Installation instructions
TS series
Installation instructions
TESVOLT TS series
incl. connection of the TS Series to SMA products
www.tesvolt.com
1
TS25TS40TS50
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Table of Contents
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1
2
2.1
2.2
3
4
5
6
7
8
8.1
8.1.1
8.1.2
8.2
8.2.1
8.2.2
8.2.3
9
10
11
11.1
11.2
12
13
14
15
16
17
18
About this document
Safety
Qualification of the technical specialists
Safty information
Needed tools
Transport at end-customer site
Installation location
Scope of delivery
Data sheet
Installation overview
Charge control
System without backup power function
System with backup power supply
Battery storage
Installation diagram TESVOLT TS
APU-Unit connections
Installation steps
Commissioning
Decommissioning
Storage system expansion
Power expansion by SMA battery inverter
Energy expansion by TESVOLT storage system
Remote monitoring via Sunny Portal
Menu structure of Batterie Monitoring (BatMon)
Battery system error and warning messages
Maintenance and storage
Guidelines for Handling Lithium-Batteries
Disposal
Contact
3
4
4
4
5
6
6
7
8
8
9
15
26
26
27
28
29
34
35
35
36
38
39
40
41
41
42
42
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6
Scope of validity:
This document applies to the following storage systems from TESVOLT GmbH:
TS system in connection with Sunny Island (48V)
Target groups: :
This document is intended exclusively for qualified technical specialists. The instructions and actions specified in this
document may only be carried out by appropriately qualified personnel.
The following battery inverters may be used:
Manufacturer
SMA Solar Technology AG
Useful Installation and planning information is available at the SMA website (www.sma.de). We recommend the following
documents.
Installation – Quick start – SMA FLEXIBLE STORAGE SYSTEM – Energy consumption optimisation
Installation – Quick start – SMA FLEXIBLE STORAGE SYSTEM – backup power supply function
Planning guideline – SMA FLEXIBLE STORAGE SYSTEM with backup power supply function
SMA, SUNNY ISLAND and SUNNYPORTAL are registered trademarks of SMA Solar Technology AG in many countries.
1 About this document
WARNING!
This document applies to storage systems from the TESVOLT company. It provides installation support for authorised
and qualified personnel.
It does not replace the complete instructions of the manufacturer SMA, and these must still be observed.
Type
Sunny Island 3.0M
SMA Solar Technology AGSunny Island 4.4M
SMA Solar Technology AG
Sunny Island 6.0H
SMA Solar Technology AG
Sunny Island 8.0H
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3
Explanation of used symbols:
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General warning
signs
Warning
electrical
tension
Warning
corrosive
substances
Warning
about striking
tension
General
information signs
See operating
instructions
IEC 60417- 5036/5416
Caution: Risk of electric
shock, auto-scheduled
dis cha rge of en ergy
storage system.
2.1 Qualification of the technical specialists
The instructions in this document may only be performed by appropriately qualified technical specialists. The technical specialists
must possess the following qualifications:
• Training in dealing with the hazards associated with the installation and operation of electrical equipment and batteries
• Training in the installation and commissioning of electrical equipment
• Knowledge of, and adherence to the locally applicable connection requirements, standards and directives
• Knowledge of the handling procedures and hazard sources associated with transporting, storing and disposing
of Lithium-Ion batteries
• Knowledge of, and adherence to this document and the associated product documentation, including all safety instructions
Participation in TESVOLT certification trainings
2.2 Safety information
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2 Safety
WARNING!
Lethal electric shock from damaged components or pole short-circuits:
Bridging the battery poles causes a short-circuit resulting in a large flow of electrical current. This short-circuit must be
avoided at all costs.
Use insulated tools
Never place tools or metal components on the battery
Always remove watches, rings and all other metal jewellery when working on the batteries
Never install or operate the battery pack in potentially explosive environments or areas
with relatively high humidity levels
Always first switch off the charge controller and then switch off all voltage supplies to the battery
before commencing work on the storage system
4
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WARNING!
Acid burns and poisoning from the battery electrolyte or poisonous gases:
Electrolyte or poisonous gases cannot escape from the battery pack under normal operating conditions. Despite careful
design and manufacture, damage to the battery pack resulting from fault can result in escaping electrolyte or low
concentrations of poisonous gases, organic solvent gases and hydrogen fluoride acids.
Store the batterypack in a dry place and within the temperature range specified in the data sheet.
