Lithium Power Supply User Manual Document rev: 01.11 Firmware rev: 01:02:18 Date: 12-02-2016 Lithium Power Supply Lithium Power Supply User Manual 1. Safety Instructions The Lithium Power Supply (LPS) is classified as Class 9 hazardous material UN3480, a power source with high energy density and dangerous materials in a closed metal case! Installation must strictly follow the national safety regulations in compliance with the enclosure, installation, creepage, clearance, casualty, markings, and segregation requirements of the end-use application. Installation must be performed by professional installers only. Switch off the system and check for hazardous voltages before altering any connection! The Lithium Power Supply must be handled only by qualified and trained personnel. The lowest protection degree of specific parts of the LPS is IP21. Ensure that the installation of the Lithium Power Supply is in accordance with IP21 requirements. This is a Class I product. Only connect 230VAC In from a source that is connected to electrical earth, including any extension cords between the source and the unit. Especially keep these rules: • Do not open the Lithium Power Supply. • Do not discharge a new Lithium Power Supply before it has been fully charged first. • Charge only within the specified limits. • Do not mount the Lithium Power Supply upside down or on the sides. • Check if the Lithium Power Supply has been damaged during transport. • Do not put Lithium Power Supplies in serial or parallel. Dangers involved in case of fire: • Danger of dust particle explosions • Decomposition through fire or heat under development of toxic and cauterizing gases • Combustion gasses which strongly irritate eyes and respiratory organs General actions to be taken by the driver if these dangers occur: • Turn of the engine • Put a warning signal on the road to warn others • Inform others about the danger and direct them to stand away from the wind direction • Call the police and fire department immediately and inform that lithium batteries (UN3480) is on board Instruction for fire extinguishing: • Extinguish with water, if possible cover lithium power supply completely in water • Extinguishing with water will produce fluoride, phosphate, fluoride-oxide and carbon-oxide. • Alternatively extinguish with a CO2 extinguisher. Note: when put to storage the battery must be fully charged and must be recharged again every 6 months. NON-SPILLABLE LI-ION BATTERY Page 2 Lithium Power Supply User Manual Page 3 Lithium Power Supply User Manual Table of Contents 1. Safety Instructions.................................................................................................................. 2 2. General information ............................................................................................................... 5 2.1. Transport ..................................................................................................................................... 5 2.2. Disposal ....................................................................................................................................... 5 3. LPS1512-100Ah Box ................................................................................................................ 6 4. Lithium Power Supply - General parameters ........................................................................... 8 5. Physical dimensions and mounting overview ........................................................................ 10 6. General Instructions ............................................................................................................. 12 6.1. Installation / Use of 230VAC Input .............................................................................................. 12 6.2. Installation / Use of 230VAC Output ........................................................................................... 13 6.3. Neutrik connector assembly (230VAC In/Out) ............................................................................. 14 6.4. Use of 12VDC Input .................................................................................................................... 15 6.5. Use of 12VDC Output ................................................................................................................. 15 6.6. Anderson connector assembly (12VDC In/Out)............................................................................ 16 6.7. Use of starter help (extra)........................................................................................................... 17 7. Operations ........................................................................................................................... 18 7.1. Power On/Off ............................................................................................................................ 