RedEarth BlackMax Off-grid Battery System User Manual

BlackMax
Off-grid Battery System
User Manual
BlackMax – User Manual

Shutdown and safety procedures

SHUTDOWN PROCEDURE

1. Press the “On/Off” button
2. Switch OFF all AC circuit breakers
3. Switch OFF the SOLAR D.C. ISOLATOR
4. Switch OFF the BATTERY SYSTEM D.C. ISOLATOR

WARNING
BATTERY SYSTEM D.C. ISOLATOR DOES NOT DE-ENERGISE THE BATTERY SYSTEM AND BATTERY SYSTEM CABLING

WARNING: Lithium Battery Hazard Fire
In the event of a fire, evacuate the area and call emergency services. A dry agent fire extinguisher should be readily available and used. DO NOT use water. Toxic gas may be
produced if the battery catches fire.
Note: MSDS document is provided with the system and also can be found at www.redearth.energy

Damaged battery
Do not use a damaged battery. Batteries should only be disposed of at an appropriate recycling center. Please contact RedEarth for advice.

WARNING: Do not open the system, operating on the inside of the BlackMax system is restricted to qualified personnel (electricians with CEC accreditation for Solar and Battery).

Many of the procedures covered in the Installation manual have inherent risks. Whilst the BlackMax is designed to be electrically safe, including residual current device and double insulated cables, the voltages connected or generated by the equipment are hazardous and potentially fatal.
The BlackMax must only be commissioned by suitably qualified personnel.
It is the responsibility of the installer to ensure the operation and all the wiring is carried out in accordance with all safety standards applicable to the installation. The wiring diagrams and installation instructions are given as a guide only and compliance with appropriate standards is the responsibility of the installer.
This document is subject to change at any time, please visit www.redearth.energy to access the latest version.

RedEarth’s BlackMax battery system is an all-in-one, ready-to-run energy storage system for off-grid applications. It consists of a RedEarth 3.6kVA hybrid inverter and up to three (3) self-managed lithium batteries (12.4kWh total). It is fully assembled, factory tested, and requires no programming.
It is ready to connect to a PV Solar array and a generator (either auto or manual start) The BlackMax system is designed to be installed either inside or outside, ideally on a flat surface and in a shaded area against a wall.
RedEarth Energy Storage provides the option to install a remote monitoring service to ensure the ongoing operation of the BlackMax battery system. A typical complete installation of the BlackMax will require the electrical connection of:

• The customer’s load – via external GPO and/or hardwiring.
• The array of PV solar panels – via MC4 connectors on the side of the unit.
• Generator – via external GPO or hardwiring.

If remote monitoring is requested the installer will need to verify that the internet/monitoring is operational. In this case. If the customer does not have internet and the installation site has mobile coverage RedEarth can provide a SIM-card based monitoring solution

Note: The BlackMax is not designed to act as a main switchboard for the premises, as it does not include space for additional main & customer circuit breakers or RCDs. The MEN link and Earth connection need to be in place at the premises as required.

Dimension & Clearance

BlackMax Weight: 176kg with 3x Troppo batteries (42kg per battery)
Or: 114kg with 2 Pylontech batteries (32kg per battery)
Dimensions w/ door and lid closed: 1028 H x 750 W x 475 D [mm]

|
---|---
BlackMax Minimum Clearance
According to AS/NZS 5139| BlackMax Fully Open
1433 H x 750 W x 1106 D [mm]

The BlackMax can be divided into four areas. The AC, the DC, the inverter, and the battery area.
With two access points available, use the lid for the batteries and the front door for the switches and electronic equipment. Below is explained how to access and what to expect in each area.

The Top:
A clear weatherproof cover on the lid allows viewing of the display, if the interaction is needed, the cover can be easily lifted by releasing the two screws and the clip tab from the front and held in a vertical position with the help of rear hinges.
For a full shutdown procedure, access to the batteries is required. This is also done via the lid as it can pivot on the rear hinges and sit in a vertical position.
Note: Refer to the Installation Manual for more information on how to lift the lid.
Once the lid is open, clear and direct access is available to the batteries

The Door:
The second access is made by the front door. To open it, the two key locks must be turned clockwise with the help of the key. These items are shown in the picture to the right.

The AC Side:
Looking at the AC side of the BlackMax on the left-hand side (LHS), you will find the items shown in the picture to the right.

• Vent;
• AC Breakers;
• 15A INLET powerpoint for the generator (a 15 Amp lead is required);
• 15A OUTLET powerpoint (the 15A lead will not fit);
• Handle
• Openings for hardwired connections.