Do not allow the battery pack to fall down
Do not open the battery pack
Never install or operate the battery pack in potentially explosive
environments or areas with relatively high humidity levels
In the case of contact with electrolyte, immediately wash the affected
area with water and seek medical advice
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3 Needed tools
5
Needed Tools
Description
Battery
13 mm attachment for the battery poles and APU connections
Torque wrench
For fixing the battery modules and APU in the battery cabinet
Cross-head screwdriver
Optional: For removing the cover of the battery rack
8 mm hex key
Optional: For moving the cable entry on the cover
of the battery rack
TX 25 Torx screwdriver
Optional: For removing the side panels of the battery rack
TX 30 Torx screwdriver
For connecting the control and measuring cables
to the Sunny Island terminal
Slot-head screwdriver
Sunny Island
For mounting the Sunny Island wall bracket
Power drill and drill bits
For removing the cover of the Sunny Island
5 mm hex key
For crimping the lugs of the DC cable
50 to 120 sq. mm crimping pliers
For crimping the wire end ferrules
Ferrule crimper
For measuring the grid and battery voltage
Voltage measuring device
Battery+
Sunny Island
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The delivered goods must always be checked for completeness and visible signs of damage.
6 Scope of delivery
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Position
A
Description
Battery module incl. ABO
BAPU incl. Cable connection set APU to 1st Battery module
CInstallation instructions
D48 V Cable connection set (included 2x Copper bars,, 1x Patch cabel, 2x Rack Balancing Plug)
ETS 25, 40 or 50 Rack
FOptional: Cable connection set to Sunny Island
6
The battery cabinet functions in temperatures from 0°C to 40°C and at a maximum humidity of 70%. Rooms that do not provide
these conditions must be air-conditioned. The battery cabinet may not be exposed to corrosive atmospheres. If the battery
cabinet is to be used in coastal areas or on farms, appropriate structural modifications to the installation room must be made to
ensure hazard-free operation of the storage system.
In regions subject to flooding, care must be taken to ensure that the battery cabinet is installed in a suitably elevated location
that cannot be reached by flood water.
The battery cabinet must not be exposed to direct sunlight. It should also not be placed in the direct vicinity of heat sources,
such as an oven or a fireplace.
The storage system must be set up in a fire-proof room that is free of fire loads and is separated by a class F30 fire door.
5 Installation location
The individual components of the TS series can weigh up to 120 kg and therefore should not be transported by a single person. It is
recommended that the system is installed by at least two people. The assistance of a hand truck is helpful. No more than 5 battery
modules should be stored on top of one another.
WARNING!
Battery modules are heavy, please ensure safe installation. Use suitable means of transport only!
RIGHTWRONG
4 Transport at end-customer site
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7 Technical data sheet
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OFF-GRID OR ON-GRID
8.1 Charge controlling
8
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8 Installation Overview
Figure: Block circuit diagram (example with backup power function, single phase)
Components
Function
Sunny Island
Battery inverter
Remote Control
Sunny Island display
TESVOLT TS
Battery cabinet
Home Manager
Transmits readings from the storage system and PV installation to the Sunny Portal
and is responsible for energy management, e.g. by controlling outlets
Energy Meter
Load meter for determining consumption or feed-in (integrated in the Home Manager 2.0)
Router
Connects the individual network participants
Grid disconnection
Disconnects the storage system from the public grid when the emergency power function
is activated in order to prevent energy from being fed back into the grid
Phase coupling
In single-phase storage systems, all three outer conductors are bridged and thus
supplied with power. However, phase-shifted alternating current is not provided.
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Figure 2: Wiring of SMAFlexible Storage System for TN and TT systems with 1 Sunny Island
8.1.1 System without backup power function
System with 1 Sunny Island
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Sunny Island connection
10
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11
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Position
A
Description/Note
Description
AC power cable
Connection AC2 Gen/Grid Terminals L, NTT and PE
Connection to the public mains grid via a 3-core cable
Conductor cross-section: 6 mm² … 16 mm²
B
Protective earthing
conductors
Connection AC1 Loads/SunnyBoys Terminal PE
Additional earth when the conductor cross-section of the AC power cable
is less than 10 mm². The conductor cross-section must be at least the
same as the conductor cross-section of the AC power cable.
Battery connection:
Conductor cross-section: 50 mm² ... 120 mm²
Cable diameter: 14 mm ... 25 mm
Tightening torque: 12 Nm
cabel DC –
cabel DC +
E
C
D
Battery temperature sensor
measuring cable
Connection BatTmp
Only Lead-acid batteries require connection of a battery temperature
sensor. The battery temperature sensor must be mounted in the middle of
the battery array, in the upper third of the battery cell.
F
Sunny Remote Control
data cable
Connection Display
G
Speedwire network cable
Connection ComETH
The Speedwire data module (SWDMSI-NR 10) must be installed in the
Sunny Island in order to connect the router/switch (see Installation
instructions for the Speedwire data module SWDMSI-NR 10).
The ComETH connection is located on the data module.
H
Data cable to Lithium-Ion
battery
ComSync In connection
Connection for the Lithium Ion Battery Management System
The communication bus must be connected to the
Lithium-Ion battery and the termination resistor must be
plugged into the ComSync Out connection.
