RedEarth Troppo-4841 Lithium Battery Installation Guide

RedEarth Troppo-4841 Lithium Battery

SAFETY INSTRUCTIONS

Installers and users are responsible for familiarizing themselves with this manual.

The Troppo-4841 battery is certified to IEC62619:2017 and AS/NZS 60950. The Troppo-4841 battery uses high-quality cylindrical Lithium Iron Phosphate (LFP) cells which are safe, robust and reliable in higher ambient temperatures. The cells themselves are also certified to IEC62619 (2015) by TuV, specifically for research, and have an industry-leading service life. They are fully recyclable. Each Troppo-4841 battery has an internal Battery Management System (BMS) designed together with RedEarth that provides protection against the operation in over and under temperature, over and under voltage, over current (charging), as well as short circuit (discharging) protection. It also extends the service life of the battery through the internal balancing of the individual cell strings. Low voltage protection feature: The Battery Management System (BMS) has a feature that shuts down the battery if the voltage goes below 40V+/-2 volts. This is to protect the cells from damage. See the relevant section of this instruction manual to restart the battery. The battery includes a 2-pole non-polarised circuit breaker specifically manufactured for RedEarth. A 2-pole circuit breaker is required to meet Australian standards for battery installations. Other safety features of the Troppo-4841 battery include the use of touch-safe high-quality industry- standard Amphenol Surlok DC connectors for the safe and easy connection of the DC battery cables. These have a significant safety advantage over legacy systems using exposed bolted terminals. Bolted connections present a short- circuit risk as well as the possibility of a loose connection becoming a hot joint. The display included in the Troppo battery increases safety by showing the voltage and current status of the battery at all times. This is helpful when batteries are being connected in parallel, and larger  balancing currents can flow if the battery voltages are not similar. Note that the BMS includes a safety feature that does not allow current to flow if the battery voltages are different by more than 2-3 volts. Bring the battery voltages closer together by charging or discharging one of the batteries before reconnecting. The display also includes an odometer function that shows the total energy in kWh that has flowed into and out of the battery. It can also be useful for indicating if one battery in a string is not doing as much work as other batteries. A status indicator light is also included on the battery. This is always lit when the battery circuit breaker is on and the battery is ready for use. If the battery has shut down due to under-voltage protection shutdown, then it will not light up. The light also incorporates a momentary button feature that is for future developments of the battery.

Installation:
Installation should only be performed by qualified and experienced installers who can specify the correct cables and DC bus arrangement, external circuit protection, polarity checking, and suitability of the design for the application. RedEarth provides factory-built and tested energy storage systems designed and engineered to national and state requirements to simplify installation.

Transportation:

Lithium Iron Phosphate Batteries are classed as Dangerous Goods (DG) Class 9 UN3480and therefore safe for transport. The batteries are shipped in approved transport protection packaging in a partially discharged state with terminal protection in place and the circuit breaker off. RedEarth Troppo-4841 battery is also UN38.3 certified. UN38.3 is the current United Nations standard that lithium batteries must meet and receive certification for safe transport.
Basic Safety and handling:

• Basic Safety and handling:

  • The battery pack is intended to be a 2 person lift when being installed.
  • The battery should not be exposed to temperatures above or below the temperature rating specified in this manual.
  • The battery should not be installed where it is in direct sunlight, or where it can become wet.
  • The battery should not be exposed to strong impacts, crushed, or punctured.
  • Do not short the battery terminals or connect with reverse polarity!
  • The battery should not be disassembled unless qualified and approved by RedEarth to do so.
  • Battery should be kept away from animals and children.
  • The maximum stacking height is 8 batteries when in RedEarth’s transport box.

• Damaged battery:
  A damaged battery must not be used and returned to RedEarth as soon as possible or disposed of via a recycling facility. Leaking electrolytes can cause skin irritation and chemical burns so the contact should be avoided .

• Fire:
  In the unlikely event of a fire, a dry agent fire extinguisher should be available and used. DO NOT use water. Evacuate the area and call emergency services. Toxic gas may be produced if the battery catches fire.
  SDS:

