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Rev.1 1 | P a g e
Prime1 & Prime3 Installation Manual
Rev Date Author/s Checked Date
2.2 3/9/2020 Jack Wright Smith & Richard Smaldino JA 3/9/20
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Table of Contents 1. Introduction ........................................................ 3
1.1 About the Prime ................................................ 3
1.2 Glossary: ............................................................. 3
1.3 Components list: ................................................ 4
1.3.1 EVO Power component package .......... 4
1.4 Required installation tools/material ................. 5
1.5 Prime Specifications ....................................... 6
2. Safety .................................................................. 9
2.1 Safety symbols ................................................... 9
2.2 Emergency safety protocol .............................. 9
2.3 General safety ................................................. 10
2.4 LG Chem battery safety documentation ..... 10
2.4.1 Symbols on battery labels ...................... 10
2.4.2 Safety instructions ................................... 11
2.5 SP PRO Inverter safety documentation ......... 12
2.5.1 Who should install this unit ...................... 12
2.5.2 Protective Earth connection ................. 12
2.5.3 Multiple Hazardous Energy Sources ...... 13
2.5.4 Installation ............................................... 13
2.5.5 Maintenance .......................................... 13
2.5.6 Inverter may start automatically ........... 13
2.5.7 Backup Generator may start automatically......................................................... 13
2.5.8 Battery ...................................................... 13
3. Prime Installation at user’s site ........................ 14
3.1 Prime installation general information ........... 14
3.1.1 Concrete slab requirements .................. 14
3.2 Prime installation near a wall ......................... 14
3.3 Installation Isobox ............................................ 16
3.4 Prime preparation ........................................... 17
3.5 Mounting the inverters inside the Prime ........ 18
3.6 Placing the batteries inside the Prime ........... 22
3.6.1 Earthing bar for batteries ....................... 25
3.7 Wiring for Grid, IsoBox and Prime ................... 27
3.7.1 Prime wiring ............................................. 27
3.7.2 Battery wiring ........................................... 27
3.7.3 Note: Passthrough from AC Source to AC Loads via SP PRO ................................................... 29
3.7.4 Inverter wiring .......................................... 30
3.7.5 IsoBox wiring ............................................ 34
4. First start-up of the Prime ................................. 36
4.1 Pre start-up safety check ................................ 36
4.2 Prime Start-up ................................................... 36
4.2.1 Batteries ................................................... 36
4.2.2 Inverter(s) ................................................. 37
4.3 IsoBox Start-up .................................................. 37
4.3.1 Internet / Communications to IsoBox ... 37
4.3.2 select.live ................................................. 37
4.3.3 SwitchDin SGD ......................................... 38
4.4 Main Switchboard ........................................... 38
4.4.1 AC Source ............................................... 38
4.5 System Check .................................................. 38
4.5.1 Check Back-up function ........................ 39
5. Final assembly .................................................. 39
5.1 Inverter access cover ...................................... 39
5.2 Prime front door ............................................... 39
5.3 Labels ................................................................ 40
6. Troubleshooting (see website) ....................... 41
7. APPENDICES: .................................................... 42
7.1 APPENDIX A : PRIME1 SCHEMATIC (ON GRID) 42
7.2 APPENDIX B : PRIME3 SCHEMATIC (ON GRID) .. 43
7.3 APPENDIX C: LG Chem battery details ......... 44
7.4 Appendix D: SP PRO communications card . 45
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1. Introduction 1.1 About the Prime
The Prime Series from EVO Power is a compact AC coupled battery system engineered for the residential and commercial power markets providing high flexibility for solar self-consumption, load shifting and complete off grid power applications.
The Prime series incorporates proven and trusted hardware with inverters from Selectronic and options from 24kWh to 60kWh of Lithium Ion Batteries from the world’s leading ESS battery manufacturer, LG Chem.
The purpose of this installation manual is to guide and advise an installer on how to install an EVO Power Prime system safely and securely.
The installer of the Prime must be a suitably qualified electrician.
As the Prime is a preassembled Battery Energy Storage System, the installer must complete all the listed installation procedures to complete a Prime installation.
This installation manual’s instructions will assist the installer with choosing where the Prime will be installed at the customer’s location, how they will place and connect the inverter’s and batteries within the Prime, and how they will connect the customers Loads and Grid to the IsoBox.
The battery capacity of the Prime1 is between 4-10 battery modules, while the Prime3 requires between 8-10 battery modules. The amount of battery modules can be increased or decreased within these specific module ranges, and these changes must be completed by an installer.
The Prime1 relates to Single Phase systems and the Prime3 uses 3 Phase equipment. The inverter capacity for all Prime models is fixed, but the inverter itself can be swapped out for a different power capacity.
1.2 Glossary:
Throughout this manual, the following abbreviations will be used:
AC – Alternating Current DC – Direct Current BMS – Battery Management System EMS – Energy Management System CAN – Controller Area Network PPE – Personal Protective Equipment SGD – Secure Gateway Device
Prime Features & Benefits
Australian made & supported solution
Premium quality inverter & battery technology
Intelligent remote monitoring and control software
Flexible storage from 24 to 60kWh
Flexible inverter options in single and 3 phase
IP45 rated compact indoor/outdoor enclosure
Prewired enclosure with all isolation devices
Applications
Off Grid Power Systems
Retrofit to existing Solar Systems
Residential Solar Self Consumption
Agricultural Power Solution
Commercial & Industrial ESS
Utility & Network Grid Service
ESS Peak shaving
Virtual Power Plant
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1.3 Components list:
Ensure that all components listed below are delivered to complete the Prime installation. Inspect each component for potential damage during delivery, and if damage is present please report this to your supplier.
Any equipment that is mechanically damaged or damaged in any other way shall not be installed.