SMA, SUNNY ISLAND and SUNNYPORTAL are registered trademarks of SMA Solar Technology AG in many countries.
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System with3 Sunny Islands
Figure 3: SMA Flexible Storage System for TN and TT systems with 3 Sunny Islands
12
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SMA, SUNNY ISLAND and SUNNYPORTAL are registered trademarks of SMA Solar Technology AG in many countries.
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Master connection
13
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Position
A
Description/Note
Description
AC power cable
Connection AC2 Gen/Grid Terminals L, NTT and PE Connection to the public
mains grid via a 3-core cable to external conductor L1
Conductor cross-section: 6 mm² … 16 mm²
B
Protective earthing
conductor
Connection AC1 Loads/SunnyBoys Terminal PE
Additional earth when the conductor cross-section of the AC-power cable
is less than 10 mm². The conductor cross-section must be at least the
same as the conductor cross-section of the AC power cable.
Battery connection
Conductor cross-section: 50 mm² … 120 mm²
Cable diameter: 14 mm … 25 mm
Tightening torque: 12 Nm
cabel DC –
cabel DC +
E
C
D
Battery temperature sensor
measuring cable
Connection BatTmp
Only Lead-acid batteries require connection of a battery temperature
sensor. The battery temperature sensor must be mounted in the middle
of the battery array, in the upper third of the battery cell.
F
Sunny Remote Control
data cable
Connection Display
+
_
+
_
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Slave 1 and Slave 2 connection
+
_
+
_
G
Speedwire network cable
Connection ComETH
The Speedwire data module (SWDMSI-NR 10) with the ComETH connection
must be installed in the Sunny Island in order to connect the router/switch
(see Installation instructions for the Speedwire data module
SWDMSI-NR 10).
H
Data cable to Lithium-Ion
battery
ComSync In connection
Connection for the Lithium Ion Battery Management System. The
communication bus must be connected to the Lithium-Ion battery.
If Lithium-Ion batteries are not used, plug the termination resistor into
the ComSync In connection.
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I
Data cable for internal
communication within the
Cluster
ComSync Out connection
Internal communication bus connection from Slave 1
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During a main grid failure, a backup power supply system with a Sunny Island provides consumers with energy and a grid-
connected PV system with voltage. In the case of a grid failure a switching unit disconnects the backup power supply grid from
the public mains grid. After disconnection the electrical consumers and the PV system are usually not supplied for 3 to 5
seconds. After this, the storage system can once more supply effective power and reactive power. The storage system supplies
the consumers with energy, the PV system can synchronise with the backup power supply grid and generate energy again.
When the public mains grid is once more available, the backup power supply system synchronises the backup power supply
grid to the public mains grid. After successful synchronisation the switching unit switches the backup power supply grid to the
public mains grid.
When the switching unit is connected to the public mains grid the backup power supply system uses the battery for energy
consumption optimisation.
You can install and wire up your own switching unit or obtain a pre-wired unit from TESVOLT.
15
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Position
A
Description/Note
Description
AC power cable
Connection AC2 Gen/Grid Terminals L, NTT and PE,connection to the public
mains grid via a 3-core cable Connect Slave 1 to external conductor L2,
Slave 2 to external conductor L3. Conductor cross-section: 6 mm² ... 16 mm²
B
Protective earthing
conductor
Connection AC1 Loads/SunnyBoys Terminal PE
Additional earth when the conductor cross-section of the AC power cable is
less than 10 mm². The conductor cross-section must be at least the same
as the conductor cross-section of the AC power cable.
Battery connection
Conductor cross-section: 50 mm² ... 120 mm²
Cable diameter: 14 mm ... 25 mm
Tightening torque: 12 Nm
cabel DC –
cabel DC +
E
C
D
F
Data cable for internal
communication within the
Cluster
ComSync In connection
For Slave 1: Internal communication bus connection from the Master
For Slave 2: Internal communication bus connection from Slave 1
Data cable for internal
communication within the
Cluster
ComSync Out connection
For Slave 1: Internal communication bus connection to Slave 2
For Slave 2: Leave the termination resistor plugged in.
Slave 2 is only connected to Slave 1.
8.1.2 System with backup power supply
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IMPORTANT!
In order to continue operation of the PV system during backup power supply operation, care must be taken to ensure
that the inverter topology matches the backup power supply grid.
Accordingly, only single phase inverters should be used in a single phase backup power supply system because the
backup power supply does not implement phase shifting.
True 3-phase power is provided in a system with 3 Sunny Islands so that 3-phase PV inverters can also generate energy
under backup power.
INFORMATION
Connecting consumers and the PV system:
The switching unit is not a distribution system for the consumers or the PV system. You must install all necessary
additional protective devices for the consumers and the PV system.
