Operating Manual
HOPPECKE sun | powerpack premium
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Foreword
Dear Customer,
Thank you very much for having decided in favour of a product bearing our brand name.
Before working on the battery system or its components, please read this documentation
carefully. It contains important information on secure and professional unpacking, storing,
installing, operating and maintaining the sun|powerpack premium battery system.
Amendments to this documentation are subject to change without prior notice. Our products
undergo continuous advanced development. As a result, there may be deviations between
the illustrations given in this documentation and the purchased product. This installation
manual is not covered by any change service.
Keep this documentation in such a manner that it is available immediately to all those who
need to carry out work in connection with the battery system or its components.
Service Hotline Germany:
0800 246 77 32
International service hotline:
+49 (0) 180 5 22 9999
Internet: www.HOPPECKE.com
Email: [email protected]
Copyright HOPPECKE Batterien GmbH & Co. KG
All rights reserved including those of patent and utility model applications.
Disclosure of as well as copying this documentation and using or revealing its contents are
not permissible unless this has been expressly approved in writing by HOPPECKE Batterien
GmbH. Infringements will lead to liability for damages.
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Table of contents
1. TARGET GROUP 5
2. MEANS OF REPRESENTATION 6
3. SAFETY INSTRUCTIONS 7
3.1. General Safety Instructions 7
3.2. Intended Use 8
3.3. Directives, Legislation and Standards 8
3.4. Obligations of the Operator 9
3.5. Occupational safety 9
3.5.1. Personnel and Qualification 9
3.5.2. Personal Protective Equipment 10
3.6. Special information on Li-Ion batteries 10
3.6.1. First-aid measures if cell contents leak out 11
3.6.2. Fire-fighting procedures 11
3.6.3. Disposal instructions 12
3.7. Transport 12
3.7.1. Intact, undamaged batteries and batteries at the end of their service life 13
3.7.2. Defective batteries 14
3.7.3. Check the delivery 14
4. SUN|POWERPACK PREMIUM BATTERY SYSTEM 16
4.1. Hints for sizing of the system 18
5. STORAGE 19
5.1. Intact, undamaged batteries and batteries at the end of their service life 19
5.2. Defective batteries 19
6. PREPARING FOR INSTALLATION 20
6.1. Installation site 20
6.2. Tools and Equipment 21
7. INSTALLATION 22
7.1. Assembling and installing the housing 22
7.1.1. Grounding the housing 24
7.2. Installing the battery stacks 25
7.3. Connecting the battery stacks electrically 30
7.4. Connecting the battery inverter 34
7.5. Commissioning 36
7.6. Final work 37
Target Group
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8. REGISTERING THE BATTERY SYSTEM 39
9. OPERATING THE BATTERY SYSTEM 40
9.1. Safety Functions 42
9.2. Display Unit 42
9.3. Operating states 43
10. MAINTENANCE AND CARE 45
10.1. Cleaning 45
10.2. Repair Work 45
10.3. BMS software update 45
11. END OF SERVICE LIFE 46
12. WARNING AND ERORR MESSAGES 47
13. SYSTEM EXPANSION 49
14. DISASSEMBLY 49
15. TECHNICAL SPECIFICATIONS 50
15.1. System 50
15.2. Battery cell 50
15.3. Norms and Standards 50
16. CE DECLARATION OF CONFORMITY 51
17. ABBREVIATIONS 52
18. FURTHER INFORMATION 53
19. APPENDIX 54
19.1. Certification of the function of the smoke detector 54
19.2. Certification of installation and commissioning 54
Target Group
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1. Target Group
This Operating Manual is meant for dealers, electricians and end users. It describes the
transport, storage, installation, operation, maintenance and disassembly of the
sun|powerpack premium battery system. The work of installation, maintenance and
disassembly should be done only by electricians.
Note:
Proper installation and commissioning must be certified by the respective electrician with his
signature in this operating manual (see chapter 19). The signed operating manual must remain
with the end user of the battery system.
Means of Representation
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2. Means of Representation
The following icons and signal words have been used in this operating and maintenance
manual:
DANGER!
Denotes an immediate hazard with a high level of risk that could lead to death or severe physical
injury if it is not prevented.