Component list:
Item Picture Item Picture Prime cabinet with IsoBox attached x1
LG Chem EM048126P3S7 x4-10 for Prime1 OR x8-10 for Prime3
Selectronic SP PRO Series II x1 for Prime1 OR x3 for Prime3
EVO Power component package x1
1.3.1 EVO Power component package Upon delivery, the Prime cabinet will contain a bubble-wrapped package containing a few necessary components for the Prime installation. These package components include:
Male Cable Mount IP67 RJ45 Plug X2)
SP PRO Tool kit
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SP PRO Expansion Card (1 per inverter) + Screws
Know Your SP PRO display quick reference card
4 Pin Microphone Line Female Connector X1
Dynabolts M8x75 x 3
4G Antenna
Dynabolts M8x100 x 4
Isobox Mount Bracket
42.5mm Conduit 2x 2mtr lengths
1.4 Required installation tools/material
The following tools will be used to complete the Prime installation:
Item Description Picture Personal Protective Equipment
Gloves, safety glasses, protective footwear
Hand drive torque wrench For power cabling into inverter
SP PRO drivers (included with EVO Power component package)
For power cabling into inverter
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Impact or Clutch Drill For screwing in the earthing bar, Bottom Air Grill’s and front door
4mm Allen key driver for front door, Bottom Air Grills and earthing bar
Flathead & Phillips driver/screwdriver
For power cabling into Inverter, IsoBox & Main Switchboard
Lifting apparatus e.g. forklift, hydraulic lift, trolley jacks, etc
For lifting Prime enclosure, inverter(s) & batteries.
Cable for Generator For plugging Generator into IsoBox via glands.
To be provided by the Installer if Generator to be added
Power Cable according to AS3000/AS3008 requirements
For cable runs between main switchboard and IsoBox.
To be provided by the Installer
NOTE: EVO Power recommends the use of lifting apparatus for Moving the Prime, inverters and batteries
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1.5 Prime Specifications
1. Useable energy & Nominal Energy is based on beginning of battery life at 25°C and at peak efficiency charge/discharge rate 2. Please refer to the detailed warranty documentation at the EVO Power website www.evopower.com.au
All specifications are at 25°C and rated DC input voltage unless otherwise stated, values may be different at higher or lower temperatures. Specifications may be updated without notice so please refer to the EVO Power website for the current information
Prime 1
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Prime 3
1. Useable energy & Nominal Energy is based on beginning of battery life at 25°C and at peak efficiency charge/discharge rate 2. Please refer to the detailed warranty documentation at the EVO Power website www.evopower.com.au
All specifications are at 25°C and rated DC input voltage unless otherwise stated, values may be different at higher or lower temperatures. Specifications may be updated without notice so please refer to the EVO Power website for the current information
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2. Safety 2.1 Safety symbols
Throughout the EVO Power Prime Installer Manual and EVO Power Prime Labelling, some instructions will have an icon next to them.
These icons represent the following important hazards or notifications:
Icon Definition DANGER!
An extremely dangerous power hazard exists during this instruction. Take extreme caution during this process. Failure to do so may cause serious injury or death.
CAUTION! This instruction is vital to complete the inverter installation safely. Failure to do so may cause an issue.
MULTIMETER: Use a multimeter to analyse the power cables in this section.
TORQUE: Ensure that all screws are thoroughly torqued to the required level in this instruction.
INSPECT: Physically inspect what the manual is asking you to look out for.
MANUAL: Refer to the manual for all hazards before powering on the Prime
WAIT: Wait a specified amount of time for the capacitors inside the Inverters to fully discharge
WARNING: Refer to the manual for this electrical hazard. Failure to do so could result in serious injury or death.
2.2 Emergency safety protocol
2.2.1.1 For all emergencies: o Turn OFF AC Load Breaker if safe to do so
o Turn OFF AC GRID(Source) Breaker if safe to do so
o Turn OFF DC Isolator/s on side of Prime enclosure if safe to do so
o Evacuate the area
o Call relevant emergency services in your area
2.2.1.2 For Flooding: o If system is submerged in water, stay out of
water that is connected to submerged system
o Do not attempt to operate the system after being submerged in water, even if the system is dry.
o If system has been submerged, product must not be used. Dispose of product accordingly.
2.2.1.3 For fires: o If safe to do so, use ABC or carbon dioxide
extinguisher to extinguish flames
o Evacuate area
o Call fire brigade
2.2.1.4 Other emergencies not covered: o Contact EVO Power
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2.3 General safety
CAUTION! All installers and servicers of the EVO Power Prime system must read and have an extensive understanding of all the installation and safety procedures listed in this manual.
Only those deemed qualified by EVO Power should provide repair services for the EVO Power Prime system.
If there are any issues or queries during the installation process, please refer to the troubleshooting section of the manual in section 6. If the troubleshooting guide does not help with your problem, please contact EVO Power.
CAUTION! Installers and Users may maintain the Prime. Refer to the maintenance manual regarding the safety precautions during maintenance.
DANGER! The Prime weighs around 150kg without any batteries or inverters inside, and the Prime will weigh up to 800kg after being successfully installed. The Prime is required to be moved with mechanical lifting equipment. CAUTION! The SP PRO Inverters weigh up to 55kg each, and each LG Chem battery weighs up to 45kg. Ensure that the inverters and batteries are lifted, mounted and removed with care. It is required to use the mechanical lift to mount the inverters, and it is recommended to use a mechanical lift to mount the batteries within the Prime system. Follow your local regulations regarding safe lifting practices.
2.4 LG Chem battery safety documentation
The Prime uses the LG Chem EM048126P3S7 series battery module. The LG Chem safety documentation is listed below in this section. To access the full instructions for this module, please refer to the LG Chem P3S series 48V Standalone Battery Module Installation Manual.
2.4.1 Symbols on battery labels The nameplate and the warning label are attached to the top of the battery module
The symbols on the battery warning label are described as follows:
Symbol Meaning
The voltage of this battery module is strong enough to cause electric shock.
Keep the battery module away from open flame or ignition sources.
Wear appropriate personal protective equipment when dealing with the battery module.
Keep the battery module away from children.
The battery module should not be disposed of with household waste at the end of its working life.
Read the manual before installing and operating the battery module.
The battery module may leak corrosive electrolyte.
The battery module may explode.
The battery module is heavy enough to cause severe injury.
The battery module should be disposed of at a proper facility for environmentally safe recycling.
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2.4.2 Safety instructions For safety reasons, installers are responsible for familiarizing themselves with the contents of this manual and all warnings before performing installation.
