Hoppecke Sun Powerpack Premium Operating instructions

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

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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Hoppecke Sun Powerpack Premium Operating instructions

Hoppecke Sun Powerpack Premium Operating instructions

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