nilar 288VDC Home Box Installation Guide

nilar 288VDC Home Box

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THIS QUICK GUIDE IS ONLY INTENDED TO BE USED BY INSTALLATION PERSONNEL WITH PREVIOUS INSTALLATION EXPERIENCE AND FULL UNDERSTANDING OF THE PROCEDURE AND SAFETY WARNINGS EXPLAINED AND DESCRIBED IN THE MORE EXTENSIVE INSTRUCTION MANUAL (73‐H014)! IF UNCERTAINTY ARISES, ALWAYS REFER TO INSTRUCTION MANUAL (73‐H014)! THE INSTRUCTION MANUAL CAN BE DOWNLOADED AT : https://www.nilar.com/partner‐login/

WARNING
This product contains powerful battery packs (NiMH) and is supplied by multiple hazardous electrical sources. Beware of stored and residual energies. Obey local regulations for live working when the casing/door is open. Wear electrically insulated gloves when handling battery packs. Battery surfaces may carry hazardous voltage due to lowered insulation resistance. Do not place battery packs on conductive surfaces. Risk for electric shock and arcing if the product is used incorrectly. The battery packs cannot be turned off electrically.

Please note:

• Work only with one battery pack terminal at a time.
• A rupture disc may release electrolytes during abnormal use. We, therefore, recommend wearing safety glasses.

Risk for electrical hazards if the product is exposed to rain or moisture. Do not operate the product with suspected failures. If you suspect that the product is damaged, have it inspected by qualified service personnel. Never install a damaged battery pack or a damaged insulation tray. Do not block or cover the rupture disc outlet on the battery pack. If a fire occurs, it can be extinguished by using CO2. Ensure that fire extinguishers are available.

CAUTION
If a battery pack is damaged mechanically, the following may occur:

• High heat generation on the surface of the battery cells.

• Electrolyte may escape.

• Eventual smoke from the battery packs can irritate the skin, eyes and respiratory system. Therefore, follow these guidelines

• Do not open the battery packs.

• Do not modify or mechanically damage the battery packs.

• Operate the Nilar Home Box only within the allowed
  operating range.

• Do not short‐circuit the baery packs.

• Do not continue to use the battery packs atier identified as faulty.

It is required that a smoke alarm, preferably with connected surveillance function, is installed in close and strategical connection with the installation of the product. Furthermore, the installation of a gas alarm that warns in case of high levels of hydrogen is recommended. Always install the product in a well‐ventlated location. To avoid potential hazards, use this product only as specified. Do not operate the product with covers removed. If covers are removed during e.g. repair, do not touch any exposedconnections. The product shall not be exposed to liquids (not even dripping or splashing) and objects filled with liquids must not be placed on or close to the product. Remove personal metal items such as rings, bracelets, necklaces, and watches when physically handling the product since it can result in a short‐circuit current causing severe burn. Keep product surfaces clean and dry.

PERSONAL PROTECTIVE EQUIPMENT (PPE)

Always use PPE during handling and installation of product. At minimum this includes safety shoes with steel toe, safety glasses, and electrically insulated gloves:

WARNING & CAUTION SYMBOLS

The following warning and caution symbols are used throughout the document: TOOLS & ACCESSORIES

SCOPE OF SUPPLY
The following components are part of the product delivery.

Note! For illustrative purposes, the components are not depicted to scale!

1. Cabinet assembly (1 unit)
2. Ambient temperature sensor (1 unit)
3. CommunicaTIon cables (3 units incl. 1 spare)
4. 120Ω CAN terminaTon plug (1 unit)
5. Nilar baTTery packs (4 units)
6. InsulaTIon trays (4 units)
7. BaTTery holders (4 units)
8. Screws for baTTery holders (4 units)

PRODUCT REGISTRATION

In order to obtain and claim full warranty for the product, the Nilar Home Box must be registered on the Nilar product registraon webpage (https://www.nilar.com/product‐registration/). As an alternaTve the QR‐code below can also be used for direct access to the webpage. Regarding the complete warranty conditions in detail, please contact your authorized local Nilar repre‐sentative.