2.4.2.1 General safety precautions
DANGER!
Failure to observe the precautions described in this section can cause serious injury to persons or damage to property.
Risks of explosion
o Do not subject the battery module to strong impacts.
o Do not crush or puncture the battery module.
o Do not dispose of the battery module in a fire.
Risks of fire
o Do not expose the battery module to temperatures in excess of 60°C.
o Do not place the battery module near a heat source, such as a fireplace.
o Do not expose the battery module to direct sunlight.
o Do not allow the battery connectors to touch conductive objects such as wires.
Risks of electric shock
o Do not disassemble the battery module.
o Do not touch the battery module with wet hands.
o Do not expose the battery module to moisture or liquids.
o Keep the battery module away from children and animals.
Risks of damage to the battery module
o Do not allow the battery module to get in contact with liquids.
o Do not subject the battery module to high pressures.
o Do not place any objects on top of the battery module.
2.4.2.2 Battery handling guide o Use the battery module only as directed.
o Do not use the battery module if it is defective, appears cracked, broken or otherwise damaged, or fails to operate.
o Do not attempt to open, disassemble, repair, tamper with, or modify the battery module. The battery module is not user serviceable.
o To protect the battery module and its components from damage when transporting, handle with care.
o Do not impact, pull, drag or step on the battery module. Do not subject it to any strong force.
o Do not insert foreign objects into any part of the battery module.
o Do not use cleaning solvents to clean the battery module.
2.4.2.3 Response to emergency situations
While the battery module comprises multiple battery cells that are designed to prevent hazards resulting from failures, this cannot guarantee their absolute safety.
2.4.2.3.1 Leaking batteries If the battery module leaks electrolyte, avoid contact with the leaking liquid or gas. Electrolyte is corrosive and contact may cause skin irritation and chemical burns. If one is exposed to the leaked substance, do these actions:
Inhalation: Evacuate the contaminated area and seek medical attention immediately.
Eye contact: Rinse eyes with flowing water for 15 minutes and seek medical attention immediately.
Skin contact: Wash the affected area thoroughly with soap and water and seek medical attention immediately.
Ingestion: Induce vomiting and seek medical attention immediately.
2.4.2.3.2 Fire In case of a fire, make sure that an ABC or carbon dioxide extinguisher is nearby.
DANGER! The battery module may catch fire when heated above 150°C.
If a fire breaks out where the battery module is installed, do these actions:
1. Extinguish the fire before the battery module catches fire.
2. If the battery module has caught fire, do not try to extinguish the fire. Evacuate people immediately.
DANGER! If the battery catches fire, it will produce noxious and poisonous gases. Do not approach.
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2.4.2.3.3 Wet batteries If the battery module is wet or submerged in water, do not try to access it. Contact EVO Power for technical assistance.
2.4.2.3.4 Damaged batteries Damaged batteries are dangerous and must be handled with extreme caution. They are not fit for use and may pose a danger to people or property. If the battery module seems to be damaged, pack it in its original container, and then return it to EVO Power or your distributor.
CAUTION! Damaged batteries may leak electrolyte or produce flammable gas. If you suspect such damage, immediately contact EVO Power for advice and information.
2.4.2.3.5 Qualified installers This manual and the tasks and procedures described herein are intended for use by skilled workers only. A skilled worker is defined as a trained and qualified electrician or installer who has all of the following skills and experience:
o Knowledge of the functional principles and operation of on-grid systems.
o Knowledge of the dangers and risks associated with installing and using electrical devices and acceptable mitigation methods.
o Knowledge of the installation of electrical devices
o Knowledge of and adherence to this manual and all safety precautions and best practices.
2.4.2.4 Safety gear Installers must meet the relevant requirements of international standards, such as IEC 60364 or domestic legislation.
2.5 SP PRO Inverter safety documentation
The Prime uses the SP PRO inverter. The SP PRO safety documentation is listed below in this section. To access the full instructions for this inverter, please refer to the Selectronic Instruction Manual for SP PRO Series 2i Interactive Inverter Charger.
DANGER! If this equipment is used in a manner not specified by the manufacturer as contained in this manual and other operational documents and Instructions, then the protection provided by the equipment may be impaired.
2.5.1 Who should install this unit While the SP PRO is designed for easy installation and can be installed by any suitably qualified person, to maximize the performance of the system and tailor the configuration of the SP PRO to the specific needs we recommend the use of a Selectronic Accredited Integrator. These selected professionals within the industry have been extensively trained to analyse the system requirements, design ancillary equipment, and have access to specialist support within Selectronic to assist with any individual requirements.
The voltages produced within a power system are hazardous. Even though the SP PRO may derive its input from a battery, the extremely high current capability of a battery bank is hazardous. Additionally, the output and input AC voltage in all the SP PRO models is just a hazardous as grid electricity.
All AC connections and hazardous DC connections to the SP PRO must be carried out by a qualified Electrical contractor or similar, failure to do so will contravene legal requirements.
All DC wiring must be carried out by a person experienced with DC electrical circuits and must understand high current low voltage circuits. To ensure an efficient system installation, cable sizing and voltage drop must be understood and the recommendations within this manual followed.
EVO Power shall have no obligation as to any equipment which has been improperly installed, stored, or handled, or which has not been operated or maintained according to this manual, nor for any operating mistakes and consequences arising from them.
DANGER! This product is not to be used for Life Support equipment
2.5.2 Protective Earth connection
DANGER! It is critical that all protective earth connections made within the SP PRO us the protective earth terminal. This is the earth terminal that is on the right-hand side of the AC terminals and marked with an earth symbol enclosed in a circle.
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2.5.3 Multiple Hazardous Energy Sources
DANGER! WAIT & WARNING: Hazardous voltages and energy are generated by the SP PRO. They are fed into the SP PRO by external wiring from multiple sources and may be stored in capacitors after the SP PRO is switched off and disconnected from external wiring. If the SP PRO has been powered on, after powering off the SP PRO wait 5 minutes before contacting any of the SP PRO power cabling. Failure to wait 5 minutes could result in an electric shock or electrocution.