WARNING!
Denotes a potential hazard with a medium level of risk that could lead to death or severe physical
injury if it is not prevented.
CAUTION!
Denotes a hazard with a low level of risk that could lead to minor or medium degree of physical
injury if it is not prevented.
ATTENTION!
Denotes a hazard in which the product, other objects or the environment may get damaged if it is
not prevented.
Denotes first-aid measures.
Note:
Denotes instructions that are important for optimal utilisation of the product.
Safety Instructions
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3. Safety Instructions
Observe and follow the safety instructions given below when handling the sun|powerpack
premium battery system as well as its components.
3.1. General Safety Instructions
DANGER!
Metallic parts of the batteries are always live. Do not short-circuit the batteries! Very high values
of current may flow and cause burn injuries in case of a short-circuit. Touching electrically
conducting parts may cause cardiac arrhythmia and shock.
Please be very careful when doing any work on the battery system in order to prevent severe
injuries caused by electrical shocks or burns.
Never place tools or other metallic objects on a battery.
Be sure to remove watches and jewellery before doing any work on the batteries.
Do not touch any exposed battery parts, jumpers, terminals or poles!
Just as with other batteries, lithium-ion batteries may represent a source of hazard even in an
apparently discharged condition by high short-circuit currents.
DANGER!
The battery stacks and the included battery cells should not be damaged mechanically
(puncturing, deforming or disassembling). Keep away from open flames or sources of intense
heat. There is a risk of heat developing and leakage of liquid electrolyte and gases.
DANGER!
At temperatures above 80 °C there is danger of the Li-Ion batteries bursting and the discharge of
liquid electrolyte and gases. There is danger of the escaping materials igniting. Reactions of the
electrolytes and the electrodes with water and humidity are possible.
Use only those battery chargers that have been approved by HOPPECKE for use with
sun|powerpack premium.
ATTENTION!
The use of an automatic smoke alarm system is necessary at the place of installation.
ATTENTION!
Children must be kept away from the battery system.
Note:
Observe and follow this operating manual and keep it such that it is easily visible at the
installation site of the battery system.
Safety Instructions
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3.2. Intended Use
The sun|powerpack premium battery system serves to store electrical energy. It is set up
and wired at the installation site. The battery system should be operated only with approved
battery inverters / battery chargers. A list of approved battery inverters / battery chargers
can be downloaded from www.hoppecke.com (see also chapter 7.4).
DANGER!
Unintended use of the batteries may lead to personal injuries or damage to property.
In case of unintended use, HOPPECKE Batterien GmbH & Co. KG shall not assume any liability
for personal injuries or damage to property that result directly or indirectly from handling the
batteries.
The operator shall be solely responsible for the risks arising from unintended use.
ATTENTION!
The sun|powerpack premium should not be used as an emergency power supply system, if the
failure of the loads connected may lead to personal injuries (e.g. for power supply to medical
devices with life-sustaining functions).
ATTENTION!
Only those inverters that have been approved by HOPPECKE must be used. The overall system
comprising inverter, PV system, battery system and any other components must be designed
diligently. In the process, the system parameters and limit values of the battery as well as all
relevant norms and standards must be complied with.
3.3. Directives, Legislation and Standards
Observe and follow the rules and regulations applicable to the installation and operation of
stationary battery installations.
Please observe the latest edition of each of the following rules and regulations:
Accident prevention regulations, especially DGUV rule 3 (formerly BGV-A3): Electrical
systems and equipment
DIN EN ISO 20345 ("Personal safety gear – Safety boots")
DIN VDE 100/IEC 60364 ("Erection of low-voltage installations")
DIN EN 50110/VDE 0105 ("Operation of electrical installations")
DIN EN 50272/VDE 0510 ("Safety requirements for secondary batteries and battery
installations")
DIN VDE 1000-10 ("Requirements for persons working near electrical equipment")
VDE-AR-E 2510-50 (“Stationary energy storage systems with lithium batteries”)
Please note that different and further rules and regulations may be required outside
Germany . Please observe local rules and regulations accordingly.
Safety Instructions
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3.4. Obligations of the Operator
Please keep the documentation in such a manner that it is available immediately to all
persons who need to carry out work in connection with the batteries or their components.
