Kon-TEC KT-LFPES512100 Low Voltage Energy Storage Instruction Manual

Kon-TEC KT-LFPES512100 Low Voltage Energy Storage

Product Information

Specifications

• Product Name: KON-TEC LITHIUM IRON PHOSPHATE LiFePO
• Model: KT-LFPES512100
• Voltage: 51.2V
• Capacity: 100Ah
• Website: www.kon-tec.eu

Product Usage Instructions

Information
Details about the product information.

1. Validity
   Validity details.

2. Target Group
   Target group information.

3. Levels of warning messages
   Explanation of warning message levels.

4. Symbol Description
   Description of symbols used.

5. Abbreviation Description
   Description of abbreviations used.

Safety

1. Safety precautions
   List of safety precautions to be followed.

2. Safety instructions

3. Safety gear
   Details on safety gear required.

4. Emergency safety measures
   Instructions on emergency safety measures.

5. Other Tips
   Additional safety tips.

Product Overview

1. Introduction
   An introduction to the product.

2. Features
   List of product features.

Specification

Dimension
Dimensions of the product.

Parameters
Detailed parameters of the product.

Frequently Asked Questions (FAQ)

Q: Can I charge the product using a regular charger?
A: No, it is recommended to use the specific charger designed for this product to ensure safe and proper charging.

Q: How often should I perform maintenance on the energy storage system?
A: Regular maintenance checks should be conducted according to the guidelines provided in the user manual to ensure optimal performance and longevity of the system.

https://www.kon-tec.eu/

LEGAL PROVISIONS
This manual describes in detail the requirements and procedures for safe installation and operation of Kon-TEC lithium battery pack. Please read this manual carefully, only qualified persons are allowed to install, operate and maintain the system, otherwise it may cause product damage or personal safety risks.
Any actions against safety operation, or do not follow rules of this manual and limited warranty letter, will void warranty and qualification of this product. Meanwhile, the manufacturer will be not responsible for the product damage, property damage, personal injury or even death.

The information contained in this manual is accurate when it’s issued. Kon-TEC reserve right to change specification (such as optimization, upgrade or other operations) without prior notice, please always view the latest document via QR code. In addition, please noted that the diagrams/schematics in this document are used to help understand system configuration and installation instructions, which may be different from the actual items at the installation.

LEGAL TERMS
Kon-TEC will retain the copyright of this document, do not extract, copy or translate in any ways without the written permission.

ON-LINE INSTRUCTIONS IN POLISH AND ENGLISH
You can find online instructions in Polish and English on our website www.kon- tec.eu. In the ‘Energy Storage’ section, select the appropriate product, then go to the ‘Download’ tab.

INFORMATION

VALIDITY
This document is valid for: KT-LFPES512100 Battery Pack.

TARGET GROUP

This document is intended for qualified persons and operators. Only qualified persons are allowed to perform the activities marked in this document with a warning symbol and the caption „Qualified person”. Qualified persons must have the following skills:

• Knowledge of how lithium iron phosphate batteries work and are operated.
• Knowledge of how an energy storage system (including PV/battery/hybrid inverter, MPPT, Meter, Distribution box etc.) works and is operated.
• Knowledge of local applicable connection requirements, standards, and directives.
• Training in the installation and commissioning of electrical devices, batteries.
• Training in how to deal with the dangers and risks associated with installing, repairing and using electrical devices, batteries.

LEVELS OF WARNING MESSAGES
The following levels of warning messages may occur when handling the product

DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury or product permanent damage.

NOTICE
Indicates a situation which, if not avoided, can result in property damage or product not work or accelerated product damage

SYMBOL DESCRIPTION

SYMBOLS ON PRODUCTS LABEL

OTHER SYMBOLS

ABBREVIATION DESCRIPTION

Single KT-LFPES512100 rechargeable lithium iron phosphate battery pack including cells, BMS and enclosure etc.

