lifepo4 diy ess - kit building documentation

7/25/2019 LiFePO4 DIY ESS - Kit Building Documentation

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LiFePO4 DIY ESS

Kit Building Documentation

Copyright 2014 CHC DO NOT COPY AND DISTRIBUTE THIS DOCUMENT 1/28


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Skills required

You have to be able to use a screwdriver, wrench, cutter, drill, soldering iron, cri ping tool, have basic!nowledge o" grid #C power and electricity in general$

Disclaimer

%n this docu entation % provide the in"or ation on how to build a &%Y 'nergy (torage (yste e)actlyli!e the one % created$ You have to be aware o" the danger dealing with grid #C power and withbatteries and ta!e all the necessary precautions$% can not be held responsible "or anything you would do wrong during the build and the use o" thissyste $

You have to co ply with the electrical code in your country$

Low Voltage Pack !ut Ver" #ig$ Power %ells & Your Sa'et" First (

*lease be very care"ul while handling the +i e*-4 battery cells .

#+ #Y( ' - ' Y-3 % 56s7, ' #++%C # CH and %( 9# &6s7, use only insulatedtools, because the power available in each cell is incredible : each cell can put out 2000 6..7 alone ;and you could 93 very badly or even +--(' your "inger6s7 or your hand i" there was a short

circuit passing close or through the $



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9uilding the '((Summar"

#n '(( is an 'nergy (torage (yste and its purpose is to store e)cess energy, not used in yourho e, and use it when necessary$%t is co posed o" a attson energy onitor, a +i e*-4 battery pac!, several grid tie inverters, severalchargers, a control board, cables$

he initial storage capacity o" the '(( is =0 68 5rid ie %nverters, 5 %7, but all these can be increased by incre ents o"


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3sage and indicate it with big red digits on its "ront panel : it can also show 3sage and 5enerated*ower ;, but also by color codings on the bac! o" the unitG e will use these color codings as inputs tothe '(( #rduino board which will deter ine, using y progra , what to do 6ieA close a charger relay,switch "ro Charger ode to 5 % ode, or open a 5 % relay, etc$$$7, ad usting power stored into orpushed out "ro the '(( every F seconds$

(et your attson trans itter to send in"or ation every F seconds 6see attson user anual7$ #lwaysleave your attson on setting &%(*+#Y C-+-3 ( D 3 9' (, and it is good to a!e it display et

*ower, but that can be changed by tilting it to display 3sed *ower or 5enerated *ower to chec!$or that we need to open the bac! cover o" the attson unit, unscrewing the 4 screws hidden behind

the rubber pads

o be able to read the color codings we have to solder s all wires at these speci"ic locations on thebac! o" attson s *C9$ % used a co puter ouse wire ; a wor!ing one, otherwise the cable ight bebro!en so ewhere ; to do this, the length is good, cable is "le)ible, and it ends with a 3(9 port thatwill a!e a proper connection to the Control 9oard later$

urn attson - by depressing the top button until its says I5oodbyeJ and shuts o""G 3nplug itspower adapter too$

&isasse ble the 3(9 ouse and cut the wires clos the its *C9 : or cut o"" the ouse "ro its cable ;,strip o" the sheath on 10c , and strip < o" cable on each wireA use the hite wire "or blue +'&6&207, 5reen wire "or 5reen +'& 6&1


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+abel the wire - # 3(9 C#9+' .. with a piece o" red tape close to the 3(9 port, this way you willnot connect it to a co puter or a power adpater by ista!e : not a good idea "or your attson . ;

*lug the 3(9 port into the "e ale 3(9 port$

urn attson - by depressing the top button until its says IHelloJ and readings appear on the "rontdisplay$ 3sing a volt eter, chec! the voltages o"" the colors 9lue 6 hite cable7, 5reen 65reen Cable7and ed 6 ed cable7 wires with the volt eter C- on the 9rown one and a!e sure you identi"ythe clearly : this is crucial ;$

Copyright 2014 CHC DO NOT COPY AND DISTRIBUTE THIS DOCUMENT


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Batter" +ack

he

"ou do not 'ollow instructions on t$is +art or use an" t$ird +art" B*S on t$e cells "ou will endu+ damaging or destro"ing t$em and +otentiall" cause a 'ire $

o per"or botto balancing, drain each cell to 2$>< using a big resistor or use y botto balanceron each cell individually and repeat the process a"ter a rest period o" 12 hours until all the cells show avoltage o" 2$>< a"ter 24 hours o" rest$

