DropBear Installation Manual · 2020. 12. 3. · AS/NZS 3008.1.1:2017 Electrical installations –...

DropBear_Installation Manual

RE_PROD_0011 Version #2 of 20 Issue Date 28/07/2020

DropBear Battery Energy Storage System

- On or Off-Grid - (Single Phase)

Installation Manual



RedEarth Energy Storage Ltd 15 Fienta Place Darra – QLD 4076 Australia Tel: +61 7 3279 6707 Email: [email protected] Web: www.redearth.energy

mailto:[email protected]

http://www.redearth.energy/



Safety procedures

WARNING: Working inside of the DropBear system is restricted to qualified personnel.

Installers must be qualified electricians with CEC accreditation for Solar and Battery.

The DropBear must only be installed by suitably qualified personnel. Many of the procedures covered in the INSTALLATION sections of this manual have inherent risks. Whilst the DropBear is designed to be safe, including residual current device and double insulated cables, the voltages connected or generated by the equipment are hazardous and potentially fatal.

The wiring diagrams and installation instructions are given as a guide only and compliance to appropriate standards is the responsibility of the installer. Such standards are listed below: AS/NZS 3000:2018 Wiring rules AS/NZS 5033:2014 (amdt 1&2) Installation and safety requirements for

photovoltaic (PV) arrays AS/NZS 4509.2:2012 Stand-alone power systems-Design AS/NZS 1170.2:2011 Structural design actions-Wind actions AS/NZS 4777.1:2016 Grid connection of energy systems via

inverters-Installation requirements AS/NZS1768:2007 Lightning protection AS/NZS 3008.1.1:2017 Electrical installations – Selection of cables AS/NZS 5139:2019 Electrical installations-Safety of battery

systems for use with power conversion equipment

In our efforts towards constant product enhancement, this document is subject to change at any time. Please visit www.redearth.energy and download the appropriate and latest version manual.

If installing within 1km from coastal line, DropBear must be indoors




Your RedEarth DropBear is an AC coupled ready-to-run energy storage system for On or Off-Grid applications. It comprises of a Fronius Primo Solar MPPT inverter, Selectronic SP Pro Battery inverter, self-managed lithium batteries and is fully assembled and factory tested. It is ready to connect a PV Solar array and generator with either auto or manual start.

The DropBear is designed to be installed indoors or outside in a shaded and weather protected environment against a wall. A changeover switch is included in case of system failure. In this case the loads can then be run off a generator until the system is operational again. RedEarth Energy can provide remote monitoring, technical support and service to ensure ongoing operation of your DropBear. You can also access remote monitoring to view your consumption online. DropBear installations require the electrical connection of;

• The customers load – there are dedicated terminals inside the unit to connect to. • Two arrays of PV solar panels which can be installed with different orientations. • Generator - there are dedicated power, auto-start and battery charger terminals

inside the unit to connect to. • Monitoring - The installer will need to connect the system to the internet via LAN

cable or 4G SIM-card. The details on how to set this up are explained in the INSTALLATION - MONITORING section of this manual.

For a smooth installation, RedEarth offers installation training as well as a tech-support phone line for any assistance regarding installation. Note: The DropBear is not designed to act as a main switch board 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 installed as per AS/NZS 3000:2018. The DropBear undergoes factory testing and commissioning at RedEarth’s headquarters before shipping. All parameters are pre-set for correct operation between the SP Pro inverter, the Fronius and the battery bank. However, some parameters may need to be adjusted during installation (eg. generator size, maintenance run, etc). Please consult DropBear Commissioning section in this manual as well as the Selectronic Manual.

Overview



DropBear Weight: 205kg without any Lithium batteries (42kg per battery) Dimensions: 200.5 cm H x 131.4 cm W x 65.6 cm D

Physical Specifications

DropBear Minimum Clearance Dimensions: 210 cm H x 166.7 cm W x 117.4 cm D



Inside:

The DropBear has two main areas, one for the batteries and the other for the switches and electronic equipment. Each section has a key-lockable double door.

The top enclosure contains all of the electric-electronic equipment, switches and AC connection terminals.

The “AC Breakers” window shown below contains all the AC protective and isolation points and the changeover switch. Each device is labelled for easy identification. Labels can be seen in the picture below.

Components



Behind the control panel, the following items are found:

The bottom enclosure consists of a robust and perforated base to support full weight of the batteries and a front and rear rail to secure the batteries in place.

Because of lithium batteries properties, it is possible to install additional batteries in your system at any time, please contact RedEarth for further details.

Components



Attached to the top of this chamber there are two fully enclosed battery busbars with the correct number of battery cables.

The DropBear comes fully equipped with the following items.