WARNING!
The requirements for safe operation of the battery installation must be complied with for
subsequent modifications at the installation site. Otherwise, any claims for warranty become null
and void.
3.5. Occupational safety
This section contains important information that needs to be observed and followed while
working on the sun|powerpack premium and its components.
Prohibit all work methods that endanger the safety of human beings and impair the
working of the batteries in any manner.
Maintain the work sequence described in the documentation while installing, dismantling
or connecting the battery terminals to the battery inverter / battery charger.
Pay attention to the polarity of the battery stacks.
Ensure that the battery connection cables are fitted tightly. Use only the battery
connecting cables supplied along with the battery.
Battery stack connections should not be made or removed while current is flowing
through the battery connection cables. Before opening the charging circuit, check the
condition of the battery inverter / battery charger by measuring the voltage. Secure the
battery inverter / battery charger against being switched on again.
Observe and follow the operating manuals of the battery inverter / battery charger
manufacturer.
3.5.1. Personnel and Qualification
Work on the battery system, especially its installation, maintenance and disassembly should
be done only by electricians.
Two persons are necessary for the installation and subsequent disassembly. The personnel
must
be well-versed with handling the batteries,
be aware of the precautionary measures that are necessary,
be trained in accordance with DIN VDE 1000-10 and DGUV regulation 3 (formerly BGV
A3) and if applicable local rules and regulations containing requirements for persons
working near electrical equipment.
Please read the documentation carefully before you do any work on the sun|powerpack
premium or its components. It contains important information on secure and professional
unpacking, storing, installing, operating and maintaining the battery system safely and
properly.
Please make sure to contact your local authorised dealer if:
you have any queries on this documentation.
there are local regulations or provisions that are not covered by this documentation or
are contrary to its contents.
Safety Instructions
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3.5.2. Personal Protective Equipment
While working on the sun|powerpack premium or its components, always wear the following
protective equipment in order to prevent injuries or at least to mitigate them:
Safety goggles
Safety gloves
3.6. Special information on Li-Ion batteries
Lithium-Ion batteries are safe if used properly. However, incorrect or improper handling may
lead to leakages and thus, the discharge of the battery constituents. There is the risk of
considerable reactions endangering health and the environment.
DANGER!
Defective batteries may reach conditions that are critical to safety. As a consequence of this, the
batteries may burst or catch fire and hazardous decomposition products may be formed. In case
liquid or gaseous substances are leaking, leave the room immediately and alert the fire brigade.
DANGER!
Basically, coming into contact with battery constituents that have leaked out may pose hazard for
health and the environment. This is why adequate physical protection is necessary and adequate
ventilation must be provided when coming into contact with abnormal batteries (discharge of
contents, deformations, discolouration, bulges or similar). Explosive gases may get released.
Lithium ion batteries may react very severely, for example in combination with fire.
WARNING!
In case of damaged or defective battery cells in sun|powerpack premium or any abnormalities in
the battery system, shut down operation of the battery system immediately. To do this, pull out
the connector of the battery connecting cable at the top of the battery system.
The following measures are applicable only if the battery system is damaged causing
damage to the battery cells and the cell contents start leaking:
Do not inhale vapours that get discharged. Leave the room immediately in case of
smoke development or gas release.
Instructions for specialists: Damaged batteries must be surrounded with dry sand,
chalk powder (CaCO3) or Vermiculite. If possible, they should be stored outside the
buildings. They should best be stored in a sealed, shock-proof and fire-proof external
packaging. The storage place should be marked and safeguarded with warning signs; in
case the battery causes smoke development the storage place must also be monitored.
Make sure to maintain a safe distance to combustible materials with Li-Ion batteries in
any case.
CAUTION!
Do not allow leakage to get into sewer system/surface water/ground water.
Safety Instructions
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Method for cleaning by specialists: Pick up residues mechanically with liquid-binding
material (e.g. sand, sawdust, universal binding agents and diatomite). Dispose of picked up
material in accordance with regulations. Avoid direct contact with the skin and eyes by
wearing protective clothing.
3.6.1. First-aid measures if cell contents leak out
If vapours are inhaled:
Take the affected persons to open air and have them rest quietly. Consult a physician.