SERIAL NUMBER

For registration the serial number of the Nilar Home Box is needed. The serial number can be found on the Nilar labels.

The labels are placed in four (4) different locations of the Nilar Home Box. On one side of the side plates ❶, as a lose sticker in the plastic pocket for the quick guide ❷, on the top plate below the cover lid ❸ and on the back plate ❹ .

1. DO NOT ATTACH THE HOME BOX TO THE WALL UNTIL INSTALLATION HAS REACHED STEP 21 IN THIS INSTALLATION GUIDE
   Ensure appropriate space for the Home Box. If required, adjust the support legs of the Home Box to level.

2. Unscrew and remove the cover lid.

3. PLEASE READ THE WARNING STICKERS ON THE TOP PLATE BEFORE PROCEEDING

4. Unscrew and remove the corner tops.

5. Slide the side plate upwards to unhook it and liti it thereatier outwards and off. Repeat procedure for the side plate on the opposite side.

6. Slide the front plate upwards to unhook it and liti it thereatier outwards and off.

7. Tilt the top plate upwards and liti it off.
   Unscrew and remove the BMS cover.

8. GENERAL CAUTION IS REQUESTED WHEN WORKING WITH THE BMS

9. IF THE HOME BOX IS IN-STALLED TOGETHER WITH A KOSTAL INVERTER WITH ITS IN-BUILT TYPE B RCD (IΔn =6mA) ACTIVATED, THIS INSTALLATION STEP IS NOT APPLICABLE
   Always install a type B or B+ (≤30mA) Residual Current Device (RCD). If an RCD of anot-her type (AC, A or F) is already installed between grid and in-verter, it needs to be replaced with an RCD of type B or B+ .

10. THE INVERTER MAY STILL PROVIDE HAZARDOUS VOLTAGE AND RESIDUAL ENERGY, ALTHOUGH IT IS SWITCHED OFF OR MAY APPEAR SWITCHED OFF Route the 288VDC system power cable(s) from the inverter through the lower right cable gland located on the backside of the Nilar Home Box.

11. THE POSITIVE (+) WIRE OF THE INCOMING POWER CABLE(S) MUST ALWAYS BE EXTERNALLY PROTECTED BY A 25A MCB/FUSE CONDUCTOR CROSS-SECTION MUST BE 6mm2 (Cu) Positive (+) wire of power cable(s) connects to the fuse marked ’F1’ of the Nilar BMS.

12. THE NEGATIVE (-) WIRE OF THE INCOMING POWER CABLE(S) MUST ALWAYS BE EXTERNALLY PROTECTED BY A 25A MCB/FUSE CONDUCTOR CROSS-SECTION MUST BE 6mm2 (Cu) Negative (-) wire of power cable(s) connects to the fuse marked ’F2’ of the Nilar BMS.

13. CONDUCTOR CROSS-SECTION MUST BE 6mm2 (Cu) The protective earth (PE) wire of the power cable(s) is to be connected to the terminal marked ‘PE’ of the Nilar BMS.

14. Route the 230VAC operating power cable through the upper leti cable gland located on the backside of the Nilar Home Box. Nilar recommends that a switch is installed for the operating power cable, preferably in the vicinity of the Nilar Home Box.

15. CONDUCTOR CROSS-SECTION MAX 2,5MM2 (CU). FUSE/MCB: C10A (MIN. 6A AND MAX. 10A, CHARACTERISTICS: B, C, D OR K ARE POSSIBLE) The live wire of the operating power cable connects to the terminal marked ’1’ of the Nilar BMS. 

16. CONDUCTOR CROSS-SECTION MAX 2,5mm2 (Cu) The neutral wire of the opera-ting power cable connects to the terminal marked ’2’ of the Nilar BMS. 