Overview

The AC breakers are behind the weatherproof cover. These can be accessed by releasing the two screws and pulling the clip tab, this window will then lift and allow access to the Generator Input Breaker (MCB), the Generator Usage Meter (AC), the PowerPoint (RCBO), and Power Output (MCB).

The DC Side:
Looking at the DC side of the BlackMax (right-hand side) you will find the items shown in the picture to the right.
Just like the AC side, by releasing the two screws and the clips on the bottom of the window, you will have access to the battery SYSTEM D.C. ISOLATOR.
Below, is the SOLAR D.C. ISOLATOR that can be operated by turning the dial 90⁰ to the left or right.

The Base:
With its R2D2-like “feet”, the BlackMax has a very sturdy base and allows the ventilation inlet to be in the base of the unit.

The House (optional)
If the BlackMax is hardwired into a Switchboard, it should be connected via one single pole breaker. This breaker will isolate the unit along with all solar, battery, and generator power.

What is in my BlackMax

RedEarth – Power Conversion Equipment (PCE)
The Sure Power by RedEarth offers a complete inverter and a solar charge controller in one attractive, compact package.
This inverter is certified to IEC62109-1 and -2 and carries the CE mark.
Emergency Power Feature: The Sure Power will generate power from the solar panels even if the battery is flat/not connected. This means that power is available ONLY if the sun is shining on the solar panels. If a cloud should come over, the power will drop out.

Lithium Battery
Batteries are a critical part of the Off-Grid system as they store energy generated from the solar panels and fuel-powered Generators. This power can then be utilized at times when solar energy is not available.
The battery bank has been sized to meet your requirements according to your Load Profile and energy assessment.
The self-managed LFP battery with internal BMS offers you a safe lithium option for any solution that requires reliability, ease of use, and a product that outperforms others.
Built to the highest quality standards, incorporating components of exceptional reliability and durability, our Australian manufactured Troppo Series is engineered to outperform and outlast its competitors.

Temperature Sensor
A temperature-activated relay is positioned on the top left-hand side of the rear panel as shown in the picture. This relay is connected to the fan also on the rear and will turn them on once the set temperature is reached. In the factory, the dial is set to activate at approximately 30⁰ Celsius.
Fan
To help keep the inside of the BlackMax at an adequate temperature, a 230V fan – activated by the temperature sensor – will push out the hot air and fresh air will come in through the vents on the base.

Generator (External)
Because the BlackMax is an off-grid system, it is highly recommended to purchase the unit with one of our recommended generators e.g. Honda EU22i. However, if purchasing separately, inverter-generators are recommended for use with BlackMax due to their better power quality. If the voltage, frequency, or current waveforms of the generator are not of a high enough quality, then they will be rejected by the inverter.
NOTE: Some low-cost generators do not provide sufficient power quality to be accepted by the BlackMax and therefore do not charge the batteries. Generators that produce poor power quality will damage devices over time.
Refer to the Installation Manual for minimum generator specifications.

How to Turn ON / Shutdown my BlackMax

To turn on the unit you must follow the steps below:

1. Switch ON the BATTERY SYSTEM D.C. ISOLATOR (#4), found on the RHS of the unit;
2. Switch ON the SOLAR D.C. ISOLATOR (#3), found on the RHS of the unit;
3. Turn ON all AC circuit breakers (#2), found on the LHS of the unit;
4. Press the “On/Off” button (#1) on the display, found on the lid of the unit;

The shutdown procedure is the reverse of the “turn on” procedure and is shown below. This procedure can be found in the unit.

1. Press the “On/Off” button (#1) on the display, found on the lid of the unit;
2. Turn OFF all AC circuit breakers (#2), found on the LHS of the unit;
3. Switch OFF the SOLAR D.C. ISOLATOR (#3), found on the RHS of the unit;
4. Switch on the BATTERY SYSTEM D.C. ISOLATOR (#4), found on the RHS of the unit;

The battery breaker on top of each battery does not have to be turned off if the BATTERY SYSTEM D.C.ISOLATOR is already off. However, we do recommend turning them off for long-term storage (up to 6 months) or during transportation.
After 6 months the system should be restarted to top up the batteries (e.g. via the generator).