In case of contact with skin:
In case of contact with skin, rinse with plenty of water immediately and thoroughly for at least 15
minutes. If skin irritation persists, consult a physician.
In case of contact with eyes:
In case of contact with eyes, rinse immediately and thoroughly with water for at least 15 minutes
and consult a physician. Protect uninjured eyes.
If swallowed:
Consult a physician immediately.
3.6.2. Fire-fighting procedures
Critical conditions may arise as a result of fire, short-circuits, high temperatures (more than
80 °C), intense mechanical impacts or damage. As a consequence of this, the battery cells
may burst or catch fire and hazardous decomposition products and gases may be formed.
WARNING!
If a cell decomposes as a result of mechanical damage or blows off thermally, temperatures up to
800 °C occur on the surface of the cell, the cell opens up and blows off its contents under
excessive pressure. In this process, a white / grey mist is formed in most cases that contains the
electrolytes and other cell constituents. This may also ignite and thus cause a jet of flame (see
also /1/).
WARNING!
Leaking gases are harmful to health and flammable. Without appropriate protective equipment
you must leave the place of fire immediately.
This white mist formed is toxic and corrosive! It can dissolve on the moist surface of the skin and
lead to chemical burns.
ATTENTION!
Alert the fire brigade immediately in case of fire. Inform the disaster relief force that there is a
Lithium-Ion (Li-Ion) battery system located in the building.
Safety Instructions
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3.6.3. Disposal instructions
Disposal should be done in accordance with the European Batteries Directive and the German
Batteries Act (2006/66/EC).
Coordinate the disposal of apparently damaged batteries with the manufacturer HOPPECKE.
Used batteries that bear the recycling symbol are renewable products.
According to the label with the crossed-out garbage can, these batteries must not be set out with
the household rubbish. Returning and recycling the batteries must be agreed upon with the
manufacturer and ensured.
3.7. Transport
To prepare lithium-ion batteries for transport, they should be packed in the original
packaging such that they are safeguarded against short-circuit. The transport to the end
customer takes place either by a freight forwarding company appointed for this purpose or
by the installation agency.
In case of new supply, each unit of delivery consists of the components of an individual
system with either 5 or 7.5 kWh energy content. One individual system is always packed on
one Euro pallet. There is one carton with the housing of the battery system on the pallet,
one carton for each of the battery stacks and the accessories.
ATTENTION!
There are two so-called battery stacks available as slide-in modules in the sun|powerpack
premium battery system (see also chapter 4). During transport the battery stacks must be packed
separately. It is not permissible to transport the complete battery system with the battery stacks
installed!
CAUTION!
The battery stacks must be transported upright and put down.
Note:
Basically, road transport of Li-Ion batteries is subject to the ADR Directive. The currently valid
version must be applied.
Safety Instructions
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Note:
"Transport of Lithium-Ion batteries, electrical tools and electrical garden appliances in connection
with the main activity of the transporter (regulation for craftsmen - ADR 1.1.3.1c):
For companies that undertake transport in connection with their main activity (e.g. delivery or
return delivery in connection with measurements, repair and maintenance work or demonstration
purposes) there are exceptions and special regulations (waiver or exemption). For Lithium-Ion
batteries or devices that are operated with Lithium-Ion batteries > 100 Wh power, the weight limit
applicable for the application of this waiver or exemption is 333 kg (Battery weight). Measures
have to be taken in order to ensure a safe transportation (load securing)."1
3.7.1. Intact, undamaged batteries and batteries at the end of their service life
Intact, undamaged batteries as well as batteries at the end of their service life should not
have any visible mechanical signs of damage or deformations.
A battery must be classified as defective if at least one of the following criteria is met.
Note:
If at least one of the following criteria is met, the regulations for packaging and transport of
defective batteries shall apply:
Battery cells have a damaged or highly deformed housing
Liquid is leaking out (and with it severe development of odour)
Peculiar smell of gas occurs
Measurable increase in temperature in the switched off condition (more than lukewarm)
Melted or deformed plastic parts
Melted connecting cables
The Battery Management System (BMS) identifies defective cells (message in display unit)
1
See also "Guidelines for the transport of Lithium-Ion batteries for electrical tools and electrical
garden appliances: Implementation of the hazardous goods regulations", issued by: EPTA - The
European Power Tool Association, Version: April: 2014
Safety Instructions
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Even intact, undamaged Lithium-Ion batteries are classified as "hazardous goods" in international
transport law.