  • Note: Refer to the SDS document for more details. The SDS is available from RedEarth Energy Storage Ltd.
  • The Troppo-4841 Battery is RedEarth’s own in-house developed and built Lithium Iron Phosphate battery.
  • It is an Australian-made product that is designed and assembled by RedEarth in its facility in Brisbane.
  • The Troppo-4841 battery’s features make it one of the easiest and safest lithium-ion batteries to install and use, and you have the support of RedEarth’s experienced Brisbane-based technical team behind you. Just call.
  • The Troppo-4841 battery has been specifically designed to be self-managing. This means it does not need to communicate with the inverter/charger to operate. There is no need for multiple communication wires between the batteries and inverter (and the complications that go with configuring it), making installation simple. It also allows the battery to be used in systems that do not have the capability to communicate with batteries. For example, older lead-acid-based battery systems need a replacement battery.
  • Troppo-4841 batteries include a display that shows the battery voltage and current. It also includes an odometer that shows how many “miles” the battery has done in its lifetime (measured in total kWh into and out of the battery)

OVERVIEW CONTINUED

• Battery connectors are the industry standard, safe, and easy to connect Amphenol connectors. A built-in two-pole circuit breaker allows for time and costs savings during installation.
• The batteries can be connected in parallel to suit applications from the smallest domestic application, right through to telecommunications and commercial-sized projects (note: they are not suitable for series connection).
• The battery can be coupled with many of the inverters available in Australia today. RedEarth can assist you in selecting the requirements for your system and setting the appropriate parameters.
• The Troppo-4841 is currently available in a 48Vdc model and is sized to be installed in standard 19” (inch) racks. RedEarth also provides its own range of purpose-built 19” racks for this.
• The Troppo-4841 battery is certified to IEC62619:2017 and AZ/NZS60950 allowing it to be used in Australia. It is supplied in the appropriate DG-approved shipping carton.

Qualified installation person (Installer)

• The installation tasks described in this manual should be carried out by a suitably qualified and skilled installer with adequate skills. qualifications. and experience. They should:
• Have a thorough understanding of operations. design. and installation principles of On and Off-grid electrical systems.
• Have a thorough understanding of the risks and dangers associated with installing and using electrical equipment.
• Hold all local. state and country-based qualifications to carry out such work.
• Adhere to all safety and installations requirements contained in this manual

PHYSICAL & DESCRIPTION SPECIFICATIONS

The Troppo-4841 battery is a Lithium Iron Phosphate (LFP) battery that contains a Battery Management System that manages the battery cells. It does not need to communicate with the charger or inverter, however, it is important that the charger and inverter are programmed to provide the correct voltage and current for the Troppo-4841 battery. The image below shows the Battery face cover plate including where the connection and control components are located.

• Battery Weight – 42.5kg
• Battery Dimensions 438mm wide x 725mm deep x 88mm high
• Package Weight (with Battery) 44.0kg
• Package Dimensions 540mm wide x 800mm deep x 160mm high

NOTE: Do not open the battery. There are no user-serviceable components and it will void the battery warranty.

UNDERSTANDING THE TROPPO-4841 BATTERY AND ITS USE

The Troppo-4841 battery is designed to be easy to install and use. It can be used in applications requiring a nominal 48VDC battery bank. The Troppo-4841 battery is designed for a wide range of 48VDC applications including but not limited to renewable energy systems, telecommunications, and mining applications. As it is designed with a self-managed Battery Management System (BMS), it does not need to communicate with the inverter/charger to operate. This makes it suitable for a larger range of applications than the typical Lithium-ion battery that requires communication with the inverter/charger to continue to operate. This section of the manual explains the characteristics, features, and options for use of the battery. Additional support is available through RedEarth Technical Support by calling 0487 002 451, emailing or visiting the RedEarth manufacturing facility in Brisbane, Australia. Additional information can be found at www.research.energy RedEarth offers a wide range of training options for our partners including regular training courses run at our Brisbane facility, on-site for our larger customers as well as online training options .

Charging and Discharging the Troppo Battery:

The battery should always be charged and discharged within the voltage, current and temperature ranges listed in the specifications for the battery at the end of this manual and in the datasheet.
When connecting to Inverters and chargers the parameters set in these devices are important for safe battery operation. The table below provides a guide to some of the key parameters to set. RedEarth also provides guides for setting up popular inverters and MPPTs. If in doubt, contact RedEarth. All currents are maximum total charging and discharging currents and should be taken into consideration when multiple devices are charging the battery (e.g. MPPT and inverter/charger). For full warranty coverage, the battery must be operated within the voltage, current and temperature windows defined on the following page and in the specifications in this manual and the datasheet.