How BlackMax Operates

The BlackMax is set up to provide power in the most efficient way possible.
The priorities set on this system are to power the loads from the PV (solar) first, then the Generator, and finally the battery.
To understand this, imagine if in the middle of the day, the generator is turned on and some appliances are running (loads). The PV will provide power to the loads. If that is not
enough, the generator (if available) will provide the rest. If that is still not enough, the battery will provide the rest.

As an off-grid system, it is very important to get the maximum amount of “free” energy into the batteries before the sun goes down. Batteries are only charged with “excess” power. This means that all the solar (and generator) power produced will go to the loads first and only the excess will go into the batteries.

NOTE: If required to charge the batteries as quickly as possible, switch off the PowerPoint and Power OUT breakers (this will turn off all appliances connected to the BlackMax), and turn on the generator and the PV. This will take all the power from the generator and PV, and “push” it all into the batteries.

How to Operate

As mentioned in the Turn/Shutdown procedure, the BlackMax has a few breakers (RCB and RCBO) that must be operated correctly in order to provide power.
Following the same steps as the Turn, the procedure, the individual and battery system breakers have printed on the handle an “I” or an “O” which can be interpreted as “ON” and “OFF” respectively.
The Solar PV Isolator is a rotary switch that can be turned ON by rotating the red handle clockwise to the horizontal position. Or OFF, counterclockwise to the vertical position.

The AC breakers also have “I” and “O” on the handle to identify if the breaker is on or off.
For the generator’s power to reach the inverter, the “Generator Input” breaker must be turned on. Once turned on, the Generator Usage Meter will light up and show the Voltage, current, and power consumption.
There are 3 breakers related to providing power to the loads. The first is the “INVERTER ISOLATOR”, which will disconnect the inverter output power. Then the power can go either to the “POWER OUTPUT plug” and to the external power point or to the “Power OUT” and to the hardwired loads. The “Power OUT” acts as a main switch for the system.

If the generator is to overload the inverter, there is an internal tripping mechanism that will protect itself. If this happens, a button on the bottom side of the inverter must be pressed to allow power from the generator.

Maintenance and End of Life

Maintenance Schedule
Weekly

• Check component operating lights are normal

Monthly

• Clean inside the enclosure for excessive dust, vermin, or obstructions
• Ensure safety labels/instructions remain visible
• Clean air filter with a vacuum or soft brush
• Clean the outside of the enclosure soft brush or damp cloth

Bi-annually

• The clean solar panel surfaces ensure optimal performance

Annually

• Visually inspect for loose cables or connections near the inverter
• Clear any vegetation or overgrowth over the solar panels
• Inspect conditions of solar panels, cables, and array frames for damage or corrosion

End of Life Recycling
Please contact RedEarth Energy Storage to arrange to recycle your battery.

CAUTION:
Servicing of batteries should be performed or supervised by personnel knowledgeable about batteries and the required precautions.
When replacing batteries, replace with the same type and number of batteries.
CAUTION:
Do not dispose of batteries in a fire, batteries may explode
CAUTION:
Do not open or damage batteries. Released electrolyte is harmful to the skin and eyes.
It may be toxic.
CAUTION:
A battery can present a risk of electrical shock and a high short-circuit current. The following precautions should be observed when working on batteries:
Remove watches, rings, or other metal objects
Use tools with insulated handles
Wear rubber gloves and boots
Disconnect the charging source prior to connecting or disconnecting battery terminals.

How to Monitor my BlackMax

OPTION 1- On the Display:
The SurePower display in the lid is designed to be as user-friendly as possible. With icons representing different stages of the power and arrows indicating the direction of power flow. Below you will find a few pictures illustrating some of the most common situations. A detailed explanation of the display icons can be found in the SurePower Quick Start Guide included with your system.

Indicators

Day Time – Solar power charging the battery and powering the loads| Day Time – Solar power helps the battery to power the loads
---|---
|
Night Time – Battery powering the loads| Night Time – Generator powering the loads and charging the battery
|

OPTION 2 – Remote monitoring via RedEarth’s Portal (Optional Component)
The BlackMax can be monitored online through the SwitchDin platform. If this option is available, follow the steps below to register and sign in to your account.

Registering

1. If you haven’t received this email from us, please email [email protected] with the following information:
1. full name, address, unit’s serial number with the subject: Set up online monitoring

1. During testing and commissioning, RedEarth will set up an account for the end-user and send out the following invitation.
2. Click on the link to create an account.
3. In a web browser, visit https://app.switchdin.com/accounts/sign-in?profile=redearth and log in to view your system.

Monitoring
Once signed in, you will see the following page.

