in kg 46
Ambient conditions
Environment indoor (conditional)
Ambient temperature range -5 °C ... 45 °C
Max. rel. humidity 90 %, non-condensing
Permissible installation altitude 2,000 m above sea level
Additional ambient conditions The ambient conditions prescribed for the
storage system apply.

Product description | 3
KD-492 | 22320 | EN | X00 9 / 40
3.2 System components
3.2.1 System components of the Backup-Box
4
6
5
7 8
9
10
12 13
11
14
1
32
Illustration1: System components of the Backup-Box
1 Backup-Box 4 X3.B terminal strip position
2 Slave inverter 5 X1.B terminal strip position
3 Master inverter 6 X2.B terminal strip position
Cable glands
7 Mains IN 11 Minus (negative) battery cable
8 Mains OUT 12 Control signal cable
9 Cable for signalling contact 13 Earthing cable to storage system
10 Plus (positive) battery cable 14 Earthing cable to main earthing terminal

3 | Product description
10 / 40 Installation instructions sonnenBackup-Box
3.2.2 Inverters of the Backup-Box
NOTICE Incorrect switch position on the inverters
Damage to the inverters of the Backup-Box!
The correct switch position was marked by a label.
Do not change the switch position of the rotary switches on the two in-
verters of the Backup-Box.
The two inverters within the Backup-Box each have a rotary switch and an LED
light.
Rotary switch
It is essential for the function of the Backup-Box that the rotary switches on both
inverters are set correctly. The rotary switches have been factory set in the cor-
rect position and this position has been marked by a sticker.
Do not change the switch position on the inverters.
• Master inverter: STANDBY area.
• Slave inverter: OFF.
LED light
The LED light indicates the current state of the inverter:
LED colour Status Meaning
-Off Power supply switched off
green Permanently illuminated Consumer device switched on
Blinking slowly Standby operation, no consumer device was
recognized
red Blinking slowly System error; please contact the sonnen Ser-
vice
Blinking quickly Overcurrent
Permanently illuminated Overheating
red-green Blinking slowly Battery undervoltage or low charge state
Blinking quickly Battery overvoltage

Product description | 3
KD-492 | 22320 | EN | X00 11 / 40
3.2.3 Connections on the Backup-Box
The positions of the terminal strips or terminals inside the Backup-Box can be
found in section System components of the Backup-Box [P.9].
X1.B terminal strip overview
Terminal Function
1–3 AC line IN phase1–3
4 AC line IN neutral conductor
5 AC line IN earthing conductor
6–8 AC line OUT phase1–3
9 AC line OUT neutral conductor
10 AC line OUT neutral conductor – free
11 AC line OUT neutral conductor – free
12 AC line OUT earthing conductor
13 Earthing conductor to storage system
14 Earthing conductor to main earthing terminal
15 Potential-free signalling contact – closed in backup operation
16 Potential-free signalling contact – closed in backup operation
X3.B terminal strip overview
Terminal block Terminal Function
X3.B 1 Plus (positive) battery voltage
X3.B 2 Minus (negative) battery voltage
Control signal connection overview
Terminal block/
terminal
Wire colour Function
X2.B:9 White GND (earth)
F3.B Brown Supply voltage 24 VDC
K5.B:A1 Yellow Digital output (DO) for emergency shutdown
K6.B:14 Green Digital input (DI) for grid detection (backup sup-
ply active)

3 | Product description
12 / 40 Installation instructions sonnenBackup-Box
3.3 Type plate
The type plate is located on the outer surface of the Backup-Box. The type plate
can be used to uniquely identify the Backup-Box. The information on the type
plate is required for the safe use of the system and for service matters.
The following information is specified on the type plate:
• Item designation
• Item number
• Technical data
3.4 Symbols on the outside of the Backup-Box
Symbol Meaning
Warning: flammable materials.
Warning: hazards due to batteries.
Warning: electrical voltage.
5 min
Warning: electrical voltage. Wait five minutes after switching
off (capacitor de-energising time).
Warning: The information in the manuals regarding the rotary
switch settings must be observed.
kg
Warning: product is heavy.
CE mark. The product meets the requirements of the applic-
able EU Directives.
WEEE mark. The product must not be disposed of in house-
hold waste, dispose of it through environmentally friendly col-
lection centres.

Product description | 3
KD-492 | 22320 | EN | X00 13 / 40
Symbol Meaning
Observe the documentation. The documentation contains
safety information.
3.5 Transport and storage
Transport and storage conditions are defined in the product documentation of
the storage system.
Observe the same transport and storage conditions for the Backup-Box.