2.5.4 Installation DANGER!
o The SP PRO requires adequate ventilation, away from hot equipment. Do not obstruct the airflow passage of the SP PRO case (top and bottom). Ensure when installed in an enclosed space that there is adequate ventilation.
o The SP PRO must be located in a place away from electrolyte and corrosive aerosols.
o The SP PRO contains arcing contacts so must not be located near explosive gas mixtures such as hydrogen from batteries or diesel fumes.
2.5.5 Maintenance DANGER! Ensure that all energy sources are isolated before working on connected wiring. A backup generator may start, or power may be restored by the SP PRO
at any time. Never work on equipment or investigate a problem without following appropriate safety isolation procedures.
2.5.6 Inverter may start automatically DANGER! The SP PRO automatically starts and/or restarts and may restore power at any time. If a fault or overload is detected the SP PRO will shut down and may automatically attempt to restart at varying intervals of up to several hours.
2.5.7 Backup Generator may start automatically DANGER! The SP PRO can automatically start and stop a backup generator. If a fault or overload caused
the SP PRO to shutdown then it will automatically attempt to start and restart the backup generator.
2.5.8 Battery
DANGER! Batteries are extremely dangerous. Please read the safety information provided by the battery supplier.
o Batteries are capable of sourcing extremely high output currents. Short circuit or high overload currents can be extremely hazardous and cause high current arcs, burns and explosions.
o Disconnecting a DC power connection (even on one battery cell) can cause dangerous high-energy DC arcs, which can cause serious burns and eject hot particles, and can be difficult to extinguish.
o Disconnecting a DC power connection (even on one battery cell) can cause renewable sources to produce large voltages (much larger than the battery voltage) on battery terminals and DC wiring. Such voltages can be lethal. They can also damage the SP PRO. Only suitably trained and qualified personnel should disconnect any DC power connection, including battery cell connections, and only with suitable procedures and safety precautions.
o System battery voltages of 60 V or greater are to be treated as a hazardous voltage.
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3. Prime Installation at user’s site 3.1 Prime installation general information
CAUTION! To ensure the longevity of the entire system, EVO Power require the Prime to be installed under the following requirements:
o Not near marine environments that may expose the unit to salt mist
o Not at an altitude higher than 2000m above sea level
o Not in direct sunlight
o Ambient operating temperature is between -3°C to 45°C
o Not hard up against a wall
o Not on an angle of more than 2 degrees forwards/backwards & sideways.
o Must be mounted and bolted down to a concrete slab or a solid surface
o Surface must be capable of supporting up to 800kg of weight
o Power loads on site do not exceed Prime’s maximum power rating
o Within range of the user’s router via ethernet cable (If 4G SIM is not utilised)
o Not located near combustible materials
o Indoors or outdoors
These installation requirements must be fulfilled to maintain the Prime’s warranty, as well as keep the Prime within its ingress rating of IP45.
Tip: The ideal installation location of the Prime is in a shaded area with natural air flow.
Suitable locations for the installation location of the Prime
o Garages
o Storage rooms
o A Verandah
o A South Facing outdoor wall under an eave
o A dedicated battery system room
o Not hard up against a wall
A Prime installed in a corridor, hallway or lobby must have sufficient clearance of no less than 1 metre.
3.1.1 Concrete slab requirements CAUTION!
The concrete slab that the Prime is installed on must be able to support up to 800kg, as the Prime with all batteries and inverters installed can weigh up to 800kg.
The installer must use his own discretion to decide if the surface that the Prime is mounted on is suitable for the Prime’s maximum weight of 800kg.
3.2 Prime installation near a wall
CAUTION! To allow adequate air flow, as well as easy access to critical breakers for the Prime and IsoBox, the Prime and IsoBox must be installed within the following measurements:
When placing the Prime near a wall, be careful of the Prime’s weight of 800kg, as knocking the Prime over can cause serious damage to the Prime as well as the Prime’s surroundings. Ensure that the Prime is always upright during the entire installation process.
o Between Prime and wall:
minimum of 50mm, maximum of 500mm. If the gap needs to be greater than 500mm, please contact EVO Power.
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o Between Prime and IsoBox:
minimum of 400mm, maximum of 600mm
o General clearances from Prime & IsoBox to other sources: According to AS 5139 and BESS Best Practices Guide.
o The Prime is considered a source of ignition and must not be installed within a hazardous area as defined by AS/NZS 3000:2018 Section 7, as well as within hazardous areas for has cylinders containing heavier-than-air gases and gas relief vent terminals as defined in AS/NZS 3000:2018 Section 4.
o Once the Prime unit has been put in place it can be secured by the Bottom Floor Brackets into the concrete floor using M8x100 Dynabolts as shown
(Typical both sides of Prime unit);
For areas that are more prone to earthquake or if a danger of impact from other equipment is possible, then a second mount bracket (supplied as a loose component) can be installed as shown (Typical both sides of Prime unit);
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3.3 Installation Isobox
Install Isobox top bracket level as per dimensions shown below (NB The distance from the prime unit is based on a 400mm minimum gap);
Fix in place using M8x75 Dynabolts supplied (Or installer supplied wood screws as required).
Adjust the M8x20 Hex Bolts on the Isobox allowing a 4-5.5mm gap between Isobox and bottom of Hex Head.
Hang the Isobox onto the top bracket and ensure hex bolts installed in previous steps are aligned and fully seated into bracket slots.
Mark hole for bottom bracket as shown below;
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With Isobox removed (or in place if drill bit is long enough), drill and fit M8x75 Dynabolt where hole was previously marked;
Place Isobox on top bracket and using a 13mm spanner, tighten the hex bolts to the top bracket (Wall and other items removed for clarity in picture below);
3.4 Prime preparation
When delivered, the Prime will have the front door on.
Remove this using a 4mm Allen Key driver.
Keep the M6 screws and washers to re-attach the door at the end of the Prime installation process.
Note: EVO Power recommend taking the bottom M6 screws off first and working your way up with the other M6 screws.
Please see suggested removal sequence in picture.