Battery system/cluster| Multiple KT-LFPES512100 battery pack connected in parallel with power, communication and grounding cables and installation auxiliaries.
BMS| Battery management system. Electronical Unit to ensure lithium cells’ safety and display information or control the battery work mode.
SOC| State of charge. The battery state of charge refers to the percentage of the remaining capacity and rated capacity of the battery.
SOH| State of health. The battery health status refers to the percentage between the full charged capacity and the rated capacity of the battery.
DIP switch| Dual in-line package switch
COCP| Charge over current protection
DOCP| Discharge over current protection
COVP| Cell over voltage protection
POVP| Pack over voltage protection
CHTP| Charge high temperature protection
DHTP| Discharge high temperature protection
CUVP| Cell under voltage protection
PUVP| Pack under voltage protection
CLTP| Charge high temperature protection
DLTP| Discharge high temperature protection
SCP| Short circuit protection

SAFETY

SAFETY PRECAUTIONS

DANGER

Explosion risk
Do not impact the battery with heavy objects. Do not squeeze or pierce the battery pack. Do not throw the battery pack into the fire.

WARNING

Fire risk
Do not expose the battery pack to the condition over 80°C. Do not put the battery near a heat source, such as a fireplace. Do not expose the battery pack to direct sunlight or raining.

CAUTION
Electric shock risk
Do not allow non-qualified person to disassemble the battery pack. Do not touch the battery pack with wet hands.
Do not expose the battery pack to moisture or liquid environment.

NOTICE
Damage risk
Do not short-circuit or reverse connect the battery.
Do not use chargers or charging devices unapproved by the manufacturer to charge the battery. Do not mix batteries from different manufacturers or different kinds, types or brands.

SAFETY INSTRUCTIONS
The battery has been designed and tested in accordance with international (such as UL, IEC, UN38.3 etc.) safety requirements. However, due to various factors during the whole lifetime process, Kon-TEC cannot guarantee absolute safety, in order to prevent personal injury and property damage and ensure long-term operation of the battery, please do read the below section carefully to operate the battery and handle emergency situations.

SAFETY GEAR
It is required to wear the following safety gear when installing and handling the battery pack.

EMERGENCY SAFETY MEASURES

Water invasion
Please cut off the AC power supply of the system first and then disconnect all switched under the premise of ensuring safety.

Electrolyte or gas leakage
If the battery pack leaks electrolyte, avoid contact with the leaking liquid or gas. If one is exposed to the leaked substance, immediately perform the actions described below.

• Gas Inhalation: Evacuate the people in the contaminated area and seek medical aid immediately.
• Eye Contact: Flush your eye with clean and flowing water for 15 min, and seek medical aid immediately.
• Skin Contact: Thoroughly rinse the exposed area with soap and water to be sure no chemical or soap is left on them, and seek medical aid immediately.
• Ingestion: Induce vomiting, and seek medical help immediately.

WARNING

In case of fire situations, please use the extinguisher suitable for lithium- ion batteries, such as an extinguishing device containing the form of water dispersion of vermiculite.

OTHER TIPS

• All the product are strictly inspected before shipment, please contact your supplier for replacement if you notice there’s any defectives such as swelling.
• Do not disassemble batteries and components, otherwise the manufacturer will not be responsible for any damage caused by unauthorized disassembly or repair.
• Do enable the battery to be safely grounded before use to make sure the system in safe and normal operation.
• Please ensure that the electric parameters of these devices are compatible mutually before connecting the battery to other devices.
• Please take the environmental factors into careful considerations to ensure that the system can work in a suitable condition as the environment and storage methods have a certain impact on the service life and reliability of this product.

PRODUCT OVERVIEW

INTRODUCTION
The KT-LFPES512100 battery is designed for residential application and works as a storage unit in the photovoltaic system. It is a 51.2V lithium battery system, with BMS inside. It could be operated in both on-grid, back-up and off-grid modes with compatible inverters. Below is the general schematic of an ac-coupled system with the batteries.