18 7.2. Icon description ......................................................................................................................... 19 7.3. Menu overview .......................................................................................................................... 20 7.4. Functionality / Menu description ................................................................................................ 20 7.5. DC OUT ...................................................................................................................................... 21 7.6. AC OUT ...................................................................................................................................... 22 7.7. DIAGNOSTICS ............................................................................................................................. 23 8. Failure description ................................................................................................................ 24 9. Additional information ......................................................................................................... 26 10. Warranty ............................................................................................................................ 27 Page 4 Lithium Power Supply User Manual 2. General information When the LPS is not used for longer periods of time it must be stored fully charged and recharged every 6 months ATTENTION: Read the safety instructions before installing the Lithium Power Supply. ATTENTION: When installing the lithium Power Supply, do not mount it upside down or on the sides. Do not cover or block the fan or the air inlet to insure the battery does not overheat. Mounting holes are for pre-fixation, suitable fixation has to be added. ATTENTION: Do not connect the Lithium Power Supply in series or parallel. ATTENTION: Make sure the Lithium Power Supply is powered down before starting the installation 2.1. Transport The Lithium Power Supply is classified as Class 9 hazardous material UN3480 and tested according to Transport of the Lithium Power Supply must always be in original certified packaging. UN 38.3. The transport of Lithium Power Supply must only be handled by trained people in accordance to ADR, RID and IMDG. For transport by air (IATA) the packaging has to be in accordance to P965, here the original packaging complies. For shipment of defect batteries, contact your retailer for further information. 2.2. Disposal Batteries marked with the recycling symbol must be processed via a recognized recycling agency. By agreement, they may be returned to the manufacturer. Batteries must not be mixed with domestic or industrial waste. NON-SPILLABLE LI-ION BATTERY Page 5 Lithium Power Supply User Manual 3. LPS1512-100Ah Box Included in the box: 1 pcs. Manual Page 6 Lithium Power Supply User Manual 1 pcs. Neutrik Input connector 1 pcs. Neutrik Output connector 1 pcs. Anderson DC Input connector 1 pcs. Anderson DC Output connector 4 pcs. M3 screws 4 pcs. Anderson SB50 pins Page 7 Lithium Power Supply User Manual 4. Lithium Power Supply - General parameters Table 1 Battery type 100Ah-12V (LiFePO4) Battery capacity 100Ah (1320Whr) Available capacity 80Ah (1050Whr) AC Input Voltage 207 VAC – 253 VAC AC Input frequency 45 Hz – 65 Hz AC Input power (Charge power) 1000 W (4,5A) AC Output voltage 230 VAC pure sine AC Output frequency 50 Hz AC Output power – Continuously 1300 Wrms (6A) AC Output power – 15 min 1500 Wrms (6,5A) AC Output current Continuously (with 230VAC input connected) AC Output power peak (10sec) 1800W (8A) / Socket DC Input voltage 12 - 15 VDC DC Input continuous current < 50 A DC Output Voltage 13,2 VDC (9,2 - 15 VDC) DC Output continuous current 60 ADC DC Output Max Impulse current (Total max 2300W (10A)) 2500 Wrms 20 min 1 min 10 Sec Operating temperature (Output will be limited below 0°C) 70 A 100 A 150 A -20°C~50°C Cooling Forced air (fan) Self-discharge rate per month (Sleep mode) < 3% Operating mode self consumption (Only DC Output active) 5W Operating mode self consumption (Inverter and DC Output active 22 W Sleep mode consumption < 25 mW Connection 230VAC Neutrik and Schuko Connection 12VDC Anderson SB50 IP rating IP21 Product Weight 28 kg Product dimensions in mm (H x W x L) 250 x 244 x 390 Package weight 32 kg Package dimensions in mm (H x W x L) 350 x 355 x 495 Page 8 Lithium Power Supply User Manual Table 2 Protection Class Class I (Do only connect to a Residual-current device (RCD) protected source) 2014/35/EU (Low voltage directive) EN 60950-1:2006 + A1:2010 + A2:2003 + A11:2009 + A12:2011 (Safety, Information technology equipment) 2014/30/EU (EMC directive); EN 61000-6-3: 2007 + A1:2011 Emission household equipment EN 61000-6-2: 2005 Immunity industrial 230vac Input protected by 10AT fuse (Not replaceable) 230vac Output Protected by 2 x 8A fuse (Resetable) DC Input Protected by 3 x 40A ATO fuses (replaceable) DC Output Protected by 3 x 40A ATO