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3.5 Mounting the inverters inside the Prime
CAUTION! EVO Power requires the use of lifting apparatus for mounting the inverters inside the Prime. The inverter bracket(s) are already attached to the Prime, and the power and communication cables are protruding through the bracket hole at the bottom. See below as an example:
Prime3 example: Prime1 example:
CAUTION! EVO Power has already preconfigured the SP PRO Inverters to the customers specifications. For a Prime3, to maintain the inverter’s allocation and configuration, the installer MUST mount the inverters from left to right in the order of 1-2-3. The final Prime3 with labels will look as follows:
Tip: Before mounting the inverters remember to remove the inverters access cover whilst in the box.
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INSPECT: Inspect that all 3 inverters are labelled with their own individual 1, 2 or 3 label. If the labels are missing, damaged or illegible, please contact EVO Power.
The inverters must be mounted in this order as they are configured by their own individual serial numbers. Because of this, the inverters cannot be swapped around. Changing the order of the 3 inverters from 1-2-3 would cause the inverters to fail during the setup process detailed later in this manual.
CAUTION! For the Prime3: When mounting the inverters inside the Prime, EVO Power requires that the inverters be mounted inside in this order:
1. Left inverter labelled (1)
2. Right inverter labelled (3)
3. Middle inverter labelled (2)
It is necessary to mount the middle inverter last, as mounting the left and right inverter inside the Prime after the middle inverter is in place is extremely difficult. The example for these steps is shown below:
Step 1. Step 2. Step 3.
CAUTION! When mounting the inverter, make sure not to bend or fray any of the cables protruding from the Prime & Inverter frame, as damaging them may prevent the inverter & Prime from being fully operational. If any serious damage occurs to these cables, please contact EVO Power.
Item Description Picture
1. Remove the access cover of the SP PRO before mounting the inverter so that the cables can be visibly seen going through the inverter’s centre-hole after being mounted. The access cover is shown labelled “A” to the right. To take the access cover off, use the T25 torx driver to unscrew the two M5 Torx screws at the bottom of the SP PRO.
A
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2. After the access cover has been removed, complete the following steps to safely mount the inverter on the Prime. Gently place the inverter upright on the lifting apparatus
3. Line up the lifting apparatus and inverter with the mounting bracket inside the Prime
4. Place inverter in enclosure aligning the inverter bracket so that it fits inside the rear flanges of the inverter.
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5. Lift the inverter slightly higher, and lower onto frame mounting bracket hooks
6. Lower lifting apparatus until the inverter is
flat against the Prime
7. Screw rear gland plate into mounting
frame using T20 screw supplied loose in position shown in red.
It is important to ensure this screw is installed.
Note: Repeat this process of steps 1-7 for all 3 inverters when installing the Prime3.
CAUTION! Do not connect any of the wiring to the inverter, this will be completed in a later step.
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3.6 Placing the batteries inside the Prime
NOTE: EVO Power recommends the use of lifting apparatus and Transport Dollys for transporting the batteries to the Prime.
After the inverter mounting is complete, place the batteries inside the bottom of the Prime cabinet.
Take care in lifting the batteries, as the batteries weigh up to 45kg each.
CAUTION! Avoid carrying the battery exclusively with the centre handle, as this can damage the battery’s internal components. If necessary, always use two hold points to carry batteries.
CAUTION! Ensure that all batteries have their lights off before placing them inside the Prime, and that all the DC battery breakers are switched off inside the Prime cabinet.
CAUTION! If a battery is accidentally turned on while placing the battery inside the prime, force shutdown of the battery by holding down the on/off button for 10 seconds until all the battery’s lights turn off. The on/off button is seen below in red:
For more information on the battery, please see Appendix C.
Place the batteries inside the Prime cabinet from Left to Right, with the left most battery against the left wall of the cabinet. See below where the first battery should be placed:
Note: The order of battery placement is determined in following instructions.
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When placing each individual battery module, follow the following steps:
Step Description Picture
1. Remove Battery Support/Earth Bar from assembly. Note that top Left Hand Screw is an Earth point and the serrated washer supplied in this location must be reinstalled here at later stage.
2. Place the battery next to the prime
3. Lift the battery onto the Prime flooring so that it is half sitting inside the Prime, as far left inside the Prime cabinet as possible.
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4. Slide battery towards rear until you are able to connect the red and black plugs at the back into the battery’s red and black ports. These are labelled 5 & 7 in appendix C.
5. Push the battery to the back of the Prime, lining it between the two hard-stops at rear. (N.B Parts in picture removed for clarity)
6. Repeat steps 1-4 for all battery modules, each time placing the battery as far left as possible inside the Prime cabinet. (N.B There should be 25mm spacing between batteries.)
Note: Ensure that the batteries are evenly spaced apart. Evenly spacing out the battery modules allows for consistent air flow and cooling across all batteries, which will increase the overall lifetime of the batteries.
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3.6.1 Earthing bar for batteries Place the Prime Earthing bar under the batteries and between both sides of the Prime cabinet side walls. The earthing bar has been provided by EVO Power in the EVO Power component package. See below as an example:
Step Description Picture
1. The Earth /Support bar is aligned in the orientation shown;
2. Once the earthing bar is in place, screw the bar into the Prime frame with 4 of the provided M6 bolts and 4 serrated washers. Note that top left-hand earth bar screw came with a serrated washer. This must be installed with this washer to maintain Earthing of this bar.
3. Note: While attaching the batteries to the earthing bar, ensure that the batteries are still evenly spaced apart. Aligning the battery centre with the corresponding Earth hole in the earthing bar will ensure that the batteries are evenly spaced apart. To connect the batteries to the earthing bar, complete the following steps: Line up the centre of the battery with the hole in the earthing bar.
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4. Screw in the battery with an M6 bolt and serrated washer into the earthing bar so that the battery is securely in place.
5. The completed battery earthing to the earthing bar will look like:
All Prime components are now in place.
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3.7 Wiring for Grid, IsoBox and Prime
This section includes the power and communications wiring for the overall system.
3.7.1 Prime wiring The power & communications wiring must be completed for the inverters and the batteries inside the Prime. All other wiring is prewired upon delivery.
Refer to the schematics for the Prime1 and Prime3 found in Appendix A & Appendix B for help with the wiring of the system.