Clean and re ove the invisible corrosion on the cells ter inals using an e)tra "ine sandpaper sheet$

ire all the cells in series using the copper straps and bolts, a!ing sure the bolts are screwed tightlyall the way and that the strap "lat part is in good contact with the cell ter inal $

%n the iddle o" the pac! wire the 9lue (ea &C brea!er / switch$

Chec! the pac! voltage, it should be e)actly 2$>< ) 8 M 22 $

Cover the battery pac! using the plastic cover that co e with the u i drawer : or an inverted bigplastic tray ; to avoid any short circuit with etal ob ects and leave the &C brea!er on 0 / - $

%ontrol Board&

he '(( Control 9oard is the central anage ent unit o" the syste where the instru entation, thecontrols are, where all cables co e and go, and also where you can onitor the state o" the batterypac!$

%t is co posed o" an #rduino board "lashed with the progra % developed, #C brea!ers, 2 yco Nilovaccontactors, 1= relays, a switch, a pushbutton, connectors, wires, 24 to < &C;&C converter, a board,

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http://media3.ev-tv.me/cellcare.pdfhttp://media3.ev-tv.me/cellcare.pdf


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screws, and a plastic cover$

Positioning t$e com+onents

a!e the board and start positioning the ite s on it to see how they will "it$

easure and ar! the position o" each ite with a pencil and double chec! that all the ite s "it in theirar!ingsG or each co ponents, here are the ) D y coordinates, starting "ro the le"t botto corner o"

the board positioned in landscape, or ore si ple positioning indicationsA 6(ee picture below7

; #C ter inal bloc!sA distance o" 2 c "ro the top

; #C cords holdersA holes at 1c "ro the top 6do not drill the 7

; #C elaysA distance o" 1c under the #C ter inal bloc!s

; &C cables holdersA holes at 1c "ro the le"t, 1c "ro the botto "or lower end

; Charger side &C bolt 64c long, =7A 1$


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; #C brea!ersA at the very botto right corner, leaving 0$Fc on the botto and theright side

; 5 % ode and Charger ode elaysA in the iddle between the #rduino board andthe #C brea!ers

(tart screwing the #C ter inal bloc!s at the top o" the board, the will be hosting all the = chargers and8 5 %s #C power cords wires, so "or each device we have F ter inals, "ro le"t to right, one "or

eutral, one "or 'arth, one "or +ine$

&rill wooden #C cords holders starting "ro the < "ro the side on both sides and every F c orso in between$ *osition the on top o" the #C ter inal bloc!s$ You will screw the in position using2$< 12 long s all wood screws when the #C cords will be connected to the ter inal bloc!s$

(a e "or &C cables holders, position the on the le"t o" the board$

*osition and glue the 0$


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)iring t$e com+onents

Cut 1 o" the the 0$< O blac! D red double cable, split the two wires on 20c , strip the on 1c ,and solder 2 8 s all lugs on each wireG -n the other side, split on Fc , strip 1c , and applysolder$ he side with lugs will go the battery pac! ter inals and the other side will go to the Control9oard 24 &C input ter inal bloc!, at the botto le"t corner o" the Control 9oard$

(crew a red wire to this ter inal, solder the other end wire to the 2# s all glass "use holder screwedne)t to it, and cut another one to continue and screw it on the olt eter ter inal


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e use ter inals 1 D 2 to power the olt eter, prolongating battery pac! voltage "ro readingter inals < D 8$

er inals 11 D 12 get the red wire "ro the 5 % ode #rduino elay and the red wire to the 5 % (ideyco Nilovac Contactor$ elay K2 will open when pac! voltage reaches its 24 lower li it while

discharging, showing a botto red +'& on the panel$

er inals 14 D 1< get the red wire "ro the Charger ode #rduino elay and the red wire to theCharger (ide yco Nilovac Contactor$ elay K1 will open when pac! pac! voltage reaches its 28upper li it while charging, showing a top red +'& on the panel$

Voltmeter set5u+

(et up %nput ype using password 008? , dot, then scroll and choose code 1 "or &C ;20 to 100range, and dot to validate, end and dot to validate

(et up the &isplay or at using password 00F= , dot, then scroll and choose dot and select 2 "or 2digits, and dot to validate, end and dot to validate

elay K1 6High ed +'&7 will be used "or upper li it cut o"" 6Charge in Charger ode7

elay K2 6+ow ed +'&7 will be used "or lower li it cut o"" 6&ischarge in 5 % ode7

(et up the upper and lower li its o" each relay using password 0001, dot, then input A

#H1 M 28

#+1 M 2=

#H2 M 24

#+2 M 2


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'nd and dot to ')it

Chec! again all these relay inputs once or twice to a!e sure they are correctG %t is crucial ..