17. CONDUCTOR CROSS-SECTION MAX 2,5mm2 (Cu) The protective earth (PE) wire of the operating power connects to the terminal marked ’PE’ of the Nilar BMS. 

18. Route the inverter communication cable through the upper right cable gland located on the backside of the Nilar Home Box.

19. CONDUCTOR CROSS-SECTION MAX 2,5mm2 (Cu) Atiach the RS485 signal wires to the correlating terminals of the Nilar BMS.

    • Signal A:   Terminal 7
    • Signal B: Terminal 8
    • Signal gnd: Empty PE terminal

20. THE NILAR HOME BOX REQUIRES A STABLE INTERNET CONNECTION FOR TECHNICAL SUPPORT AND FULFILLING OF WARRANTY CONDITIONS Connect an internet cable to the RJ45 port on the backside of the cabinet.

21. THE HOME BOX MUST ALWAYS BE FIRMLY ATTACHED TO A STABLE WALL. TYPE AND LENGTH OF SCREWS DEPEND ON MATERIAL IN WALL AND THE SCREWS ARE NOT SUPPLIED WITH NILAR HOME BOX. Fix the Home Box by attiaching the mounting brackets with two (2) screws each onto a stable wall.

22. NEVER EVER INSTALL BATTERY PACKS WITHOUT INSULATION TRAYS ENSURE THAT NO CABLES ARE SQUEEZED IN-BETWEEN THE SHELVES AND THE INSULATION TRAYS Place all four (4) insulation trays in all four (4) shelf openings of the Home Box.

23. REMOVE BOTH LIFTING STRAPS FROM THE BATTERY PACKS ID-MARKING ON BATTERY PACK MUST MATCH ID-MARKING IN BATTERY SHELF SLOT OF HOME BOX IT IS RECOMMENDED TO USE LIFTING AIDS Carefully liti/slide all four (4) battery packs into their dedicated shelf slots.

24. Fix the battery pack to the insulation tray with the screw. Repeat for all battery packs.

25. BE CAREFUL TO CONNECT THE CURRENT SENSOR CONNECTORS WITH THE CORRECT ORIENTATION. THE CLAMPING SCREWS ① MUST BE VISIBLE ON THE FRONT SIDE AND THE CABLES ② MUST POINT DOWNWARDS. Connect the current sensor cable connectors to the battery packs ’1B’ and ’2B’. 

26. Connect the pre-routed communication cable from BMS to battery pack ’1A’ (RJ45). Connect the interpack communication cables between battery pack ’1A’ and ’2A’, between ’2A’ and ’2B’ (pre-routed), and between ’2B’ and ’1B’. Insert the 120Ω termination plug in the last empty CAN connection of battery pack ’1B’.

27. Connect all the pre-routed fan cables to all battery packs.

28. BE CAREFUL TO CONNECT THE 24VDC CONNECTORS WITH THE CORRECT ORIENTATION. THE CLAM-PING SPRINGS ① MUST BE VISIBLE ON THE FRONT SIDE AND THE CABLES ② MUST POINT DOWNWARDS. Connect all the pre-routed 24VDC power supply cable connectors to all battery packs.

29. ALWAYS LET THE AMBIENT TEMP. SENSOR CABLE HANG DOWN FREELY. NEVER EVER LET IT TOUCH THE BATTERY PACK MODULES. Connect the ambient temperature sensor cable to battery pack ’1A’.

30. Connect all the ETPU-cable connectors with all the pre-routed ETSU-cable connectors for each battery pack.

31. Install the cover lids back on all the battery packs and check that all connected cables are routed through the cable entry ①.

32. CHECK THAT THE FUSES ARE NOT ACTIVATED , SEE INSTALLATION STEP #38 Connect the pre-routed negative (-) power cable into the negative (-) chassis connector of battery pack ‘1A’.