Inverter or charger programming – battery parameter settings

|

Installer Information

---|---

Battery type

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Lithium. User -d efined or Sealed Lead-acid

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If no Lithium or user-defined option is available then set to sealed Lead-acid

Charging method

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CC-CV

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Constant Current (CC) (<m ax . charge current ofTROPPOs)… then… Constant Voltage (CV) setting of 57.6V

Recommended continuous Discharge Current

|

maximum 40A per Troppo battery

|

Install sufficient batteries to ensure that the batteries are not overloaded (see Red Earth recommendation)

Recommended continuous Charge Current

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maximum 76A per Troppo battery

|

Install sufficient batteries to ensure that the batteries are not overloaded (see Red Earth recommendation)

Max. Charge/Discharge Current

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maxim um 63A per Troppo battery

| Limited by the 63A MCBand also the fixed BMS internal charging current protection of78amps +/- 8 amps

Charging end current

|

0.8amps (O.OlC)

|

End Constant Voltage charging once current drops below

0.8 amps per TROPPO battery

Continuous Charge Voltage (Absorption voltage)

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57.6V DC

|

Recommended charge voltage ofTROPPO

Float Voltage

|

disable float. otherwise set to 53. SV

|

Float voltage charging is not required

Equalization Voltage

|

disable equalization, otherwise set to 53.5 Voc

|

Avoid equalizing the TROPPO battery

Inverter Shut Down voltage (per Warranty)

|

48.0V (most of the battery capacity used)

|

Inverter stops inverting. Leaves enough capacity to avoid an internal shutdown while waiting for a charging source (e.g . solar)

Inverter Shut Down Soc

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20% if available as an option

|

The inverter stops inverting. This leaves enough capacity to avoid an internal shutdown while waiting for recharging (e.g. solar)

Restart the Voltage of the inverter

Peukert Exponent

|

SOY

|

Set restart voltage of inverter at SOYoc to allow battery to recharge enough prior  to  applying  the  load  to  the  inverter if required

7.02

Cable Size

|

Refer to the relevant manual or cable sizing standard

|

Amphenol  5.7mm Surlok – rated at 720A with 25mm2  cable norm with 76mm 2)

The inverter (or MPPT) connected to the Troppo needs its battery parameters set as listed above. If the inverter shut down voltage is set too low there is a  risk that the battery switches itself off internally for protection. This then requires a manual restart of the Troppo battery.

RedEarth’s The Vault Preassembled battery cabinet:

This allows qualified installers to add RedEarth’s approved Battery System as the storage component of a 48Vdc installation. The Vault is supplied as a fully pre-wired (incl 70mm battery cables) IP20 cabinet to the house with a maximum of 8 to 20 batteries for indoor applications. The Vault can be configured with a built-in Battery Breaker (160-250amp NOARK MCCB) and a Victron BMV-712 battery monitor. This allows monitoring of the whole stack of TROPPO batteries and includes an alarm option (eg low battery voltage) as well as Bluetooth monitoring on your phone. There is a standard and premium version of the Vault system available. This configuration allows 9 batteries to be installed. The Vault can be paralleled together to increase total capacity. An optional remote monitoring option is also available from RedEarth when mobile phone coverage is available. This requires the Vault version with the BMV battery monitor plus MCCB.18 and 21 battery cabinets are also available as well as IP54+ cabinets for outdoor applications. These outdoor enclosures can be air-conditioned if required. Contact RedEarth with your requirements.

Custom installations by qualified installers:

Sizing the System is often dictated by the application. In these cases, the installation location of the battery must take into consideration the IP rating (IP40) and operating temperature range specified in the Specification section of this manual. The optimal ambient temperature range is 0°C to 45°C. Troppo-4841 batteries do not vent any harmful gases and do not require special ventilation or cooling.
The Troppo-4841 battery is designed to be installed in The Vault or an electrical enclosure of your choice. If the battery is to be installed outdoors a suitable IP54 enclosure should be used.

The location of the batteries should meet the following conditions:

• A >3mm clearance is required around the battery for a minimum of 70% of the surface area.
• The batteries are not located in a salt-air environment, e.g. by the ocean. If this is unavoidable then appropriate air filtration should be used to prevent salt air from contacting the battery.
• There are no explosive or flammable materials nearby (refer to AS5139 and the Best Practise guide https://batterysafetyguide.com.au/.)
• Charging and discharging outside of the optimal ambient temperature range should be limited to C5 and the battery cells should remain between the max and min operation temperature range as specified in this manual. (the internal BMS will stop the operation of the battery if the cell temperatures move outside their specifications)
• The temperature and humidity remain relatively constant to avoid condensation.
• The area is clean with minimal dust.
• The batteries and battery cabinets/housings are not exposed to direct sunlight.
• The Troppo-4841 battery can be installed horizontally, vertically, or on its left or right side.