Close the panel lid gently without pressing too uch, this will prevent any button being touched$

-nce the set up o" the olt eter is done, switch the &C brea!er on 0 / - , "or sa"ety

Detail o' t$e 6 *odes 7%$arge 8 9,I: rela"s wiring

Connect the positive red 24 wire "ro the olt eter ter inal 1 to one pin 6called input now7 o" theControl 9oard ain switch$

&isasse ble the car 24 to 3(9 converter to !eep only the 24 ;< &C;&C converter e bedded in it$

Continue "ro the other pin 6called output now7 o" the ain switch to the positive 24 input o" the 24 ;< &C;&C converter ne)t to it$

Connect the negative blac! wire "ro the olt eter ter inal 2 to the negative 24 input o" the 24 ; R Charger ode elay &C relay

%onnect )attson %olor %oding )ires to t$e ;rduino

*osition the "e ale 3(9 port to the le"t o" the Control 9oard and prolongate the 4 wires to a 4;ter inal bloc!, "ro there screw wires o" colors 9lue, 5reen, ed, and 9lac! "ro the hite, 5reen,

ed and 9rown ones$ *lug these into the #rduino input pins A

attson 5reen wire R #rduino *in #0

attson 9lue wire R #rduino *in #1

Copyright 2014 CHC DO NOT COPY AND DISTRIBUTE THIS DOCUMENT 1=/28


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attson ed wire R #rduino *in #2

attson 9lac! wire R #rduino *in 5 &

Forced %$arge *ode Pus$!utton

3sing an -h eter, see how the pushbutton should be wiredA "ind the nor ally open pins, and whenyou depress it, chec! that there is a contact between the pins$ Cut o"" the other pins$ hen plug in

#rduino pin 1F a yellow wire, solder it to one o" the pushbutton pins, solder a s all red wire to theother pin, and solder the other end o" the red wire to the < : - 24 . ; output o" the &C;&C

converter or to the red /positive o" the #rduino input ac!$ *osition the pushbutton on the right side o"the Control 9oard ain switch$

his orced Charge ode can be used to charge at night "or e)a ple 6low rate electricity7 and re;usethe stored energy during the day 6high rate electricity7, or chec! that the Charger (ide is wor!ingproperly$ he charge rate can be ad usted by ?2 decre ents$

o switch to orced Charge ode, "or testing or to really charge when you want to, depress thepushbutton "or 4 seconds, release, and you will start seeing the '(( go into orced Charge ode$

ait until all the Chargers #C relays are switched - $ %" you want to lower the charge power, depressthe pushbutton brie"ly, and release, you will see one Charger #C relay switch - , wait another F

seconds, and repeat this procedure until you have the desired Charge regi e$

o get out o" orced Charge ode and go bac! to #uto atic/ or al ode, depress the pushbutton"or 4 seconds, release, and you will see all the Chargers #C relays being switched - , and the '((will ad ust auto atically to the new color codings "ro attson$ You can also switch - the wholesyste "ro the Control 9oard ain switch and switch it bac! - $

*ake t$e D% %a!les

Cut and cri p, using an hydraulic cri ping toolA

Copyright 2014 CHC DO NOT COPY AND DISTRIBUTE THIS DOCUMENT 1>/28


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2 1$< long F< 2 cables with F< 2 8 lugs on both endsG ar! one o" the as red,using red tape, red heat;shrin! or use a red cable

1 1 long F< 2 cable with F< 2 8 lugs on both endsG ar! it red or use a red cable

1 1 long 10 2 cable with 10 2 = D 8 s all lugs on each side

1 4c long 10 2 cable with 10 2 8 lugs on both ends

Connect the 1 long red cable "ro the 9attery pac! positive ter inal to the bac! ter inal o" the 5 %side yco Nilovac Contactor 6"ront one7G -n the 9attery ter inal, re ove the previously screwedControl 9oard wires, and a!e sure you put the big cable lug in contact with the ter inal "irst,because it will carry a lot o" current, then place the s all Control 9oard wire lug on top o" it, then thewasher and the nutG ighten very well the connection$