fuses (replaceable) Lithium battery protected by fuse (Not replaceable) L/N relay hazard is hardware protected. PE/N relay hazard is hardware protected. Certifications Safety protections 230vac AC Output protections Overload Short circuit 230vac AC Input protections Over / Under voltage Frequency Controlled charge levels Additional protections DC Input Over / Under voltage Overload Controlled charge levels DC Output Overload Controlled charge levels (reverse on output) Internal Lithium battery protections Over charge Deep discharge Temperature Overload Page 9 Lithium Power Supply User Manual 5. Physical dimensions and mounting overview ATTENTION: Mount the LPS topside up, never upside down or on the side. ATTENTION: The LPS has forced air cooling. Make sure air can flow freely around the unit. The LPS has four M5 mounting holes in the bottom as shown in figure 1. 4 x M5 25.00 194.00 25.00 25.00 303.00 386.00 194.00 244.00 Figure 1 Page 10 Lithium Power Supply User Manual Figure 2 Figure 3 Page 11 Lithium Power Supply User Manual 6. General Instructions ATTENTION: Before installing, make sure that all appliances are turned off. When installing the LPS the following connections can be used. - 230VAC Input for charging from external mains plug (Blue Neutrik. Assembly described in section 6.3) 230VAC output to power 230vac equipment (Grey Neutrik. Assembly described in section 6.3) 12VDC Input for charging from the car generator (12VDC input, Grey Anderson SB50. Assembly described in section 6.6) 12VDC output to power 12VDC equipment (12VDC output, Red Anderson SB50. Assembly described in section 6.6) 6.1. Installation / Use of 230VAC Input When connecting the LPS1512-100Ah to a 230VAC source, the unit will start up and begin to charge the internal battery. Please note that when a 230VAC source is connected the unit will loop the 230VAC directly through to the output sockets, enabling 230VAC out. Note: Always use a RCD protected source to supply the LPS 1512-100Ah from 230VAC. When installing the LPS into a vehicle it is important that the 230VAC in is supplied from a unbroken cable from the external power source to the 230VAC input on the LPS as shown in figure 4. If the 230VAC charge wire is connected to anything else, an RCD must be present immediately after the input socket as shown in figure 5. LPS 230VAC Figure 4 RCD LPS 230VAC Figure 5 Page 12 Lithium Power Supply User Manual 6.2. Installation / Use of 230VAC Output Fuses Both 230VAC outputs on the LPS (Schuko on the front, Neutrik in the back) is protected with 8A relays and a RCD, which allows you to make fixed 230VAC installations in the vehicle. If an installation is wired around the LPS, separate relays must be used. Connections For fixed 230VAC installations from the LPS the Neutrik 230VAC Out on the backside must be used. This it to ensure that vibrations will not loosen the connection. General function When 230VAC In is connected the 230VAC power will be looped directly through the unit. If both 230VAC In and 230VAC Out is running and 230VAC In is subsequently disconnected, the LPS will change from charge to discharge mode and continue to deliver 230VAC Out. Page 13 Lithium Power Supply User Manual 6.3. Neutrik connector assembly (230VAC In/Out) Figure 6 For 230VAC installations, 3-core, 1mm2 minimum is recommended Page 14 Lithium Power Supply User Manual 6.4. Use of 12VDC Input In order to charge from the 12VDC starter battery of the vehicle the diagram in figure 7 must be followed. Please note that a fuse must be placed as close to the starting battery as possible. D+ + - * *12VDC, 100Ah fuse Figure 7 Note: Fuses can be purchased at your Clayton Power sales representative. For the LPS to charge from the surplus energy from the vehicle, the D+ signal from the generator must be connected to pin 9 of the communications connector. This signal insures the LPS is activated and only charges from the vehicle when the engine is running. NOTE: When the signal in pin 9 of the communications connecter is active (high) the power botton on the fron panel is not functional. 6.5. Use of 12VDC Output For 12VDC equipment connected to the 12VDC out no fuse is needed, as this is included in the LPS. Page 15 Lithium Power Supply User Manual 12VDC Load + Figure 8 6.6. Anderson connector assembly (12VDC In/Out) When installing the unit, make sure to use 16mm 2 cables for the DC connections. Figure 9 Step 1: Use 16 mm2 cable. Maximum length 5m. Strip 14 mm. Figure 10 Step 2: Insert cable in contact and crimp with tool. Step 3: Insert contact in housing, push until click. Page 16 Lithium Power Supply User Manual 6.7. Use of starter help (extra) 12VDC Load + CDR * +" #" *12VDC, 100Ah fuse Figure 12 Connect plus to both 12VDC out and in. From there the starter battery and 12VDC load(s) is connected according to figure 12. The blue and black wire must be connected to pin 6 in the DB9 communication plug as seen in figure 13. Figure 