4 | Mounting
14 / 40 Installation instructions sonnenBackup-Box
4 Mounting
4.1 Scope of delivery
Check the following scope of delivery to ensure it is complete.
1x
1x
1
9
8
1x
4
1x 1x
5
2x
7
1x
2
3
6
2x 1x
1 Backup-Box incl. internally pre-assembled lines (Battery lines, Control signal line)
2 Earthing line for connection to the storage system
3 Branch terminal
4 Cable entry plate, round
5 Blanking plug with membrane grommet
6 Battery line, red and black
7 Safety label
8 Installation instructions
9 Operating instructions
4.2 Additional parts required
The following components are not included in delivery and must be selected
and ordered by the qualified electrician accordingly:
2 x mains connection cable (for Connecting the mains cables [P.24])
• Cable cross-section as per country-specific specification (at least 5G6mm²).
1 x earthing cable (for Connecting earthing cables [P.22])
• Cable cross-section: 10mm2.
Optional: Cable gland with multi-seal insert (see Routing cables into the storage
system [P.27]).

Mounting | 4
KD-492 | 22320 | EN | X00 15 / 40
4.3 Selecting the installation location
4.3.1 Requirements for the installation location
Observe the required ambient conditions (see Technical data [P.8]).
4.3.2 Observe minimum and maximum distances
• The Backup-Box should be mounted to the right or left of the storage system.
Install the Backup-Box at the same level as the top edge of the storage sys-
tem, if possible.
15
5
10 - 50
15 cm
10 30 - 50
Illustration2: Distances to the Backup-Box
(Figure not to scale - all specifications in centi-
metres)
Observe the specified maximum dis-
tances between the Backup-Box and
the storage system, so that the length
of the pre-assembled and supplied
cables is sufficient.
Observe the specified minimum dis-
tances to the storage system and
neighbouring objects, so that there is
sufficient heat dissipation, the door
can be opened easily and there is suf-
ficient space for installation and main-
tenance work.
4.4 Mounting the Backup-Box
4.4.1 Requirements for mounting material
Use only screws with the following properties:
8 mm max. 15 mm
max. 6 mm
Illustration3: Parameters of the screw used
• Screw head diameter: max. 15 mm
• Screw diameter: 8 mm
• Hight of screw head: max. 6 mm
• The screw lengths and the wall plugs used must be suitable for the nature of
the wall.
4.4.2 Drilling the holes
A drilling template is part of the packaging of the Backup-Box. Therewith it is
easier to mark the position of the holes on the wall. Please use the holes
marked as ‘main cabinet’ for the Backup-Box.

4 | Mounting
16 / 40 Installation instructions sonnenBackup-Box
1610
1532
838,5
524
226
33
626
526
Illustration4: Drill template for Backup-Box
(Figure not to scale - all specifications in milli-
metres)
Drill the holes shown in red in the illus-
tration on the left.
4.4.3 Fastening the Backup-Box
1. Apply the screws
There are keyhole attachments on the rear of the Backup-Box. The Backup-Box is
mounted using these attachments.
2 mm
Illustration5: Distance between screw head
and wall
Apply suitable screws and anchors
(see Requirements for mounting ma-
terial [P.15]) to the previously drilled
holes.
The screw should not be completely screwed in. The screw head should protrude
from the wall by approx. 2 mm.
2. Attach the Backup-Box
Illustration6: Hanging up the Backup-Box
Attach the Backup-Box to the previ-
ously mounted screws.
3. Tighten the screws
Illustration7: Tightening the screws
Tighten all visible screws.

Electrical installation | 5
KD-492 | 22320 | EN | X00 17 / 40
5 Electrical installation
DANGER Electrical work on the storage system and electrical distributor
Danger to life due to electrocution!
Switch off the storage system to electrically isolate it.
Disconnect the relevant electrical circuits.
Secure against anyone switching on the device again.
Wait five minutes so the capacitors can discharge.
Check that the device is disconnected from the power supply.
Only authorised electricians are permitted to carry out electrical work.
DANGER Touch voltage in the event of a fault during backup operation
Danger to life due to electrocution!
A residual current device (RCD) must be installed downstream of the
output of the Backup-Box.
NOTICE Observe maximum line lengths
None of the lines connected to the Backup-Box and the storage system
(mains line, ethernet line, other data lines) are allowed to exceed a max-
imum length of 30m.