• DropBear pre-wired enclosure • Selectronic inverter • Fronius Primo inverter • Parts Kit Box

o 2x Wall mount bracket o Various screws/ Dyna-bolts for fixing base and wall

brackets o PV and Battery Sticker Kit o Glands and plain to screwed adapters o MC4 connectors o Aerial for 4G

connection • DropBear Installation Manual • DropBear User Manual • SP PRO user manual • Fronius manual • Battery Specifications • Warranty Information

Components



Transporting:

The DropBear system is supplied strapped down to a pallet. It is fully ready to run. The system weighs around 205kg without batteries. The system requires lifting equipment to be removed from the pallet and placed in position.

The base of the system has spaces for either a forklift or a standard trolley jack to be used.

If the DropBear is too heavy to manage the Inverters and batteries can be removed and then replaced once the system is in position. Each battery module weighs 42kg and up to 12 can be installed in the system.

The DropBear is designed to be placed against a wall in a shaded and weather protected area with the system securely connected to the wall with the wall bracket included. Air inlet vents are on the side and base of the system. Do not block them, ensure they are kept clear at all times

Step 1: Securing in position

At installation position, mark a height of 1925mm from the floor. As shown in the picture on the left, this mark indicates the centre of the large hole. The two brackets should be spaced so that they securely fastened to the wall (eg. wall studs).

The wall bracket has two sets of different size holes “A”s and “B”s. As illustrated (right), set “A” is for screwing into a wall stud with the

screws (supplied) and set “B” is for a solid concrete/ brick wall to be secured with Dyna-bolts (supplied).

Installation

IMPORTANT: Before positioning the DropBear, be sure that there is an available area of 2100 x 1667 x 1174 (H x W x D). This will allow a minimum of 90⁰ open door angle as well as lateral ventilation.



Once wall brackets are firmly attached to the wall, move the DropBear into place with the help of a trolley jack (or forklift) lifting it high enough to clear the bracket and slide in behind it.

On the base of the DropBear, there is a hole at the front on each side. These holes are for securing the base with supplied Dyna-bolts, then plug these holes with supplied 25mm plugs to limit pest ingress.

Masking tape is strategically positioned in between the doors and the unit. These are common rubbing spots and the purpose of the tape is to avoid paint chipping during transportation. This can now be removed.

With the DropBear in place, rotate the handles on the top and bottom door counter-clockwise to open the doors. Remove the Control covers by unscrewing all identified screws in above picture. By doing this, you will have access to all AC and DC, wire connection terminals and the “Comm’s Area”.

Installation



Step 2: Electrically connect the DropBear

NOTE: Before proceeding any further, ensure that all breakers and isolators, as well as those supplying power to the unit, are turned OFF.

AC Connections

All AC cables should be brought through the 25mm or 32mm holes on the left hand side of the rear panel (behind battery breaker), secured with a gland (or plain-to-screwed adaptor if using corrugated conduit), and attached to the correct terminals of the breaker as shown below.

Grid termination (if requested)

Active must terminate into the bottom side of the grid breaker. Earth and Neutral must be terminated into an empty slot in their respective Busbar.

Load connection

Active must terminate into the bottom of the Load circuit breaker, as shown in the above picture. Earth and Neutral must be terminated into the respective busbars.

NOTE: All other devices are already connected as per SLD available in the back of this manual.

Generator termination

Active and Neutral must terminate into the bottom of the generator circuit breaker. Earth must be terminated into an empty slot in the Earth Bar.

Installation



Generator Auto-Start and Charger

The DropBear contains four terminals in the Comms area. These terminals are displayed in the picture on the next page and can be identified as:

• Gen Start: Dry-contact

The two terminals on the left must be connected to a cable to activate the generator auto-start.

• Positive Terminal (charger)

The third terminal from the left must be connected to the positive (+12V) terminal of the generator’s battery.

• Negative Terminal (charger)

The fourth terminal from the left terminal must be connected to the negative (0V) terminal of the generator’s battery.

GENERATOR REQUIREMENTS

Please ensure that your generator meets or exceeds the following specifications:

- Generator waveform THD: < 10%. - Generator Vrms range: 180 ~ 264Vac - Generator voltage crest factor (Vpeak/Vrms): < 1.6 - Generator peak voltage: <380V - Frequency range: 45Hz ~ 55Hz - Frequency slew rate: <0.3Hz/sec

NOTE: Inverter-generators are recommended for use with DropBear for their better power quality. If voltage, frequency or current waveforms of the generator are not of a high enough quality, then it will be rejected by the inverter.

For the SPMC481 (5kW), the recommended generator size by Selectronic is around 9.5kVA.

For the SPMC482 (7.5kW), the recommended generator size by Selectronic is around 14kVA.

Installation



DC Connections

Battery

The batteries are located in the lower enclosure, behind the bottom double doors.