Classification according to ADR (Road transport):1
UN3480 Lithium batteries class 9 packaging group II,
classification code: M4 Lithium battery
Hazard label:
UN3480 LITHIUM-ION BATTERIES
3.7.2. Defective batteries
WARNING!
Defective batteries may reach conditions that are critical to safety. As a consequence of this, the
batteries may burst or catch fire and hazardous gases may be formed by decomposition.
WARNING!
Transporting or collecting defective or damaged batteries should be done only in coordination
with HOPPECKE. In case of queries, please contact the HOPPECKE Service hotline (Germany:
0800 246 77 32 / International: +49 (0) 180 5 22 9999)
3.7.3. Check the delivery
This chapter pertains to the transport of the system components from the HOPPECKE
factory. Depending on the agreement, the transport is done to the wholesale dealer, installer
or the end customer. The transport from the HOPPECKE factory is done by a freight
forwarding company appointed by HOPPECKE for this purpose.
WARNING!
Defective batteries may reach conditions that are critical to safety. As a consequence of this, the
batteries may burst or catch fire and hazardous decomposition products may be formed. In case
liquid or gaseous substances are leaking, leave the room immediately and alert the fire brigade.
Observe and follow the safety instructions (see chapter 3).
Note:
If you notify apparent defects or incomplete deliveries to the freight forwarder too late, this may
lead to your claims becoming null and void.
Safety Instructions
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HOPPECKE packs all supplies with the maximum possible care and diligence, so that the
goods are received by you in undamaged condition.
Check the delivery immediately on receipt for completeness
Check the goods for damage in transit.
Note down any damage on the outer packaging
Note down any visible spots or moisture.
If the delivery is incomplete or there are signs of transportation damage:
write a brief report on the defects or shortcomings on the consignment note before you
sign the same.
Request the freight forwarder to check the consignment and note down the name of the
person carrying out the check.
Write a defect report and send this to the suppliers within 7 days.
Sun|powerpack premium battery system
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4. Sun|powerpack premium battery system
The sun|powerpack premium battery system serves to store electrical energy. The major
components of the system are illustrated in Figure 1.
No.
Description
1
Housing
2
Lower battery stack
3
Upper battery stack
4
Battery Management Systems (BMS)
5
Display unit
6
Connector
7
Service interface
Figure 1: Sun|powerpack premium battery system (without cover)
ATTENTION!
If the selected version of the sun|powerpack premium is not compatible with the application, there
may be loss of functionality (e.g. safety shut-downs).
HOPPECKE offers multiple versions of sun|powerpack premium with different capacities. For
optimal utilisation of the battery system, the capacity selected must be compatible with the
application. In case of queries, please contact your local HOPPECKE partner.
Sun|powerpack premium battery system
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The system consists of the following components:
1 x housing with cover
2 x battery stacks (with individual battery cells connected in series and parallel
respectively) (Mat.-No 6011302980 for 5kWh variant / 6011302981 for 7.5kWh variant)
1 x Battery Management System (BMS) with display unit and installed in the housing
(Mat.-No. 6143192000)
Further:
1 x wall mount for installation (Mat.-No.: 6261302986)
1 x battery connection cable incl. data cable (Mat.-No.: 6154310006)
1 x operation manual (Mat.-No.: 6140203036)
4 x Washer (DIN 9021-6 A2) (Mat.-No.: 6234000002)
4 x Toothed washer M6 – Type M-A4 (Mat.-No.: 4234000083)
4 x Hexagon nut ISO 10511-M6-05 ZN (Mat.-No.: 4242000111)
1 x Sticker for sealing of housing (Mat.-No.: 6142000002)
1 x Protective foil for nameplate (Mat.-No.: 4142000095)
The battery stacks consist of individually connected lithium iron phosphate battery cells (see
also nameplate for the system and battery stack in Figure 2 and Figure 3). The two battery
stacks are connected in series. This yields a storage capacity of approx. 5 kWh or 7.5 kWh
at a nominal voltage of 51.2 V.
