i-G3N E-Wall Lithium Lifepo4 Battery User Manual

E-Wall Lithium Lifepo4 Battery
User Manual

SPECIFICATIONS

Table 1 shows the specifications for the E-Wall for each additional Expansion Box.

54. Capacity @ 80% DoD [kWh]| 4.| 9.| 13.| 17.| 22.| 26.| 30.| 34.| 39.| 34.0
    Design Life| >16 years (>5 500 cycles) expected life at 80% DoD
    Warranty| >10 years (4000 cycles)
    Max. Discharge Current (Continuous) [A]| 100| 200| 300| 400| 500| 600| 700| 800| 900| 1000
    Max. Discharge Current (not Continuous – 3 sec) [A]| 125| 250| 375| 500| 625| 750| 875| 1000| 1000| 1000
    Discharging cut-off voltage (LVD)| 50V
    Operating Conditions
    Temperature range (recommended)| Charge – (0 °C – 55°C) Discharge – (-20 °C – 55°C)
    Protection Class| IP22 – no solid ingress and near-vertical water droplets
    Dimensions
    E-Wall Storage Unit (L x H x W) [mm]| 520 x 605 x 190
    E-Wall Control Box (L x H x W) [mm]| 360 x 285 x 103
    E-Wall Storage Unit weight [kg]| 45
    E-Wall Control Box weight [kg]| 5

INTRODUCTION

Thank you for trusting i-G3N as an alternative to your energy storage.
The elegant wall-mounted design of the e-Wall supports two battery rack assemblies, which combined form the 5.6 kWh LiFePo4 energy storage unit.
This manual offers relevant information to the proper installation and operation of the E-Wall energy storage system.
Please read the manual carefully before use for safety and as a reference during operation.
The E-Wall is designed to operate in a master/secondary configuration, allowing additional battery expansion endeavors up to two years after the original unit was fitted. As each unit is capable of 1C output, it allows the end-user to utilize a “start small” mentality upon initial installation.

Main Features

• Quick charge enabled.
  – Can be charged within 1 hour.

• Long Life Span
  – More than 4000 cycles, the design life of 20 years, provided it is operated under the recommended charge and discharge conditions.
  – The system incorporates smart charging and battery protection technology to prolong battery life.

• Highly scalable
  – One Control Box can support up to 10 expansion units in parallel, depending on the user’s needs.

SAFETY PRECAUTIONS

The E-Wall energy storage system is designed with full consideration for safety.
However, all applications that have an electronic aspect can be dangerous if used incorrectly Fires and electric shock could be caused if used incorrectly, which leads to serious injury or death.
For your own safety, read the safety precautions thoroughly.

Precautions for use

1. No Battery Box may be connected directly to an inverter.
   The Control Box has built-in safety features that are necessary for a safe connection between the battery and the inverter.

2. IP22 Water and dustproof rating
   The units will be able to withstand near-vertical water droplets, but prolonged exposure could lead to saturation of the ports which in turn could lead to a short or damage to some of the components.

3. Vents are clear
   During installation ensure that the vents underneath and on the right side of the Expansion Box are not covered. Proper ventilation is needed to ensure the cell temperature can be controlled.

4. Wiring and installation to be done per specifications
   Please follow the manual thoroughly to ensure the Control Box and the Battery Boxes are connected in a safe manner to guarantee the longevity of the batteries.

PRODUCTION DESCRIPTION

System Introduction

The entire energy storage system consists of a Control Box and Expansion, or Battery Box. Figure 1 shows the Control Box and Figure 2 shows the Battery Box. One Control  Box can control up to 10 Expansion boxes. Each box adds roughly 5 kWh to the system. The system specifications for the system, along with the number of Expansion Boxes used, are shown in Table 1.

The Control Box and the Battery Box are connected using 35 mm² wirings. The Battery Boxes connect to the busbar provided on the Control Box with M8 bolts.

The dimensions for the Control Box are 360 x 285 x 103 (deep) and the Battery Box dimensions are 520 x 605x 190 (deep) (L x H x W). These sizes can be viewed in Figure 1  and Figure 2 respectively. These sizes can be viewed in Figure 1 and Figure 2 respectively (diagrams not to scale).

Please take the size of the busbar covers on the Control Box into consideration (66 x 62 x 33).
Figure 3 shows an estimation of the layout of the busbar covers. 2 x M8 holes are added to each busbar of the Control Box for lugs to be fixed.

INSTALLATION

This section elaborates on the process to install the E-Wall energy storage system safely

Tools and equipment required

• Hammer
• Phillips screwdriver
• 13 socket
• 35 mm² cabling with 35 to 8 lugs (2 x Expansion Box)
• 70 – 95 mm² cabling with 70-95 to 8 lugs, wire size depending on inverter specifications
• M6 and M8 masonry drill bits
• Drill
• 4 x M6 fisher plugs per Control Box
• 8 x M8 Rawl bolts per Expansion Box
• M8 nuts, bolts, and washers to connect to the cables to the Control Box

QUICK INSTALLATION

Refer to Figure 9 and Figure 10 for the recommended layout configurations.

Control Box Mounting

1. Drill 4 x M6 holes in the wall at the correct spacing according to mounting plates.
2. Insert M6 fisher plugs with mounting plate.
3. Ensure bolts are tightly fastened when the Control Box is fitted

Expansion Box Mounting

1. Drill 8 x M8 holes in the wall at the correct spacing according to the mounting plate.
2. Insert M8 rail bolts with mounting plate.
3. Ensure bolts are tightly fastened when the mounting plate is fitted.
4. Mount Battery Box on the mounting plate on the hinges.
5. The sides of the Battery Box sit flush with the sides of the mounting plate as a reference.