CAUTION
This electrical connection in this diagram is only for illustration, please follow the Manual suggestions of related devices and operate in accordance with locally applicable connection requirements, standards, and directives.

FEATURES

• Highest safety, battery is made from LiFePO4 chemistry and comply with highest international safety and transport standard.
• Modular and flexible, support up to 32 batteries connect together to expand the system energy.
• Built-in pre-charge circuit to avoid rush current when connecting with different inverter/chargers.
• Automatic dynamic addressing function when connected multiple batteries together.
• Support a maximum of 96% DOD under off-grid and back-up application
• Built in BMS provide warning and protection functions including over-discharged, over-charged, over-current, short-circuit and high/low temperature.
• LiFePO4 as cathode material and automatic balancing function to meet longer cycle life
• Compact size and light weight for easy installation and maintenance.
• Multiple installation bracket to adopt with different customers’ requirement.
• LED display, CAN/RS485 port for external communication and upgrade the BMS firmware.

SPECIFICATION

DIMENSION

PARAMETERS

NOTICE
The optimum operating temperature range is from 15°C to 30°C, Frequent exposure to the harsh temperatures may worsen the performance of the battery pack and cycle life.

PANEL INTERFACE

2   channels output signal

|
E| Reset| Used to sleep(3s)/awake(3s)/reset(6~10s) BMS in power on mode.|
F| M/S| Used to indicate the module is Master or Slave battery| Single mode:OFF

Parallel mode:

ON- Master battery OFF-Slave battery

G| Link IN Link OUT| For internal and external communication|
H| DIP| Used to set the RS485 baud rate and inverter protocol choosing|
I| RUN| Used to show battery is in running status when lighting or flashing|
J| ALM| Used to show battery Alarm/Protection status|
K| SOC| Used to show battery real-time SOC|
L| Power switch| Used to Power on/off battery|
M| Negtive terminal| Used to connect the inverter/charger|
N| Mounting ear| Used to fix with rack or cabinet|

1 D: DRY CONTACT

2
3| NO Output2, discharge enable/disable signal
4
5| Passive INPUT signal.

Rapid Shut Down function for US

6

G: LINK IN / LINK OUT

1.Used to connect with external devices to establish communication. 2.Used to connect with upper battery pack Link OUT.

2| RS485-A1
3| SGND
4| CAN-H
5| CAN-L
6| SGND
7| RS485-A1
8| RS485-B1
Link OUT| 1| RS485-B2| ****

Used to connect with downward battery pack Link IN.

2| RS485-A2
3| SGND
4| CAN-H
5| CAN-L
6| SGND
7| RS485-A2
8| RS485-B2

DIP ADDRESSING

to inverter brand Slave: keep default setting

NOTICE

Fail to follow the DIP switch setting will cause the communication fault between battery and inverter, for more detail setting with different inverter/charger, please contact your supplier for consultation.

RUN/ALM/SOC

Note: ‘Warning’ including items of cell imbalanced/low voltage/high current/high&low temperature.

PROTECTION FUNCTION

reach the protection value and it will be auto-released only when both Pack and cell voltage back to the release voltage range or there is efficient discharge current.|
Discharge end CUVP

PUVP

| The BMS will stop discharging if any cell or PACK voltage is under the protection value and it will be released only when all the cell voltage back to the release voltage range or there is efficient charge current.| Can Automatic recovery. Please charge timely, otherwise it may be in Low-power mode to be over-discharged and damage battery.
CHTP DHTP| The BMS will stop charging or discharging or both if any cell/ environment/MOS temperature is beyond the range.| Automatic recovery when temperature falls.
---|---|---
CLTP DLTP| The BMS will stop charging or discharging or both if any cell/ environment/MOS temperature is under the range.| Automatic recovery when temperature rise.
COCP| The BMS will stop charging when the charging current is higher than the protection value. And it will release from the protection when the system delays time is met.| Automatic recovery. If locked after three consecutive times, manual intervention is required.
DOCP| The BMS will stop discharging when the discharging current is higher than the protection value. And it will release from the protection when the system delays time is met| Automatic recovery. If locked after three consecutive times, manual intervention is required.
SCP

Reversed polarity

| The BMS will stop charging when detect short circuit or reversed polarity.| Charge to release. Manual press reset.
Temperature, Voltage, Current sensor failure| Enter the failure mode, manual intervention is required no charging and discharging.| Manual intervention.
Sleep mode| After reaching a certain condition, BMS will enter dormancy mode to reduce BMS consumption| Charge, press reset or restart to activate.