Figure 2: Example of a battery system nameplate
Sun|powerpack premium battery system
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Figure 3: Nameplate and safety instructions on the battery stack
Note:
The battery system should be operated only with approved battery inverters / battery chargers.
The nominal battery voltage is 51.2 V, and communication between the battery inverter / battery
charger and the battery system takes place via a data interface (CANOpen).
4.1. Hints for sizing of the system
The battery system communicates with the battery inverter and therefore realizes an
automatic system operation. It is not required to operate the system manually. However for
system sizing and operation the following hints shall be observed:
Note:
Sizing of the entire system including installed PV and inverter power and the operation scheme of
the system (electrical loads) must realize occasional battery full charges (state of charge – SOC
= 100%).
Note:
Sizing of the entire system shall consider the usage of 80% to 90% of the nominal battery
capacity.
Storage
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5. Storage
This chapter pertains to the storage of the battery system components at the premises of
wholesale dealers, installation agencies or end customers. For installation agencies or end
users, the individual system components should be stored only temporarily until the
installation of the battery system.
5.1. Intact, undamaged batteries and batteries at the end of their
service life
Do not store the battery system together with flammable substances. It is recommended to
have a smoke detector at the place of installation. Protect from exposure to sunlight,
sources of radiation and heat sources. Store it in a dry and cool place.
HOPPECKE recommends storage in the original packaging.
ATTENTION!
A maximum of up to two battery stacks in original packaging may be kept or stored such that they
are stacked on one another.
Instructions for wholesale dealers and installation agencies:
Coordinate other safety measures with the local authorities and loss insurers.
Storage period:
For ambient temperatures of -20°C to 35°C the battery stacks may be stored up to 6
months. If the maximum storage period is exceeded, please contact HOPPECKE Service.
ATTENTION!
The battery stacks should be charged only when they are installed in the system and during
normal operation.
5.2. Defective batteries
WARNING!
Defective batteries may reach conditions that are critical to safety. As a consequence of this, the
batteries may burst, ignite and hazardous decomposition products may be formed (see also
chapter 3).
Instructions for specialists: Damaged batteries must be surrounded with dry sand, chalk
powder (CaCO3) or Vermiculite. If possible, they should be stored outside the buildings.
They should best be stored in a sealed, shock-proof and fire-proof external packaging. The
storage place should be marked and safeguarded with warning signs; in case the battery
causes smoke development the storage place must also be monitored. Make sure to
maintain a safe distance to combustible materials with Li-Ion batteries in any case.
Preparing for installation
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6. Preparing for installation
Before you begin with installation, check whether the installation site meets the
requirements (see chapter 6.1).
Keep all necessary tools ready at hand (see chapter 6.2).
6.1. Installation site
The sun|powerpack premium must be installed and operated in a dry and frost-free indoor
room (e.g. utility room or cellar). The installation site must be vibration-free.
WARNING!
The battery system should not be stored, installed or operated in rooms endangered by floods.
CAUTION!
At the installation site maintain a minimum distance of 2 m to flammable items. The battery
system should not be installed on combustible surfaces. Operation in explosive zones is not
permissible.
CAUTION!
The battery system must be installed in such a manner that the battery stacks inside the battery
system are in an upright position. For the installation of the battery system on a wall it must be
ensured that the wall concerned has adequate load-bearing capacity (see also specifications of
the weight in chapter15.1).
ATTENTION!
Keep a distance of at least 0.3 m at the installation site between adjacent sun|powerpack
premium battery systems as well as other items, side walls or floors. Observe and follow the
manufacturer's specifications for the minimum distances to the battery inverter or other
equipment installed in the room.
ATTENTION!
In order to dissipate waste heat optimally, the battery system should not be covered up or
concealed.
Note:
While installing batteries, the respective national building regulations must be observed and
followed.
Note:
The max. installation height of the battery system is 1.20 m (distance between the floor and the
bottom edge of the battery system).
Note:
The battery system is fixed to a wall at the installation site. Only the wall mount supplied along
with the battery should be used for this purpose.
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