33. Connect the positive (+) chassis connector of battery pack ‘1A’ to the negative (-) chassis connector of battery pack ‘1B’ by using the pre-routed interpack power cable located beneath the battery pack shelf.

34. THE TEXT MARKING “LEM” ① OF THE CURRENT SENSOR MUST ALWAYS POINT TOWARDS THE POSITIVE (+) CHASSIS CONNECTOR. Connect the pre-routed positive (+) power cable equipped with the current sensor and connect it to the positive (+) chassis connector of batiery pack ‘1B’. Place the current sensor partly inside the shelf beneath.

35. THE CABLE IS A TWO (2) CABLE ASSEMBLY EQUIPPED WITH A FUSE. DO NOT DETACH THE CABLE ASSEMBLY. Connect the pre-routed fuse equipped negative (-) power cable into the negative (-) chassis connector of battery pack ‘2A’.

36. THIS CABLE IS ATTACHED TO THE PREVIOUSLY INSTALLED CABLE BY CABLE TIES. DO NOT DETACH CABLES FROM EACH OTHER. Connect the positive (+) chassis connector of battery pack ‘2A’ to the negative (-) chassis connector of battery pack ‘2B’ by using the pre-routed interpack power cable located beneath the battery pack shelf.

37. THE TEXT MARKING “LEM” ① OF THE CURRENT SENSOR MUST ALWAYS POINT TOWARDS THE POSITIVE (+) CHASSIS CONNECTOR. THE CABLE IS A TWO (2) CABLE ASSEMBLY EQUIPPED WITH A FUSE. DO NOT DETACH THE CABLE ASSEMBLY. THIS CABLE IS ATTACHED TO THE PREVIOUSLY INSTALLED CABLE BY CABLE TIES. DO NOT DETACH CABLES FROM EACH OTHER. Connect the pre-routed fuse equipped positive (+) power cable equipped with the current sensor and connect it to the positive (+) chassis connector of battery pack ‘2B’. Place the current sensor partly inside the shelf beneath.

38. Remove the adhesive tape over the blow fuses (288VDC), activate the fuses by closing the hatches. Switch the MCB (24VDC) for the operation power to position ’ON’.

39. PLEASE VERIFY THAT ALL THE LISTED CHECKPOINTS ARE CARRIED OUT AS PREVIOUSLY DESCRIBED

    • HAVE ALL THE PREVIOUSLY STATED SAFETY WARNINGS AND CAUTIONS BEEN FOLLOWED?
    • IS THE INVERTER POWER AND THE PROTECTIVE EARTH CONNECTED CORRECTLY TO THE NILAR HOME BOX?
    • IS THE OPERATING POWER INSTALLED CORRECTLY?
    • IS THE COMMUNICATION CONNECTION OF THE INVERTER MADE CORRECTLY?
    • IS A STABLE INTERNET CONNECTION ESTABLISHED?
    • IS THE NILAR HOME BOX FIRMLY ATTACHED TO A STABLE WALL?
    • ARE THE INSULATION TRAYS AND BATTERY PACKS INSTALLED CORRECTLY?
    • RE ALL EIGTH LIFTING STRAPS REMOVED FROM THE BATTERY PACKS?
    • ARE THE FUSES INSERTED AND THE MCB ACTIVATED?

40. ASSEMBLE THE NILAR HOME BOX CABINET IN THE REVERSE ORDER OF HOW IT IS DESCRIBED IN INSTALLATION STEP 2 – 7 AND CHECK THE INVERTER MANUFACTURER’S INSTRUCTIONS FOR FURTHER INFORMATION BEFORE TAKEN INTO OPERATION.

41. PLEASE HAND OVER THE ENCLOSED ’END CUSTOMER LETTER’ TO THE CLIENT

Nilar AB Stockholmsvägen 116 B, 6tr SE‐187 30 Täby, Sweden

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