If supplied separately, unbox the batteries, place them on the battery shelf, re-install the front battery rail and finally attach the battery cables.

PV Connections

The PV cables should be brought through the 25mm holes on the right-hand side of the unit using the supplied plain to screwed adapters.

The PV cables should then be terminated with the MC4’s connectors provided and then plugged into the pre-terminated tails. (one tail per string)

If the tails are not needed, the installer can remove the Fronius from its wall-mount and terminate the cables in the appropriate terminals. Or additional strings can be added if required.

Installation



Monitoring Connection

The Dropbear uses a SwitchDin Utility Droplet Controller to provide remote monitoring for the system. The Utility Droplet Controller is a high-end but simple device that will allow RedEarth to monitor and provide accurate information on the system operation.

See below how to correctly install the Droplet.

Ports on the Droplet that are not identified here, must not be used.

Setup

1. Connect the Selectronic inverter to one of the Droplet’s USB ports using the cable already in place inside the DropBear.

2. Plug the power supply into the power port of the droplet. 3. Place the antenna outside of the unit, run the cable through the supplied 16mm gland and

then attach to the droplet. 4. Connect the droplet to internet.

a) Wired Connection (recommended) Connect a standard Ethernet cable between the Droplet and an on-premises internet router. It should simply start working once plugged in. This is the simplest and most reliable connectivity option.

b) 4G Cellular network Connect the provided antenna to the droplet. Place antenna in a suitable position outside the DropBear enclosure.

(Note that if installing both the wired connection and 4G, the SwitchDin will automatically switch between the two if it loses signal from one source)

Installation



The DropBear is commissioned and tested in factory to guarantee correct operation. However, some last-minute parameter adjustments may be required (eg. generator size or warm-up time). Carefully follow the procedure below on how to make these alterations without compromising the existing configuration.

NOTE: This must be done by a qualified person.

NOTE: The program Selectronic SP Link can be downloaded from Selectronic’s web page (http://www.selectronic.com.au/)

Step #1:

With the system powered, connect a computer to the Selectronic SP Pro using the USB cable from the back of the SwitchDin.

Step #2:

Open the program “Selectronic SP Link”. The following page shall appear:

In the Easy Start Guide window, click on “Advanced Configuration”.

Commissioning

http://www.selectronic.com.au/



Step #3

Click on the “Connection” tab and then on “Connect”.

The program will request you to “Save Site” before proceeding. Fill in a site name and then click “Save Site”.

Commissioning



Step #4

Click on “Configuration Settings” tab and then on the “Get SP PRO’s Configuration” button to download existing settings from the SP Pro to your laptop.

Step #5

Adjust the required parameters (any altered settings will be highlighted in yellow) and then click on the “Configure SP PRO” button to send the new settings back to the SP Pro.

NOTE: In case of a factory reset on the parameters, the installer may contact RedEarth Energy Storage and by providing the DropBear’s serial number request the configuration file.

Tech Support:

• +61 (4) 8700 2451 • +61 (7) 3279 6707.

Commissioning



Once the DropBear is in place and correctly installed, you may start the system.

To power up the unit you must follow the steps below:

1. Turn on individual battery breakers.

This will charge up the capacitors inside the inverters. The LED on the inverter will flash and beep. Wait for approximately 10 seconds.

2. Turn on the Main Battery Breaker. 3. Turn on the PV isolator located under the Fronius Primo.

Before step 4, the inverters are powered up but not inverting (outputting AC power).

4. Turn ON the Selectronic by pressing and holding the “ON” button on the top left-hand-side of the inverter.

5. Turn on all AC circuit breakers.

The following shutdown procedure should be followed:

Start-up / Shutdown Procedure



RedEarth is available to assist commissioning the system during business hours.

Phone Tech support on +61 487 002 451 or +61 7 3279 6707.

RedEarth also provides training in our facility in Brisbane. Training can potentially be arranged at your facilities if requested.

Our website, www.redearth.energy includes updated documents as they become available.

Options available from RedEarth

RedEarth can provide several options for the DropBear • Additional batteries for system expansion. • Extended warranty options. • Miscellaneous spare parts (including indicator lights for Generator start) • Solar kits with combiner boxes, PV panels, racking and pre-terminated PV cables • Diesel Generator with 2-wire auto start. • Generator backup kit (for on-grid applications) • Ongoing remote monitoring – Concierge RED service.

RedEarth support options




Single Line Diagram (SLD)

DropBear Installation Manual · 2020. 12. 3. · AS/NZS 3008.1.1:2017 Electrical installations –...

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Transcript of DropBear Installation Manual · 2020. 12. 3. · AS/NZS 3008.1.1:2017 Electrical installations –...