Overview Tab

In this example the solar PV is producing 0.77kW of power, there is 0.05kW of load and solar PV is charging the battery with 0.54kW. The battery is providing 0kW to the loads.
LIVE DATA – Illustrates the movement of PV production, battery power, generator, and load all in Real-Time.
WEATHER – Displays the current weather at the location of the system, time of day when solar is available, wind speed, and humidity.
SYSTEM STATUS – This shows the last time data was collected from the BlackMax system and updated to this profile.
SOC – This graph shows the State Of Charge (SOC)of the battery for today as a percentage value.
SO FAR TODAY – This section has three charts. Two of these are doughnut charts and relate to Production (PV) and Consumption (Loads). The third shows power values from solar, load, generator, and battery over time.
In the example above, 0.75kWh energy was produced from solar. 0.05kWh of it was “exported” to the Loads and 0.71kWh was stored in the battery. Of the 0.05kWh “exported” (consumption), 0.05kWh came from the PV and 0kWh came from the battery.

Performance Tab
The performance tab can be customized to see several historical data about the system.

If the “Battery Power” is a positive value (above the zero line) then it is in a charging state. If this is a negative value (below zero the line), then it is discharging.
Live Tab
The Live Tab displays all the live readings of data in numerical form from the connected devices.
Users Tab
This tab shows the users who can view this system. This will include you, the customer, and the research team involved in monitoring your system.
Alert Tab
The alert tab shows any errors or warnings received about the system. You will also receive an email if an alert occurs.
Further Questions
For further questions, feel free to email us at [email protected]t or call us on 1800 733 637.

FAQ’s

1. “I lost power!” What should I do?
   R: The most likely reason for this is that the battery has reached the low SOC limit and has stopped inverting (producing 230V). In this situation, turn the system off, start the generator, and turn your BlackMax on again as recommended in the “Shutdown and Start-up” procedure in this manual. HOWEVER, be sure to leave the Power OUT breaker turned off. This will allow all the power generated to go directly to the battery and not to the load. Let the batteries charge for 15 minutes and then turn on the main breaker.
   NOTE: You can turn the main breaker on again but be careful not to use more than is being produced. This will lead to draining the batteries even more and possibly damaging them.
   If you do not have a generator, then wait until there is PV power available. The inverter will automatically recharge the battery and turn it back on once the battery is at a safe level.

2. What happens if my batteries go flat (no lights on the battery itself)?
   R: This will happen if the BlackMax is re-started and the battery is not immediately charged. Contact RedEarth’s technical support on 1800 733 637.
   NOTE: This system will still work in Emergency Power Mode – meaning that limited power will be available when the solar panel is in sunlight.

3. My Generator is not charging the batteries. What does this mean?
   R: The first and most obvious thing to check in this situation is that the Power IN breaker is turned on. If so, the power produced by the generator might not be within the inverter’s acceptable range.
   Look at the generator requirements in Attachment C of the installation manual. Some cheap generators do not produce power of sufficient quality to charge the batteries, even though they can still run simple loads like fans and heaters. Another possibility is that the generator is supplying power to the loads and there is not enough to recharge the batteries. Try turning off the Power OUT breaker for a while and see if the batteries are now taking charge.

4. How do I know if the battery is full/empty?
   Because the Troppo batteries don’t interact/communicate with the inverter, the SOC is a calculation based on voltage parameters. What this means is that the SOC is not always accurate.

The best way of estimating the SOC of the batteries is by analyzing the Voltage. In the example on the right, if the battery has about 53V, the SOC is neat to 100% (blue arrow). Or, if at 48V, the SOC is below 6% (red arrow).
With a range between 64 and 45 Volts, identify the SOC according to Appendix A in this manual.

Services and options available from RedEarth

RedEarth can provide several options for the BlackMax that will help you optimize power consumption and monitoring benefits.

• Membership in the RedEarth Customer Community
• Additional batteries for system expansion
• Remote and ongoing monitoring option
• Miscellaneous spare parts (including indicator lights for Generator start)
• BlackMax Power Kit: PV panels, racking, and pre-terminated PV cables
• Generator with 2-wire autostart
• Generator backup kit (for on-grid applications)

RedEarth’s Monitoring and Customer Community Monitoring Visit us in Brisbane

Appendix – A

Battery curves:

1800 733 637
****[email protected]
redearth.energy

RE_PROD_0006 Version 3
Issue Date 23/03/2021

References

• Products | Atlassian
• Stormcloud

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Download this manual  >>