CAUTION
Please re-charge the battery via MPPT, grid/generator or other energy source within 24h if the battery is over discharged, otherwise, it may be damaged.

NOTICE
Manually short-circuit and reverse the battery will void the warranty.

INSTALLATION

PREPARATION

SAFETY COMPLIANCE
The system installation must be finished by qualified person(s), During the whole installation process, please strictly follow the local safety regulations and related operating procedures.

ENVIRONMENT
The operating environment shall meet the following requirements:

temperature)
Relative humidity| 5%~90%, No condensation
Altitude| <3000m
Safety requirement| Do not expose the battery to direct sunlight, rain and snow. Do not place the battery within children/pet touchable area.

Do not place the battery near heat source and flammable material Do not drop, deform, impact, cut or spearing with a sharp object. Do not put heavy things on battery.

Do not disassemble the battery without Manufacturer’s permission. No conductive dust and water or other liquid to contact battery.

Follow the emergency measure if there is water invasion or electrolyte and gas leakage. Contact your supplier within 24 hours if any product failure happens.

TOOLS

INSPECTION

UNPACKING

• Please load and unload it in accordance with the specified requirements to prevent sun and rain when you receive the equipment.
• Please check and confirm the goods (such as quantity, appearance, etc.) according to the „scope of delivery „ before unpacking.
• Do light take and put during unpacking process to protect the surface coating of the object;
• Please record and feedback to the manufacturer if the inner packing is damaged after unpacking.

SCOPE OF DELIVERY
Check the scope of delivery for completeness and any externally visible damage. Contact your supplier for supplementary delivery if the listed material is incomplete or damaged.

GENERAL MATERIALS (BATTERY UNIT)

OPTIONAL MATERIALS
(NOTED THAT EACH PACK UNIT TOGETHER WITH ONE TYPE BRACKET AS DEFAULT)

EXTERNAL CABLE KITS
Cables connected to inverter or junction box belongs to an External Cable kits, NOT include in battery carton. Customers need buy it separately, the information are as below.

For inverter communication PIN definition detail, please check Appendix I

Notice

• Keep the unused cable pins NULL to avoid affecting the closed loop communication.
• A ground connection of communication cable may be required from some inverters, please follow the rules from inverter manufacture.

START INSTALLATION

REMAINDER

Please check again the following conditions or equipment whether meet the requirements before installation:

• Check if there’s enough space for installation, and if the load-bearing capacity of the bracket or cabinet meets the weight requirements.
• Check whether the power cable pair(s) used meets the maximum current requirement for operation.
• Check whether the overall layout of power supply equipment and batteries at the construction site is reasonable.
• Check whether the installer is wearing anti-static wristband.
• Check whether there’re two people on the construction site for installation work.
• Check if there’s potential risks at location of installation site, e.g flooding, sun exposure, corrosion, and salt spray.

PROCEDURES

CAUTION

• Injuries may result if the product is lifted incorrectly or dropped while being transported or mounted. Wear suitable personal protective equipment for all work on the product.
• Ensure that no lines are laid in the wall which could be damaged when drilling holes.

RACK MOUNTED

1. Take the battery pack out from carton.
2. Get the Rack or cabinet ready and place it horizontally at a reasonable location.
3. Place the battery on the rack or cabinet tray via manual-lift, Insert the screws and fasten the battery to the rack or cabinet.
4. Finish the cable connection

STACK MOUNTED

WALL MOUNTED

FLOOR MOUNTED

TIPS

INSTALLATION NOT ALLOWED

OTHER INSTALLATION

NOTICE
ANY others installations, please avoid the battery directly contacting the ground and avoid of high salinity, humidity to prevent the product from rusting and corrosion.