13 Note: The fuse, CDR and DB9 communication connector can be purchased at your local Clayton Power sales representative. Page 17 Lithium Power Supply User Manual 7. Operations 7.1. Power On/Off To turn the unit on press and hold the power button To shut off the unit press the power button the power button twice and approve for 5 seconds until the fan comes on. . (If the following mode is enabled: “DC Out Keep Active Time” press , see section 7.5) LPS OK 230V 12V LITHIUM POWER SUPPLY 1500W – 100Ah Figure 14 Charging When 230VAC or 12VDC input is connected, the unit will turn on and start charging. The inputs are automatically inactive when no charging source is detected. Page 18 Lithium Power Supply User Manual 7.2. Icon description Table 3 12VDC In Shows the status of the 12VDC In module. The power bar shows the level of total 12VDC charge current. ! 12VDC Out ! Shows the status of the 12VDC Out module. The power bar shows the level of total discharge current. 230VAC In Shows the status of the 230VAC In module. The power bar shows the level of total 230VAC charge power. ! 230VAC Out Shows the status of the 230VAC Out module. The power bar shows the level of total 230VAC output power. ! Battery ! Shows the current battery charge in 10% steps. When the battery is charging the top most bar will flash. If the battery is empty a warning will show Warning If there is an error or warning the exclamation mark will flash. ! Power flow Indicates the direction of power flow. Module on Module is on but with no load / consumption (Idle mode). Page 19 Lithium Power Supply User Manual 7.3. Menu overview Home screen Menu o DC Out Activate Jumpstart Keep Active Time Auto Shutdown Time Auto Shutdown Current o AC Out Enable above SOC Auto Shutdown Time Auto Shutdown PWR o Diagnostics Errors About 7.4. Functionality / Menu description By pressing OK the main menu will be entered. Three submenus can be selected Figure 15 Page 20 Lithium Power Supply User Manual 7.5. DC OUT DC Out Activate Jumpstart Off Keep Active Time: Off Auto Shutdown Time: Off Auto Shutdown Current: Off Figure 16 In the DC Out menu there are following options: Activate Jumpstart If Jumpstart is enabled the unit will provide a 12VDC – 50A output on the DC input for 5 minutes. The purpose of this is to charge the start battery in the vehicle. Keep Active Time Will keep 12VDC active and allows 230VAC out to be turned off separately. When enabled 2 push on the power button is needed to turn off 12VDC out. Options: On Off On in a time range (00:01:00 – 04:15:00) Auto Shutdown Time Auto shutdown for the 12VDC output. The DC output is automatically disabled in relation to time and the 12VDC output current. The timer is active when current is less than the set ”Auto Shutdown Current”. The timer resets if the current rises above the set level. (Auto Shutdown Current must be set) Options: Off Time (00:01:00 – 04:15:00) Auto Shutdown Current For description see “Auto Shutdown Time”. Options: Off Current Limit (1A – 50A) Page 21 Lithium Power Supply User Manual 7.6. AC OUT AC Out Enable Above SOC: 0% Auto Shutdown Time: 01:00 Auto Shutdown PWR: 20W Figure 17 Enable Above SOC Disables 230VAC output when State Of Charge (SOC) drops below the set percentage. Options: SOC range (0% – 100%) Auto Shutdown Time Auto shutdown for the 230VAC output. The AC output is automatically disabled in relation to time and the 230VAC output power. The timer is active when power is less than the set ”Auto Shutdown PWR”. The timer resets if the power rises above the set level. (Auto Shutdown PWR must be set) (Only functional when no 230VAC in) Options: Off Time (00:01:00 – 04:15:00) Auto Shutdown PWR For description see “Auto Shutdown Time”. Options: Off Power Level (0W – 1500W) Page 22 Lithium Power Supply User Manual 7.7. DIAGNOSTICS Diagnostics Errors About Figure 18 Errors Shows present errors. About Shows: Serial Number Manufacturer Date Hardware Version Software Version – System Software Version – Display Page 23 Lithium Power Supply User Manual 8. Failure description If the unit detects a failure in the electronics it will display a failure code. The following table shows the failure codes and the action required to solve the problem. In case the unit displays a failure code that is not listed in the table, the unit needs service. Table 4 Failure codes E001,E002 E003 Inv = Inverter, Chg = Charger Failure level Critical Critical Affected module All Inv/Chg Solution Warning Inv/Chg Simple Inv/Chg The internal electronics is getting too warm. The internal electronics is too warm. Warning Inv/Chg Simple Inv/Chg Critical Critical All All E020,E21 A temperature sensor is broken. The calculated efficiency of the unit is too low. Inverter failure Allow the unit to warm up, or place it in a higher ambient temperature. Place the unit in higher ambient temperature. Allow the unit to cool down, or place it in lower ambient temperature. Allow the unit