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-n the yco Nilovac side, use the bac! ter inal, and sa e thing as on the battery pac!, put this biglug directly in contact with the "lat conductive part o" the ter inal, then put the s all 4 c cable on topo" it, and "inish with the washer, loc! washer and nut, tightened very well also$

a!e the 1$< red cable and connect one end to the "ront ter inal o" the 5 % (ide yco Nilovaccontactor, add the washer, loc! washer, nut and tighten "ir ly$

Connect the other end o" the s all 4c 10 2 cable to the Charger (ide yco Nilovac contactor,using the "ront/right ter inal, add the washer, loc! washer, nut, and tighten "ir ly$

a!e the 1$< long blac! cable and connect it to the battery pac! negative ter inal, "ollowing thesa e procedure used "or the positive side about the big D s all lugs order 6.7

-nce all the battery connections are ade, cover the battery pac! with a non conductive protection

%onnect t$e 9,Is to t$e %ontrol Board

+ay out the 8 5 %s on two colu ns o" 4, ne)t to each other, starting with 5 %1 on the botto le"t endding with 5 % 8 at the top rightA

5 % 4 5 % 8

5 % F 5 % >

5 % 2 5 % =

5 % 1 5 % , and "ro there the &C power is spread to the other 5 %s 6e)cept5 % 17$ here is a bridge between the two colu ns on 5 % 2 and 5 % = with 2 2$< 2 solid corestraight wires and 8 s all lugs$

iring 5 % 1 with the '(CA

(older a 8 s all lug to each o" the 4 wires o" the '(C, then connect the blac! and red to thenegative and positive ter inals o" 5 %


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a!e each #C cord co ing with the 5 % bo), cut o"" the #C plug, strip the sheath on Fc , each cableon < , apply solder and screw it tightly into one o" the 5 % side ter inals 6respecting the wirescolors o" course7$

Connect the #C wires to the #C ter inals o" the Control 9oardG eutral 6 hite7 on eutral, 'arth65reen7 on 'arth, and +ine 69lac!7 on +ine$ ighten "ir ly$

-nce the connections are ade and tightened, loc! the cables in place, screwing the wooden loc!sdown, bloc!ing any ove ent$

*lace a piece o" tape on the other side 6where it plugs at the bac! o" the 5 %7, and ar! the nu ber o"the 5 % on it 61 to 87$

*lug all the #C cords in the bac! o" all the 5 %s starting with 5 % 1 at the botto le"t, and "inishing with5 % 8 at the top right o" the 2 colu ns$ 3se the labels on each cord to !now which cord goes where$

%onnect t$e %$argers to t$e %ontrol Board

or each charger, cut o"" the &C plug 6"e ale one7, strip the sheath on 10c , and the wires on 1c

each$ 9e"ore anything, chec! the voltage using a volt eter and plugging in the #C side to a!e surenothing changed since % used then$

ar! the 9lue wire with a piece o" red tape as the *ositive one$ (older this wire into an 8 s all lug$(older the 9rown wire 6 egative7 into an = s all lug$

-nce this is done "or each charger, put all the 9lue, ar!ed red, wires on the Charger (ide Nilovac,spread the to a!e sure all the lugs are in good contact with each other, add the washer, loc!washer, nut, and tighten "ir ly$



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or the egative side, all the lugs o" the 9rown wires have to be ounted on the egative bolt that isgoing through the Control 9oardA (tart with a washer, put F "irst chargers leads lugs, then the = lugend o" the 1 long 10 2 cable, then the other F on top, this way the current split will be eBuala ong the , spreading the li!e on the *ositive side to a!e sure all the lugs are in good contactwith each other$ inish with a washer and 2 nuts, screwing the "irst one tightly , then the second oneon top o" the "irst one, tightly too, to loc! the "irst one in place$

-nce all the &C cables are positioned, loc! the in place using the wooden loc!s screwed into the le"tside o" the Control 9oard$

or the #C cord, cut o"" the #C plug, strip the sheath on Fc , the wires on < , apply solder ontothe $

Connect the #C wires to the Charger (ide #C ter inals o" the Control 9oardG eutral 69lue7 oneutral, +ine 69rown7 on +ine, there is not 'arth on this all plastic casing chargers$ ighten "ir ly$