RedEarth can supply connectors, bus bars, DC battery cable, battery breakers, and ancillary items to assist qualified installers in completing their installations. Call RedEarth Technical support on 0487 002 451.

• DC battery cables:
  Each battery has a positive and negative Amphenol SurLok non-keyed male connector for easy snap-on connection. A full range of pre-made cable and mating connectors are available from RedEarth.

• Multi-battery bus bar and DC Battery Breaker:
  If multiple batteries are to be connected, then RedEarth can supply a Victron busbar which is rated to 1000A. Several can be bolted together when larger numbers of batteries are required. RedEarth also uses and can supply Noark MCCBs.

• Monitoring:
  RedEarth can supply a Victron BMV-712 monitor with an alarm relay and Bluetooth capability (see next page). It is included in The Vault product as standard. A pre-configured remote monitoring option is also available. It requires mobile phone coverage. Battery Connection and Operation

• Connecting batteries together in parallel:

  • SurLok Plus 5.7mm (IP67)
  • Right Angle Plug (Black) Suit 16mm² and 25mm² cable SLPPA16BSB
  • Right Angle Plug (Red) Suit 16mm² and 25mm² cables SLPPA16BSR
  • Panel Mount (Black) Threaded Post SLPRATPSB
  • Panel Mount (Red) Threaded Post SLPRATPSR

1. When connecting multiple Troppo-4841 batteries to a single inverter/charger follow the steps below.
   • Confirm the status of the battery
   • On each battery switch ON the OVERCURRENT PROTECTION MCB and confirm that the display and indicator light illuminates. By looking at the display, confirm that the battery voltage is between 48.0VDC and 57.6VDC. It is recommended that the voltages of all the batteries are within 0.5 volts of each other to avoid high current flows between the batteries once they are all connected in parallel. Note that the BMS in the batteries will not allow electrical connection if the voltage difference between the batteries is greater than 2-3 volts. Bring the battery voltages closed together by charging or discharging one of the batteries before connecting in parallel.
2. Switch OFF the OVERCURRENT PROTECTION MCB of all batteries.
3. Next, ensure the separate Main Battery Breaker connected to the inverter/charger is OFF.
4. Connect all the batteries in parallel, by connecting them to the main bus bar using the correct Amphenol 5.7mm Surlok cables (available from RedEarth and already included in all RedEarth systems). This busbar will be connected to the inverter/charger via a separate Main Battery Breaker (Double check that all the battery cables are connected to the correct polarity).
5. Switch on all the OVERCURRENT PROTECTION MCBs of the batteries and monitor the displays to ensure there are no large currents flowing. These currents will reduce quickly and will balance the batteries if their SOC was not the same. Once all balancing currents are below 5 Amps move to the next step.
6. Switch on the Main Battery Breaker. The inverter/charger should power up depending on the type.
7. Adjust the parameters of the inverter/charger to match the requirements of the Troppo-4841 batteries. Refer to the settings included in this manual. This is a critical step. If you are unsure of the settings required contact RedEarth, as damage to batteries caused by incorrect settings of the inverter/charger will affect your warranty.
8. If you have purchased a RedEarth system with the RedEarth remote monitoring option, you can contact RedEarth now. RedEarth will log into your system and confirm that everything is operating correctly.

Shutdown Process

To shut down the battery, the OVER-CURRENT PROTECTION must be switched towards the OFF position. Shutting down the battery will cause a loss of power on the battery terminals (+ve and -ve) Earthing: Next to +ve and -ve, there is an attachment point for an M6 screw. This is where an earthing cable (secured by an M6 screw up to 12mm long) must be connected should the application require grounding of the case to the same potential of its enclosure.

TROPPO BATTERY SPECIFICATIONS

The table below, extending to the following two pages, includes all the specifications of the Troppo-4841 battery that need to be understood. It also includes additional information to help the installer to understand the specifications and parameters of the battery. More detailed information on specific settings required for Victron, Electronics, Voltronics, and SunGrow hybrid inverters are available separately. These are the inverter brands currently used by RedEarth. If your inverter is not included in the above, please contact RedEarth for further instructions.

Troppo-4841 Self-Managed LFP Battery Module
The Troppo-4841 battery incorporates a self-managed BMS that does not require communication with the inverter/charger to operate. It does however require the inverter/charger settings to be within the specification of the battery as listed below.

TROUBLESHOOTING

The Troppo-4841 battery is a self-managed lithium battery system. This simplifies installation as no communication cables are required between the inverter/charger and Troppo-4841 batteries.
It does however require the inverter/charger settings to be correct to operate without any issues. Contact RedEarth if the following information does not solve your problem.