5 | Electrical installation
18 / 40 Installation instructions sonnenBackup-Box
5.1 Emergency operation design
Before installation, the installer must explain or clarify with the operator the fol-
lowing points.
• Emergency operation does not offer the same output as grid operation.
• Three-phase current is not available during emergency operation (as only one
phase is supplied with power).
•Which consumers should be supplied with power in emergency operation? The
current paths in the building network can be installed in such a way that phase
L1 of the Backup-Box (emergency phase) is laid on the phase that supplies
power to the relevant consumers. The electrical consumers which are crucial
for the operator in emergency operation are relevant here. Different con-
sumers which may be important during a grid outage are specified in the
sample calculation presented below.
•How much capacity of the storage system should be reserved as an emer-
gency buffer? The following example can be used to determine this. This ex-
ample is based on a grid outage lasting one hour (the individual power con-
sumption values are estimated values).
Electrical consumer Power
consumption
[W]
Active during
grid outage
[h]
Electrical
work
[kWh]
Refrigerator 600 0.25 0.15
Freezer 600 0.25 0.15
Heating 700 0.25 0.175
Door/garage door opener 50 0.1 0.005
Aquarium pump 20 1 0.02
Lighting 500 1 0.5
Router, telephone 10 1 0.01
Flat-screen television/radio 100 1 0.1
Alarm system, grid-connected
smoke detector
50 1 0.05
Total 1.16
In this example, the total power requirement for a grid outage lasting one hour is
approx. 1.2kWh, in order to maintain the function of all of the listed consumers.
Use this calculation to determine with the operator which emergency buffer
should be set, taking the total capacity of the storage system and other re-
quirements (e.g. from sonnenFlat tariff) into account (see Setting the backup
buffer [P.33]).

Electrical installation | 5
KD-492 | 22320 | EN | X00 19 / 40
5.2 Positioning components in the electrical distributor
The following components must be installed in the electrical distributor for the
Backup-Box:
•Circuit breaker (miniature) | typeC | 32A
A miniature circuit breaker with typeC tripping characteristics and a nominal cur-
rent of 32A must be installed upstream of the input for the Backup-Box.
•Residual current device (RCD)
A residual current device must be installed at the output of the Backup-Box. This
RCD protects against electrocution during backup operation. An RCD must be
used which complies with the respective country-specific regulations and the
local network conditions.
•In network with TT earthing: Additional residual current device (RCD) |
300mA
In networks with TT earthing, an additional residual current device must be in-
stalled upstream of the input for the Backup-Box. An RCD with a nominal differen-
tial current of 300mA is sufficient for this. RCDs with a nominal differential cur-
rent of 100mA or 30mA can also be used. A selective residual current device
must be used.
5.3 Wiring components in the electrical distributor
Wire the components previously installed in the electrical distributor as shown
in the following figure.
Note:
The figure on the following page shows a connection diagram with an overview of
the electrical connections of a storage system with the Backup-Box. Two areas A
and B are labelled in the figure.
• The figure shows the installation of a sonnenBatterie eco8.0 as an example,
which has been installed in accordance with the specifications in the product
documentation (areaA) and to which a Backup-Box has now been added
(areaB).
• In the case of a sonnenBatterie hybrid8.1, pro2.0 or a sonnenFlat, the installa-
tion of the Backup-Box (areaB) is identical, but the installation of the storage
system itself in areaA differs.
The information on the differing electrical installations can be found in the docu-
mentation for the product in question.

5 | Electrical installation
20 / 40 Installation instructions sonnenBackup-Box
11
L1 L2 L3 N PE
10
12
1
2
5
AB
kWh 3~
L1 L2 L3 N PE
NL1 L2 L3
A1 A2
16
15
13
14
3
1
2
L1 L2 L3 N PE
L1 L2 L3 N PE
17
1
1 2 3
2
6
1
4
9
8
7
L1
L2
L3
N
PE
L1
L2
L3
N
PE
6
3
2
33
4
1 2 3
5
Section A - Existing installation of the storage system
1 PV inverter 7 Current transformer consumption L1 13 Bidirectional counter
2 Current transformer generation L1 8 Current transformer consumption L2 14 Public electrical mains
3 Current transformer generation L2 9 Current transformer consumption L3 15 Power meter MCB
4 Current transformer generation L3 10 RCD1
5 Transformer interface generation (A1) 11 Storage system MCB216 Power meter
6 Transformer interface consumption (A2) 12 Storage system 17 PV inverter MCB
Section B - Altered installation by Backup-Box
1 Consumers in building 3 Earth connection 5 RCD (in TT networks)
2 RCD 4 Backup-Box 6 Miniature circuit breaker | Type C | 32A
1 According to the requirement in the installation instructions of the storage system.
2 Miniature Circuit Breaker.