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You can put 2 chargers on one ter inal to charge "aster, but never on Charger 1 ter inal, because itis used to regulate up and down the charge level ore precisely$

-nce the connections are ade and tightened, loc! the cables in place, screwing the wooden loc!sdown, bloc!ing any ove ent$

+ay out the chargers on 2 stac!s o" F, or ore i" you added ore to charge "aster$

he Control 9oard and '(( is now ready to be tested$

-nce everything is ounted, it should loo! li!e thisA

,ake time to test t$e newl" !uilt s"stem o-er se-eral weeks to make sure e-er"t$ing works ase


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Dis+la" Pr o gram log and c$ange , $res$old V alues in t$e EEP0O* 7O+tional:

%" things are not wor!ing the way you would li!e to, and you need to see what is going on in theprogra loaded into the #rduino boardA

Connect the #rduino +eonardo to the co puter$

&ownload #rduino s latest %&' "ro their website www$arduino$cc , download section$

hen launch the (erial onitor and you should see a new window opening and displaying the progralog, with all the values and the changes detected, actions triggered, etc

Co unication between the ac and the #rduino 9oard set up A; ools / Card ype M #rduino +eonardo; ools / (erial *ort M irst in the list 63(9 ode "or ac, co "or *C7

*rogra log displayed in the (eries onitor o" the #rduino %&'A

http://www.arduino.cc/http://www.arduino.cc/http://4.bp.blogspot.com/-D4CSdrc1PeU/Ue_oht3MTwI/AAAAAAAAdO8/WnXNMBGbvSw/s1600/photo%2B2-725922.JPGhttp://2.bp.blogspot.com/-u1QEIeBY1Jo/Ue_ohGa8pkI/AAAAAAAAdO0/z_U7EoPWd_A/s1600/photo%2B1-723725.JPGhttp://www.arduino.cc/


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he ''* - 6 ead -nly e ory7 o" the #rduino board has been initiali@ed with 2 threshold valuesAg4$=8 E 'nter A %nput green thresholdr4$>2 E 'nter A %nput red threshold

save E 'nter A (aves threshold values into the ''* -

con"ig E 'nter A eads the stored values "ro the ''* -

You can change these values, and test the '(( with new valuesG

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(ave the i" they wor! "or you and also a!e sure you test the also without the 3(9 cableconnected the #rduino board because it is providing < to the board also and ight change the

attson readings a little bit, so test using the '(( nor al power supply be"ore you validate anything$

9A %" you do not save, and restart the board, the newly input values in the ''* - will be lost$ ypecon"ig E 'nter to read the $

-" course you can always go bac! to the original values by inputing their values above, and save$

,$e *etal %a!inet

hen everything has been wor!ing well "or several days or wee!s, get an %N'# *( etal Cabinet$ %chose it because it is not e)pensive, should e)ist al ost everywhere, is pretty durable, loc!s and loo!scool$ %nside, you can put our


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5et a grid "or 12c "an and ount it on the e)terior to protect people "ro the "an blades$

o power the "an, solder blac! and red wires to the Control 9oard ain switch output and the &C;&Cconverter negative input, this way the "an will spin only when the '(( is - $

he speed can be reduced by adding a * !it allowing potentio eter controlled "an speed or bysi ply adding at 24 to 12 &C;&C converter on the line$

*o-ing t$e ESS into t$e *etal %a!inet

(witch - the entire '((A ain switch, &C brea!er, #C brea!ers$

3nplug the #C cords "ro the bac! o" the 5 %s, unplug the attson 3(9 port, disconnect the &Cbales "ro the battery pac! and disasse ble it in pieces o" 2 cells 6otherwise too heavy to ove7$

hen position all the '(( co ponents in the cabinetA Control 9oard on the botto le"t, Chargers onthe le"t part o" the shel", 5 %s on the right part, battery pac! in the iddle on the botto right$ *ass theChargers and 5 %s #C and &C wires behind the shel", place the '(C on the very right o" the shel",up"ront$

e;connect all the co ponents li!e they were be"ore, and test a"ter switching all bac! - $

a!e sur you leave the le"t side botto air vent open 6big hole7 by not pushing the Control 9oard too"ar$

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-nce closed, with attson on top, it loo!s neat D clean and can be placed anywhere in your house orapart ent, the "an is Buiet and the sounds o" the chargers and 5 %s are trapped inside the cabinet$

lifepo4 diy ess - kit building documentation

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