CABLE CONNECTION AND COMMISSIONING

GET BATTERY READY

1. Ensure all the battery is in OFF mode, check and confirm the installation is tighten and stable.
2. Check the number and specification of cable kit accessories are correct according to the Scope of delivery item, if you are making cable yourself,please follow manufacturer’s requirements.
3. Switch on all battery individually before wiring, check whether there is any alarm/protection information, if yes, turns to troubleshooting. Then switch off all batteries.

GROUNDING CABLE CONNECTION

1. Take out the grounding screw on the battery panel, and get the cable conductor through it. 5.2.2 Fix them together, with a cylinder screwdriver and tighten it.
2. Connect the grounding cable with next battery module.

COMMUNICATION CABLE CONNECTION

1. Take out battery to battery communication cable.
2. Confirm the location of Master battery, insert the RJ45 plug into the Link Out port and connect the other side to next battery Link IN port, daisy chained all batteries.

Note: the module with empty Link IN port is Master battery

NOTICE
The BMS inside the battery pack will automatically terminate BOTH end of CANBUS pins, DO NOT need to plug the 120Ω terminator again.

ILLUSTRATIVE DC POWER CABLECONNECTION (EXAMPLE ONLY FOR MAX. 100A, 5KW RATING)

1. Take out battery to battery power parallel cable.
2. Insert the Plug into the power socket until you hear the ‘click’ sound.

CONNECTING WITH INVERTER

CAUTION
Confirm inverter AC input and PV input is disconnected before wiring connection, and the DC/ signal switch of inverter/charger is in off status.

1. Connecting Master battery Link IN port with inverter CAN or RS485 communication port via inverter communication cable (Version I/II/III or customized).
2. Connecting battery OUTPUT (+) with inverter battery INPUT (+), battery OUTPUT (-) with inverter battery INPUT (-), an external disconnection  breaker between battery system and inverter is recommended, choose the corresponding power cable pair and wiring them correctly.

Note:

NOTICE
Choose the suitable disconnection breaker considering the inverter power/current, rated voltage, tripping characteristic etc.

DANGER
Depending on the output power of the energy storage, the cross-sections of wires should be properly matched and the appropriate connection diagram (type) should be used.

ALLOWED CONNECTION DIAGRAMS (TYPES)

Type 1: Maximum continuous current 100A, maximum energy storage output power 5kW.

Type 2: Maximum continuous current 200A, maximum energy storage output power 10kW.

Type 3 : Maximum continuous current 400A, maximum energy storage output power 20kW.

WIRING DIAGRAM NOT ALLOWED:

NOTICE
The maximum communication cable length is required to be less than 15m between inverter/charge and battery. The maximum power cable length is suggested to be less than 10m between inverter/charge and battery.
For Australia market please contact with Kon-TEC.

CAUTION
The maximum tolerance current of each power cable and terminal is 125A, 100A for continuously is suggested, please use corresponding number of power cable pairs according to the field configuration and local connection requirements, standards, and directives.

COMMISSIONING

1. Set the DIP address of the Master battery (and the Slave battery if there is any RS485 baud rate changed).
2. Switch on all battery modules, wait for 10s, make sure that only M/S led is on Master battery.
3. Turn on the breaker between the inverter and battery if there is any, then turn on the inverter/charger isolator.
4. Finish the setting on inverter/charger or any other control devices, if everything is correct, you are ready to use the system.

battery pack)
9| Rated discharging current limited value| 50AN (N is the Quantity of the battery pack)
10| Max. charging current limited value| 70AN (N is the Quantity of the battery pack)
11| Max. discharging current limited value| 100A*N (N is the Quantity of the battery pack)
12| Force charge| Enable

For more information to connect with different inverter/charger, please contact your supplier for technical support.