Wire Connections

Before connecting any wires, ensure the Battery is switched off and all external breakers/fuses are open

35 mm² cable is the recommended size cable to connect the Battery Box terminal block to the busbar on the Control Box. It is important to use the same length of cable from each Battery Box to the Control Box.

1. Open the control panel of the Battery Box

2. Break the knockouts, either at the top or bottom of the Battery Box

3. Run the power cables and RJ45 communication cable through the knockout holes into the control panel

4. Connect the power cables to the negative and positive terminal blocks in the control panel of the Battery Box
   o Connect the other end of the positive and negative cable to the respective busbars on the battery side of the Control Box (35 x 8 lug size)

5. Connect the incoming RJ45 cable to the RJ45 port
   o Connect RJ45 Termination Plug to the exit port of the last Battery Box in configuration

Once all communication/power cables are connected, the start-up procedure can be followed to switch the battery on.

START-UP PROCEDURE

Follow the entire procedure closely before closing the fuses to the inverter (See Figures 7 and 8 for a diagram showing the buttons used during the start- up procedure)

This procedure boosts the BMS and runs a self-diagnostic procedure, including checking that the communication wires are connected correctly.

1. Verify the polarity of connections between the units and the inverter

2. Close the breakers on the e-Wall to energize the battery inside the control panel of the Battery Box

3. Switch the ON/OFF button on the Control Box to ON
   o This brings the electronics out of storage mode / online

4. Press the “Start” button to initialize boot up.
   o The button can be pressed momentarily
   – A yellow light will glow until the 48V relay is switched on. This will indicate if the Control Box receives power from the Battery Boxes.
   o A blue light on the “Fan Test” button will illuminate to indicate that the system is powered.

5. Should all be in order, a pre-charge sequence will be started and applied for 25 seconds after which the main contractor will be engaged
   o During this stage a small click will be heard, after which a loud audible click can be heard.

6. After this, the “Start” button should be pressed to unlatch the button.
   o The light should no longer be illuminated.

Additional:

1. Press the “Fan Test” button (inverter side) on the Control Box to check the communication between the Control Box and the Battery Boxes.
2. The light on the “Fan Test” button is an indicator if the battery is on.
3. The yellow light should only be on pressed the Start-Up procedure
   o The light should not glow during normal battery operation

Once a voltage of ± 54 V is measured on the inverter side of the Control Box can the inverter fuse be closed, and the inverter is switched on.

Restart Procedure for Fully Drained Battery

1. Switch off the system
   o Disconnect the MPPT (if applicable)
   o Isolate the battery from the inverter
   Open the fuse/breaker between the battery and the inverter
   o Switch off the battery

2. Disconnect all loads on the inverter
   o Switch off AC supply from the inverter to DC board

3. Restart the battery with the Start-up procedure

4. Once the battery is ON, connect MPPT and allow the battery to charge, and keep the inverter OFF

5. If no MPPT is present, switch ON the inverter and connect the battery to the inverter.
   o Keep the loads disconnected during this stage

6. Loads can be added when the battery reaches 80% SOC

Control Box

M6 fisher plugs should be used to mount the Control Box on the wall. The recommended distance from the Control Box to Invertor should be less than 0.5 m.

The cabling between the Control Box and the inverter should be done to the inverter’s specifications, depending on the amount of Battery Boxes.

The RJ45 port used for communication can be found on Control Box. UTP RJ45 cables will be used for communication between the Battery boxes and the Control Box. The  Control Box will link with the Expansion Boxes in a daisy chain configuration, with the provided termination plug at the outlet of the final Battery Box to complete the loop.  See Figure10 for reference.

The cable length is dependent on the mounting configuration and proximity of Battery Boxes to one another.

Battery Box

M8 Rawl bolts should be used to mount the Battery Box on the wall.

The Battery Boxes must be mounted at a recommended proximity to the Control Box and one another if more than 1 Expansion Box are installed. Figure 9 illustrates the recommended configuration of one Expansion Box and Figure 10 shows the configuration of 3 or more Expansion Boxes.

Ensure the vents on the Battery Box are not obstructed during operation.

The Battery Box wiring can exit either above or below the Battery Box as there is a knockouts on either side of the control panel. Trunking of your choice can be used.

The Battery Boxes’communication is done in a daisy chain configuration, with the provided termination plug at the outlet of the final Battery Box to complete the loop.

35 mm2 cable is the recommended size cable to connect the Battery Box terminal block to the busbar on the Control Box. Ensure the cable lengths from the Battery Boxes to  the Control box are the same.

Communication Connection

Battery communication is in a daisy chain methodology, with a termination at the very last unit.
The blue line in Figure 9 illustrates the wiring for the RJ45 cable between the Control Box and one Battery Box. Figure 10 illustrates this concept for 3 or more Expansion  Boxes.

Recommended Layout Configurations

TRANSPORTATION AND STORAGE

This section elaborates more on conditions that are suitable to transport the Control Box and Expansion Box, as well as storing the units while they are not in use.

Transportation
Avoid serious vibration or shock during transport.

Storage
It is recommended that the Battery Box be stored at room temperature in a dry environment for a maximum period of 6 months with the isolators switched off. If the units are  not stored under the correct conditions i-G3n will not be held liable for any damage to the system.

If the units have been in storage for a while, it is recommended that the “Restart Procedure for Fully Drained Battery” procedure be followed.

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