to cool down, or place it in lower ambient temperature. Contact your retailer for service. Contact your retailer for service. Simple Inv E022 Charger failure Simple Chg E030-E040 E049 E050 E051 Missing calibration DC Communication failure Cell Voltage measurement failure Battery Empty Critical Critical Critical Warning All DC in/out All Inv/DC out E052 One or more cell voltage(s) is getting too low One or more cell voltage(s) is too low One or more cell voltage(s) is getting too high Warning All Warning Warning All All E055 One or more cell voltage(s) is too high Warning All E056 One or more cell temperature(s) is getting too low One or more cell temperature(s) is too low One or more cell temperature(s) is getting too high Warning All Simple All Warning All E004 E005 E006 E007 E008,E009 E010 E053 E054 E057 E058 Failure description EEPROM memory failure. Internal High Voltage communication. The internal electronics is getting too cold. The internal electronics is too cold. Page 24 Contact your retailer for service. Contact your retailer for service. Restart to remove failure. If a restart does not remove the failure, contact your retailer for service. Restart to remove failure. If a restart does not remove the failure, contact your retailer for service. Contact your retailer for service. Contact your retailer for service. Contact your retailer for service. Apply charge current from 230VAC in or 12VDC in. Recharge the battery. Recharge the battery. Remove any charge inputs and allow the unit to balance the cells. Contact your retailer if the warning is still present after 24hrs. Remove any charge inputs and allow the unit to balance the cells. Contact your retailer if the warning is still present after 24hrs. Place the unit in higher ambient temperature. Place the unit in higher ambient temperature. Allow the unit to cool down or place it in lower ambient temperature. Lithium Power Supply User Manual E059 One or more cell temperature(s) is too high Battery voltage is too low for operation DC input voltage is too low to charge the battery DC input voltage is too high to charge the battery DC input charge current is too high Simple All Critical All Simple DC in Simple DC in Simple DC in Simple DC in E094 E095 E096 DC input discharge current is too high DC output relay connect failure DC output relay disconnect failure DC output charge current too high Critical Critical Simple DC out DC out DC out E097 DC output discharge current too high Simple DC out E101 E102 E103 AC current measurement failure DC current measurement failure PSU startup failure Critical Critical Simple All All Inv/Chg E104 PSU short circuit Simple Inv/Chg E105 High voltage failure Critical Inv/Chg E106 E150 Control circuit power supply failure 230VAC output overload Critical Simple All Inv E151 Simple Inv E152 E153 E154 E200 E201 E202 230VAC output peak current duration too long 230VAC output peak current to high PE/N relay failure PE/N relay failure Charge current too high Charge current too high High voltage failure Simple Critical Critical Simple Simple Simple Inv Inv/Chg Inv/Chg Chg Chg Chg E203 E204 E205 E206 230VAC output overload Transfer relay failure Transfer relay failure High voltage over voltage Simple Critical Critical Simple Chg Inv/Chg Inv/Chg Chg E060 E090 E091 E092 E093 Page 25 Allow the unit to cool down or place it in lower ambient temperature. Recharge the battery. Provide a higher 12VDC voltage for the unit to charge. Provide a lower 12VDC voltage for the unit to charge. Provide a lower 12VDC current for the unit to charge. Provide a lower 12VDC current for the unit to discharge. Contact your retailer for service. Contact your retailer for service. The 12VDC output has a power source connected that generates too high charge current. Remove or adjust the power source. The 12VDC output load is drawing too much current. Contact your retailer for service. Contact your retailer for service. Restart to remove failure. If a restart does not remove the failure, contact your retailer for service. Restart to remove failure. If a restart does not remove the failure, contact your retailer for service. Restart to remove failure. If a restart does not remove the failure, contact your retailer for service. Contact your retailer for service. The 230VAC output is overloaded. Remove some of the load on the 230VAC output. Contact your retailer for service. Contact your retailer for service. Restart to remove failure. If a restart does not remove the failure, contact your retailer for service. Contact your retailer for service. Contact your retailer for service. Restart to remove failure. If a restart does not remove the failure, contact your retailer for service. Lithium Power Supply User Manual 9. Additional information Battery Management System The LPS has a built-in Battery Management System ensuring full control and safety. The BMS monitors lithium cell activity and uses the information for