CAUTION
If your system is a back-up or off-grid system, make sure your configuration can cover the worst situation to avoid battery to be over-discharged.

SWITCH OFF BATTERY

1. Turn off the inverter.
2. Turn off the disconnection breaker if there is any. 5.7.3 Turn off all batteries signal switch.

TROUBLESHOOTING AND FAQ

battery can be started.

Charge the battery use a charger or inverter to provide 54~57.6V voltage and observe it can be started.

| ****

If the abnormal status still alive after above steps, please contact your supplier.

If there is any other situation(s) excluding in this table, turn off the fault battery, contact your supplier.

Unable to charge| Check whether the cable connection between the battery and the inverter/charger is correct.

Check whether the inverter/charger setting is correct.

Check whether the battery is in charge protection mode, if yes, try to discharge the battery.

Unable to discharge| Check whether the cable connection between the battery and the inverter/charger is correct

Check whether the battery occurs short circuit, reverse connection, pre-charge failure during connection inverter etc.

Check whether the battery is in discharge protection mode, if yes, try to charge the battery.

High/Low temperature| Stop the battery system for a while, check whether the installation location temperature meet the requirement.

Avoid continuous full charging and discharging.

High current| Check the configuration and parameters setting on the inverter/ charger is correct.
ALM always on| Turn off all the batteries, and remove the fault battery from the system, ask your supplier
Communication fail| Check the communication cable type is correct and is contacted well. Check the DIP switch setting is correct.

Check the inverter protocol related setting is correct. Check both battery and inverter are working properly.

Q1: Battery maximum SOC is 99% and never goes to 100%SOC during daily cycle use, why?
Generally, there is no effect to system on this point. BMS will calibrate the SOC to 100% when reached cut-off current or trigger CHVP, however, to avoid battery from being overcharged and to extend the cycle life as longer as possible, we left a room and set a charging profile to let battery not be charged at high voltage near full. Keep float the battery for approximately 0.5~1 hour to calibrate.

Q2: ‘High voltage’ and ‘cell unbalance’ warning and alarm in rare cases, does it mean battery is damaged?
No. This is not unusual and happened on new batteries that are not balanced yet, please lower the maximum charge voltage (54.6V) and float the battery via grid or generator. If not solved, please contact your supplier.

Q3: When having multiple batteries in parallel connection, the battery on the end can’t be fully charged.
Pay attention to your wiring diagram, please always follow the manual wiring advises and choose proper cable size and pair.

Q4: The current is 0A when connecting with a very small load at the situation that having multiple batteries in parallel connection, how to solve it?
Each BMS has a threshold current of 0.5A (~25W) before it begins to report, this leads the inaccurate display of the current.

Q5: SOC suddenly jump to 100% during charging.
This is normal in off-grid application and usually happened on batteries that not been calibrated SOC for long time, we suggest to fully charge the batteries per month.

TRANSPORT, STORAGE

• Do not violently shake, impact or squeeze, and prevent sun and rain during the transportation.
• Do light take and put and strictly prevent falling, rolling, and heavy pressure during loading and unloading.
• The battery should be placed in a dry, clean, dark, and well-ventilated indoor environment for long-term storage, and the recommended storage temperature range is 15~30ºC.
• No harmful gases, flammable and explosive products and corrosive chemical substances in the storage location.
• The batteries should be stored and transported in close to 50% SOC, do not store over 80%SOC for long time.
• If do not use for a long time, the battery needs to be charged every 6 months.
• No fall down, no pile up over 6 layers, and keep face up.

DISPOSAL OF BATTERY

Disposal of battery must comply with the local applicable disposal regulations for electronic waste and used batteries, please review your local Battery recycling or management regulations or contact your supplier for more information.

APPENDIX – INVERTERS / CHARGERS CONNECTIONS

Kon-TEC sp. z o.o.

T: +48 572 001 151

E: info@kon-tec.eu

W: www.kon-tec.eu

References

• tec.eu

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