3.7.2 Battery wiring The DC power cables have already been connected from the battery to the inverter during step 3.6.
The battery connection points are labelled in the diagram below:
The battery to inverter communications cable and battery wakeup cable need to be connected to the master battery. These are taped to the inside left wall of the Prime, just above the batteries.
Un-tape these cables and plug them into the left most battery by completing the following.
Step Description Picture
1. Plug the “CAN” labelled cable into the RJ50 port as shown.
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2. Plug the “Wakeup” labelled cable into the RJ50 port for intra-rack communication cable on the left side of the battery.
3. For all other batteries, daisy chain them together with the yellow & black short ethernet cables. To daisy chain, connect these cables to the batteries RJ50 port for intra rack communication cable. This is shown in red in the diagram:
4. An example of some batteries daisy-chained together is shown:
5. Note: The furthest right battery will only have 1 daisy-chain black and yellow cable connected to it. There is no need to terminate the last connection.
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The completed daisy-chaining for all modules should look similar to this:
INSPECT: Ensure that these cables are plugged in and clicked into place securely to avoid communication issues between the batteries and the inverter.
3.7.3 Note: Passthrough from AC Source to AC Loads via SP PRO
Note: After the completion of all Prime installation wiring, the SP PRO allows for AC Bypass from the AC source to AC loads via the SP PRO, even when the SP PRO is not powered on by the batteries. This passthrough will display on the SP PRO’s LED display, for example:
For Grid connected AC bypass from AC Grid to AC Loads via SP PRO:
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For Generator connected AC bypass from AC Generator Source to AC Loads via SP PRO:
For off grid: when the SP PRO isolators are turned off, no power will be supplied to the loads from the batteries, unless a generator is available.
3.7.4 Inverter wiring All inverter power and communications cables pass through the inverter gland plate holes.
3.7.4.1 Inverter power wiring Connect the power cables into the inverter before the communication cables. The AC power cables are from the bottom left punch holes, and the DC power cables are from the bottom right punch holes.
The inverter’s power connection terminals are labelled as follows:
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INSPECT: Match all AC and DC labelled cables to the corresponding inverter terminal. E.g. connect the “B-“ labelled wire to the “B-“ inverter terminal:
Note: For the Prime3: the power cabling is the same for all 3 inverters.
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The final connected AC earthing, Neutral, Grid, Loads and DC positive and Negative wiring should look like this:
TORQUE: Ensure all power cables are thoroughly torqued by hand in this section. (1.5-2Nm for AC and around 10Nm for DC). Failure to properly torque these cables will result in power losses and improper contact.
DANGER! Ensure that all power cables correctly match with the labelled inverter terminals. Failure to do so can cause severe damage to the inverter, battery & IsoBox. Incorrect wiring may also cause the installer and/or customer to be electrocuted, causing serious injury or death.
3.7.4.2 Inverter communications wiring After all the power cables are secured, connect the communication cables from the top left punch hole into their labelled ports on the communications card as shown:
INSPECT: The communications cables are labelled, plug these cables into the same labelled ports on the communications card.
Cable Cable Colour Jacket Colour Select.Live Green Green RJ45 SCERT INV Blue Blue RJ45 BATT CAN Grey Blue RJ45 Gateway USB Grey Grey USB B 3Φ INV SYNC 1&2 Red Clear RJ45 3Φ INV SYNC 2&3 Black Clear RJ45
Single Phase system:
Three Phase – Inverter 1 (L1)
Select Live
SCERT INV
BATT CAN
Gatew
ay USB
Select Live
SCERT INV
BATT CAN
INV SYNC1
INV SYNC2
Terminal Resistor Pre-Installed by EVO Power
Gatew
ay USB
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Three Phase – Inverter 2 (L2)
Three Phase – Inverter 3 (L3)
Note: For a complete description of the SP PRO comms card ports, refer to Appendix D.
3.7.4.3 Inverter Generator wiring If the user does not have a generator, skip to section 3.7.6
If the user has a generator, the generator’s controller wiring must be connected to the inverter. This will be done via the SP PRO expansion card. The expansion card has been provided by EVO Power in the EVO Power component package.
To connect the expansion card to the inverter, push the card up into the front of the inverter, in front of the power cabling at the connector interface. Use the T20 torx driver to screw in the two bottom screws of the expansion card into the inverter, as shown;
After connecting the expansion card to the inverter, leave the generator communication wiring hanging out the front of the inverter. The control cabling labelled “Genset Start” from the generator to the inverter will be completed in a later step.
INV SYNC1
INV SYNC2
Terminal Resistor Pre-Installed by EVO Power
INV SYNC1
INV SYNC2
Connector
Two T20 Torx screws
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3.7.5 IsoBox wiring
The installer must wire the IsoBox to the Grid, Generator or AC Source and the Loads.
The installer must also connect the following through the IsoBox glands if the customer requires them:
o Generator controller
o Selectronic Certified grid-tie inverter communications (e.g. Fronius)
o Internet for SGD (this is REQUIRED)
Note: The IsoBox is already pre-wired and connected to the Prime.
Note: The temperature controller in the Isobox is used to control the two fans in the Prime enclosure. The temperature settings are pre-set be EVO Power according to the conditions at the install location.
Note: The red Battery Wake-up button in the Isobox is used to turn the batteries back on in the case were they have shut-down to protect themselves or to initially start the system.
DANGER! Before completing any IsoBox cabling, ensure that all breakers are turned off at the Prime, IsoBox and Main Switchboard.
Refer to the schematics in Appendix A for Prime1 or Appendix B for Prime3 if there is any confusion regarding the IsoBox wiring.
3.7.5.1 Accessing the IsoBox internals Open the IsoBox front cover with the provided key to access the power wiring inside, as well as the select.live & SwitchDin SGD. To remove the internal covers off, unsrew the bolts on either side of the cover plate as shown;
3.7.5.2 IsoBox power wiring from Main Switchboard The IsoBox has 2 large glands at the bottom for the installer to pass the user’s AC supply and AC load cables through. (Designed to take upto 4 cables @ 25mm2 each)
Note: It is recommended to use the Left breaker & IsoBox gland for AC Source (Grid, Genset etc), and the
right breaker & Isobox gland for AC loads.