safety, maintenance, SOC, and interface control. Charger Control It is necessary to control the charging of lithium batteries in order to avoid uncontrolled disconnections and to protect the lithium cells from unstable conditions. The integrated Battery Management System always ensures the lithium cells are operated within their safe operating parameters. Cell voltage measurement The LPS measures cell voltage with high accuracy. The accuracy is necessary to calculate the SOC as only a few 1/1000 of a volt makes a difference. Cell temperature measurement The LPS measures the temperature of all individual cells to ensure that none of the cells overheat or cause thermal runaway. The temperature information is also used for SOC calculations. Shunt and current measurement The current passes through an integrated shunt resistor so the LPS can measure the current to and from the cells and use it for protection and SOC calculation. Integrated safety breaker The most important part of the LPS circuit protection is the integrated safety breaker. It allows the LPS to cut off all charge and discharge currents in potentially hazardous situations. Overload protection The advantage of the internal safety breaker is its capability to disconnect high currents without damaging the main switch. The LPS can use the safety breaker for overload protection without damaging the cells. Short-circuit protection The LPS is protected against short circuits by fuses on the inputs and outputs. The 230VAC output furthermore has a built-in RCD to protect the user. Cell balancing The advanced SOC calculation ensures that all cells are kept in a balanced condition at all times. The BMS has a high cell-balance current that reduces the need for active cell balancing and restores the cells to a balanced condition faster. The BMS is cell balancing each single cell in charge, discharge and idle mode. Page 26 Lithium Power Supply User Manual Interface Each LPS has a service interface that allows a qualified technician to analyse any failures and the general condition of the LPS. The service port also allows for firmware updates. Power conservation When the LPS is not in use it will enter a low power state. In this state the LPS keeps power consumption very low to avoid unnecessary discharge of the battery. The LPS can be reactivated through the power switch or by applying a charge source to either the 230VAC input or the 12VDC input. 10. Warranty CAUTION & WARNING: DO NOT USE OR ATTEMPT TO USE THIS PRODUCT UNTIL YOU HAVE READ THIS USER'S MANUAL IN ITS ENTIRETY. IMPROPER INSTALLATION OR USAGE OF THIS DEVICE MAY BE HAZARDOUS AND MAY CAUSE DAMAGE TO OTHER ELECTRICAL EQUIPMENT AND WILL VOID WARRANTY. Clayton Power warrants, to the original purchaser only, for a period of 24 months from the date of purchase, that the Clayton Power device will be in good working order when properly installed and operated as described in this manual. If the device fails within this time period under normal use, Clayton Power will, without charge, at the place of Clayton Power's choosing, repair or replace the device - with new or reconditioned parts or a new or reconditioned device as Clayton Power deems necessary. This warranty is not valid in cases of: Usage against the recommendations of this manual. Usage in applications outside of general automotive, solar, industrial or marine applications without the agreement of Clayton Power. Device modification or repair without written authorization from Clayton Power. Reverse polarity, excessive overloading, general abuse, neglect, wear & tear, ingress of liquids (water, oil, acid, or otherwise), foreign objects, lightning strikes, over or under voltage, RFI/EMI, etc. Obtaining Warranty Service To obtain warranty service, please contact the outlet at which you purchased your product. Do not contact Clayton Power directly. For warranty service provide the following: Proof of purchase The unit model number The unit serial number A brief description of the application and problem including any failure codes displayed on the unit. Contact your Clayton Power dealer for an authorization number prior to dispatch - do not send without authorization. Once this number has been obtained, please carefully pack your unit and send (freight paid) to the Clayton Power dealer. Please note that the unit contains Lithium batteries and must be shipped as dangerous goods according to UN3480 (Lithium-Ion Batteries) Copyright The information contained within this document remains the sole property of Clayton Power. No part of this document may be copied or reproduced in any form or by any means, and the information contained within is not to be communicated to third parties, without the prior written consent of Clayton Power. Page 27 Lithium Power Supply User Manual Clayton Power Pakhusgården 42 – 48 DK-5000 Odense C Denmark Phone: +45 4698 5760 E-mail: sales@claytonpower.com Web: www.claytonpower.com Page 28