Flat Battery
Field experience has shown that the most common problem is the battery being discharged to the point where the internal BMS in the Troppo-4841 shuts down the battery. Follow the procedure shown on the right to restart the battery. If this is unsuccessful you will need to apply a 48VDC voltage to the terminals of the battery to “jump-start” it. RedEarth can supply a suitable charger, which needs to be plugged into 230VAC.

Adding additional batteries:
It is possible to add additional batteries to an existing Troppo-4841 installation at a later date. If you are to add extra capacity the battery must be of the same type, part number, and specification.
Before adding the new battery, the original battery bank and the new battery must be bought up to a similar same voltage (within 0.5 volts as shown on the battery displays). This is achieved by discharging or recharging the existing battery until it is at the same voltage as the new battery. The new battery can then be connected to the existing batteries.

Repairable TROPPO-4841:
The Troppo-4841 battery is designed to be repairable, however, this is only able to be done by RedEarth or by personnel trained and qualified by RedEarth. This could be a larger partner with technical repair capabilities. Attempting to repair the RedEarth Troppo will void the warranty.

• RedEarth has additional information on the website: www.redearth.energy, including instructional videos.
• RedEarth Energy Storage Ltd 15 Fienta Place, Darra Brisbane QLD 4076, Australia
• Phone: (07) 3279 6707 or 1800 733 637 Technical Support: 0487 002 451
• Email: [email protected]

Maintenance

The Battery system should be checked regularly as part of your system maintenance cycle, or at least every 6 months. These checks include:

• Check the battery Display to confirm all batteries are operating as expected. Current and odometer readings are similar in each battery (within +/-5%)
• All LED indicators on the batteries are on.
• Check for any obstructions placed around the battery that may reduce ventilation.
• Check for animals, insects, or creatures nesting in or around the battery system.
• Check for the build-up of any foreign objects in or around the cabinet.
• Check battery connections and cables for secure fitting or cable damage. (eg rats eating the cables)

OPTIONS AVAILABLE FROM RED EARTH

Additional batteries:
One of the key advantages of the modular self-managed Troppo-4841 battery design is that additional batteries can be added to an existing Troppo-4841 installation at a later date. Additional battery modules can be ordered from RedEarth together with the required battery cables. Some parameters of the inverter/charger may need to be adjusted to get the best performance from the new larger battery bank, e.g. increase the charging current setting. RedEarth’s own systems that are being monitored by RedEarth can often be remotely updated. Talk to RedEarth’s technical support team when you order your extra batteries.

The Vault
RedEarth can supply the system in the following sizes; Indoor rated (IP20):

• • 18RU = 7 to 9 Troppo-4841 batteries (7 if the additional Battery Breaker and Victron BMV shelf are used)
• 22RU = 9 to 11 batteries
• 27 RU = 11 to 13 batteries
• 42 RU – 19-21 batteries – this system normally does not include a built-in battery breaker is usually an external one is used.

Other components:
Busbars, DC cable, MCCB battery breakers, and battery connectors are available to qualified installers from RedEarth. RedEarth can also provide a LiFePO4 charger for an emergency should a Troppo-4841 battery have discharged to the point where it has turned off internally and will not restart. Call us to see how we can help you.

WARRANTY

• RedEarth provides a 10-year repair/replace warranty for the battery.
• Refer to RedEarth’s warranty document for details.
• These five things will void your warranty:
  1. Incorrect battery wiring (e.g. connecting with reverse polarity or connecting batteries in series instead of in parallel)
  2. Connecting the battery to incompatible equipment (e.g. 12V battery charger).
  3. Incorrect inverter and/or charger settings.
  4. Disassembling battery.
  5. Incorrect battery bank sizing, e.g. too few batteries for the size of the inverter.
• RedEarth does not warrant damage or defects caused by or from the following:
  • Incorrect storage or transportation
  • Incorrect installation and wiring
  • Not installed according to this manual
  • Incorrect operation of the battery
  • Inappropriate environmental conditions when operating the battery
  • Failure to follow safety requirements
  • Tampering with the battery
  • Unauthorized repairs or modifications to the battery
  • External influences such as physical damage, over-charging or electrical damage
  • Use outside of warranty terms and conditions
• RedEarth Energy Storage Ltd 15 Fienta Place, Darra Brisbane QLD 4076. (07) 3279 6707 or 1800 733 637
• Technical support: 0487 002 451 [email protected] www.redearth.energy

References

• Battery Safety Guide – Battery Safety Guide

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