Note: Please note use of a separate Nuetral breaker for Grid and Load connection, this requirment is in-line with Best practices guide from CEC and need only be used for maintainance purposes only
The AC Source breaker can be used for the following:
o AC Grid supply from Main Switchboard
o AC Generator supply from Off-Grid Generator
o AC Source supply from AC Grid & Backup Generator relay
Note: The AC Source – AC Grid & Backup Generator relay will be preconfigured by the installer. The EVO Power Prime installation manual does not cover how to set up an AC Grid & Backup Generator relay.
1. Connect to the Source, Loads and Earth cables to the earth bar in the Isobox
Undo screws to remove cover plate
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2. Connect the AC Source and Earth wiring through the left gland and into the left breaker, connecting the L1, L2, L3 & Neutral wires (Live & Nuetral for single phase).
3. Connect the AC Loads wiring through the right gland and into the right breaker, connecting the L1, L2, L3 & Neutral wires (Live & Nuetral for single phase).
Refer to the Prime1 and Prime3 schematics in Appendix A and Appendix B for their respective single line diagrams.
3.7.5.3 IsoBox external connections The IsoBox has 4 communication connectors on the gland plate as shown;
The four ports are connected (If necessary) as follows;
1. 4G Antenna connection: Only used if you have purchased an Optional 4G data plan for the customer. An antenna is supplied as part of loose items and can be screwed on if required.
2. SCERT Inverter RJ45 female: Only used if a SCERT Inverter is connected to system. Please use corresponding Male connector which is supplied as a loose item. If required, you will need to make a patch cable between SCERT inverter and Isobox.
Refer to Selectronic Tech notes on installing respective SCERT Inverters.
3. Internet Connection: Must be used in most cases if customer has a router. Wifi connections are not reccomended. Please use corresponding Male connector which is supplied as a loose item. You will need to make a patch cable between Customer Router and Isobox.
4. Autostart Generator output connector: Only used where a Generator is required. Please refer to next section for Genset control
3.7.5.4 Generator controller wiring To connect the generator controller wiring to the IsoBox, connect the user’s generator wires to the generator control socket. This socket then connects to the generator control wires within the inverter.
The Pinouts for the connector control wire are as follows;
Pin Colour 1 Brown 2 White 3 Green 4 Not Used
For help wiring the user’s generator controller pins to the expansion card, refer to Selectronic’s document TN0025_07: “SP PRO Generator Controller Wiring Guide”.
3.7.5.5 Internet access for the IsoBox The user must provide ongoing internet access to the IsoBox. This can be done via:
o An ethernet cable into the IsoBox external internet port (As described in previous section)
o A 4G SIM into the SGD
The user must choose 1 of the 2 options.
If the customer has chosen to use a 4G SIM to provide internet access to the IsoBox, then the 4G SIM is already inside the SGD and ready to be provided data.
The customer has been provided the 4G SIM details, and must purchase a data plan to provide the 4G SIM (and IsoBox) internet access.
An ethernet cable can be connected to the IsoBox at any time, which can provide internet access to the IsoBox with the 4G SIM at the same time.
3
1 4
2
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4. First start-up of the Prime 4.1 Pre start-up safety check
DANGER! Before turning any of the batteries on, ensure that all breakers and isolators for the system are all turned off.
This includes the breakers in the:
Main Switchboard o AC Grid
o AC Loads
o Any PV AC or DC isolators/breakers
IsoBox o AC Grid
o AC Loads
o Fans x 2
Prime o Battery breakers x 10 (above batteries)
o Inverter isolators x 3 for Prime3, or x 1 for Prime1 (outside right side of Prime)
4.2 Prime Start-up
Before turning on any of the breakers or isolators on the IsoBox and Main Switchboard, check that the Prime wiring is correct first. To do this, check the battery wiring and then the inverter wiring inside the Prime with the following steps.
4.2.1 Batteries Turn on all the battery DC breakers above the batteries. This will allow the batteries to share a common busbar.
Power the batteries on by pressing the Wakeup/Start-up button inside the IsoBox:
The far-left battery will power on with a green light, and every other battery will turn on their green light as well.
The batteries will then display their position in the battery array via their blue lights forming a binary code. From left to right the batteries will display their ID number within the battery array. This should match the Binary lighting shown as follows;
If the batteries do not display the correct binary ID’s in increasing value from left to right then hold down the first batteries ON/OFF button for 10 seconds to reset, then press the Wakeup/Start-up button inside the IsoBox again.
If problems still persist, please go to the troubleshooting guide in section 6.
After displaying their position in binary, the batteries will rest on the following lights: (Note that more blue lights may be lit showing an increased SOC.
While the left most battery will be flashing its blue light to show it is the Master BMS:
If the batteries display any red lights during this process, go to the troubleshooting guide in section 6.
If there are any other issues during the battery start-up section, refer to the troubleshooting guide in section 6.
If the batteries all power on correctly, leave the batteries on and proceed to next step.
Note: If the following step is not done within 10 minutes the batteries will shut down if they do not notice communication with inverters.
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4.2.2 Inverter(s) Turn on all the inverter isolator(s) on the external right side of the Prime:
For Prime3: All 3 inverter isolators within 10secs
For Prime1: 1 inverter isolator
The unit will now conduct its Communication checks and Phase balancing if three phase system.
After about a minute the inverters will be powered on by the batteries.
The 1st inverter should display the following LEDs:
Note: The battery SOC may differ from above. The nominal SOC as delivered by LG Chem is approximately 25%
Note: For Prime3, Inverter 2 & 3 will not display any LEDs in the battery area, see below as an example:
If the inverter(s) is not displaying the same LEDs as shown in the previous image(s), refer to the troubleshooting guide in section 6.
If inverter is beeping or displaying any LEDs in the “Alarm” area, refer to the troubleshooting guide in section 6.
N.B The Alarm can be silenced by pressing the button “Silence Alarm”
If there are any other issues during the inverter start up process, refer to the troubleshooting guide in section 6.
4.3 IsoBox Start-up
4.3.1 Internet / Communications to IsoBox All wiring should already have been completed for the IsoBox. In this IsoBox start up section we check that the SGD and select.live are being powered by the Prime and that they have internet access. The following breakers should now be switched to the on position in the Isobox.
CAUTION: To avoid any potential issues the customers loads at the Main switchboard should all be off.
o AC Loads Breaker
o Fans
o Comms
4.3.2 select.live The select.live unit that comes with your system has already been pre-configured to work with your inverters and batteries.
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Check that the select.live screen is on, and after a few minutes it will display its connection to the cloud and inverter. An example of this screen is shown below:
If after 10 minutes the select.live is not turning on, or is not displaying that it has connected to the internet, go to the troubleshooting guide in section 6.
4.3.3 SwitchDin SGD The SwitchDin unit that comes with your system has already been pre-configured to work with your inverters and batteries.
Once the select.live and SGD are on and properly
displaying their connection to the internet, proceed to next
section.
4.4 Main Switchboard
This section will test the Main Switchboard’s wiring to the IsoBox, and thus the Prime.
4.4.1 AC Source Turn on the AC Source and Loads from the Main Switchboard. Turn on the AC Source and Load at the IsoBox, and the inverters should have their AC Source LEDs on.
After about a minute, the inverters will Sync with the Grid or Source and Transfer of Power will be possible. An audible sound will be heard indicating that the internal relays are allowing flow of energy.
If the Inverters are not displaying their AC Source LEDs, go to the troubleshooting guide in section 6.
The system should now be fully operational.
4.5 System Check
You would have been given login details be EVO Power for the respective monitoring portals.
Please refer to separate COMMs document for detailed Monitoring and Connection Instructions.
Using a phone, tablet or computer, Check that the select.live and SwitchDin SGD are set up correctly by logging into the websites and checking the data being sent by the system.
Example of Select.Live/SpLink display is shown below;
SPlink can be accessed via Select.Live portal by following this video;
https://youtu.be/nyGYZkkDyqg
Please remember that we will setup your user access during factory commissioning and will supply you with all the access information when system is delivered.
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Example of EVO Power monitoring display is shown below;
If select.live and/or EVO Power portals are not displaying the correct power flow of AC Source to batteries, go to the select.live and/or SwitchDin troubleshooting guide in section 6.
4.5.1 Check Back-up function Complete the following steps to test the customer’s Back-up capability with the Prime:
Turn on some lights in the premisis.
Turn off the AC Grid breaker at the Main Switchboard.
Check if lights remain on.
The light should remain on and be powered by the Prime’s inverters and batteries.
If the light does not turn on, refer to the AC Load troubleshooting guide in section 6.
The Main Switchboard, IsoBox and Prime are all fully operational and in sync with each other at this point.
5. Final assembly After the Main Switchboard, IsoBox and Prime system are all fully functional and have been tested for all connections, the Prime can be fully secured.
5.1 Inverter access cover
Put the SP PRO front cover on with a T25 Torx driver and the Torx screws used previously.
5.2 Prime front door
Place the front door of the Prime back using the screws and Plastic washers removed in section 3.4 Step 1. The screws should be mounted in the reverse order that they were removed. Ensure that these screws are tightened adequately to create a seal but not tight enough to start crushing the door skin. The screws must go in smoothly if they bind remove and realign holes in door skin. Follow procedure below to ensure correct and repeatable fit of door.
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5.3 Labels
The following labels are supplied and fitted by EVO Power, the installer shall supply all other labels to ensure compliance of the installation.
45
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6. Troubleshooting (see website)
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7. APPENDICES: APPENDIX A : PRIME1 SCHEMATIC (ON GRID)
DC Busbar
250A MCCB
L1 ‐ GRID
N ‐ LOAD
N ‐ GRID
L1 ‐ LOAD
N ‐ LOAD
N ‐ GRID
L1 ‐ GRID
N ‐ BUS
L1 LOAD
63A DC Breakersnon‐polarised
+‐
+ ‐
L1 ‐ LOAD
‐ + ‐ +
PV PANELS
SCERT SOLAR
INVERTER
CommsComms
RCB 10A
Temp. Switch
Fan Fan
Thermocouple
Battery Restart Button
9V Battery
63A MCB
63A MCB
L1 ‐ GRID
RCB 10A
N ‐ LOAD
L1 ‐ LOAD
4‐10x LG Chem 6.5kWh
Battery Modules
4G Antenna (optional)
AutostartGensetInput
(optional)
Ethernet
Existing MCB
Comms
Comms
Comms
Comms Comms
Comms
Note. Schematic for typical installation wiring example, Earth connections are not shown for clarity purposes
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7.1 APPENDIX B : PRIME3 SCHEMATIC (ON GRID)
Comms
DC Busbar
3x 250A MCCB
L1 ‐ GRID
Comms
N ‐ LOAD
Comms
L2 ‐ GRID
L3 ‐ GRID
N ‐ GRID
L1 ‐ LOAD
L2 – LOAD
L3 ‐ LOAD
N ‐ LOAD
N ‐ GRID
L3 LOAD
L2 LOAD
L1 ‐ GRID L2 ‐ GRID L3 ‐ GRID
N ‐ BUS
L1 LOAD
63A DC Breakersnon‐polarised
+‐
+ ‐ + ‐ + ‐
Comms
L3 ‐ LOAD
L2 – LOAD
L1 ‐ LOAD
PV PANELS
SCERT SOLAR
INVERTER
CommsComms
RCB 10A
Temp. Switch
Fan Fan
Thermocouple
Battery Restart Button
9V Battery
63A MCB
63A MCB
L3 ‐ GRID
L2 ‐ GRID
L1 ‐ GRID
RCB 10A
N ‐ LOAD
L1 ‐ LOAD
L2 – LOAD
L3 ‐ LOAD
8‐10x LG Chem 6.5kWh
Battery Modules
4G Antenna (optional)
AutostartGensetInput
(optional)
Ethernet
Comms Comms
‐ + ‐ +
Comms
Note. Schematic for typical installation wiring example, Earth connections are not shown for clarity purposes
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7.2 APPENDIX C: LG Chem battery details
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7.3 Appendix D: SP PRO communications card