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Single phase backup power supply system
Figure 4: Circuit diagram of a single phase switching unit with all-pole disconnection
17
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SMA, SUNNY ISLAND and SUNNYPORTAL are registered trademarks of SMA Solar Technology AG in many countries.
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Backup power supply system with 1 Sunny Island
Figure 5: Interconnection overview: Connection of the single phase switching unit with all-terminal disconnection (e.g. for Germany)
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SMA, SUNNY ISLAND and SUNNYPORTAL are registered trademarks of SMA Solar Technology AG in many countries
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Sunny Island inverter connection
+
_
+
_
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Position
A
Description/Note
Description
B
Battery connection
Conductor cross-section: 50 mm² ... 120 mm²
Cable diameter: 14 mm ... 25 mm
Tightening torque: 12 Nm
cabel DC –
cabel DC +
D
E
Cable for the control voltage
AC power cable
Sunny Island: Connection AC1 Loads/SunnyBoys Terminals
L and N, switching device: Connection X5 Terminals L and
N , conductor cross-section: 2.5 mm² ... 16 mm²
Sunny Island: Connection AC2 Gen/Grid Terminals L, NTT
and PE , switching device: Connection X3 Terminals L1, N
and PE, conductor cross-section: 10 mm² ... 16 mm²
C
Measuring cable for voltage
measurement
Sunny Island: Connection ExtVtg Terminals L and N,
switching device:: Connection X4 Terminals L1 and N,
conductor cross-section: 1.5 mm² ... 2.5 mm²
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F
G
Battery temperature sensor
measuring cable
Control cable for the
tie-breaker
Sunny Island: Connection Relay1 Terminals C and NC, switching device:
Connection X4 Terminals 1 and 2
The contactor of the coupling switch engages when the multifunction
relay engages. Conductor cross-section: 1.5 mm² ... 2.5 mm²
H
Control cable for contactors
Q4 and Q6
Sunny Island: Connection Relay2 Terminals C and NO
Switching device: Connection X5 Terminals 1 and 2
The contactor engages when the multifunction relay engages.
Conductor cross-section: 1.5 mm² ... 2.5 mm²
I
Measuring cable for
monitoring the tie-breaker
Sunny Island: Connections DigIn+ and BatVtgOut+
Switching device: Connection X5 Terminals 3 and 4
Use a separate cable as the measuring cable for monitoring the
tie-breaker. This prevents interference in the transmission of signals.
Conductor cross-section: 0.2 mm² ... 2.5 mm²
Connect the DigIn − and BatVtgOut − connections within
the Sunny Island inverter.
Sunny Island: Connection BatTmp
Only Lead-acid batteries require connection of a battery temperature
sensor.The battery temperature sensor must be mounted in the middle
of the battery array, in the upper third of the battery cell.
K
Sunny Remote Control data
cable
Sunny Island: Connection Display
L
Speedwire network cable
Sunny Island: Connection ComETH
The Speedwire data module (SWDMSI-NR 10) must be installed in the
Sunny Island in order to connect the router/switch (see Installation
instructions for the Speedwire data module SWDMSI-NR 10). The ComETH
connection is located on the data module.
M
Battery management data
cable
Sunny Island: ComSync In
Batterie: CAN SMA
SMA, SUNNY ISLAND and SUNNYPORTAL are registered trademarks of SMA Solar Technology AG in many countries
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3-phase backup power supply system
Figure 6: Circuit diagram of the 3-phase switching unit with all-terminal disconnection
21
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SMA, SUNNY ISLAND and SUNNYPORTAL are registered trademarks of SMA Solar Technology AG in many countries
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Backup power supply system with 3 Sunny Islands
Figure 7: Interconnection overview: Connection of the 3-phase switching unit with all-terminal disconnection (e.g. for Germany)
22
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SMA, SUNNY ISLAND and SUNNYPORTAL are registered trademarks of SMA Solar Technology AG in many countries
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Master connection
+
_
+
_
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Position
A
Description/Note
Description
B
Battery connection
Conductor cross-section: 50 mm² ... 120 mm²
Cable diameter: 14 mm ... 25 mm
Tightening torque: 12 Nm
cabel DC –
cabel DC +
D
E
Cable for the control voltage
AC power cable
Sunny Island: Connection AC1 Loads/SunnyBoys connection, L and N
Switching device: Connection X5 Terminals L and N,
conductor cross-section: 2.5 mm² ... 16 mm²
Sunny Island: Connection AC2 Gen/Grid Terminals L,
NTT and PE, switching device: Connection X3 Terminals
L1, N and PE , conductor cross-section: 10 mm² ... 16 mm²
C
Measuring cable for voltage
measurement
Sunny Island: Connection ExtVtg Terminals L and N,
switching device:: Connection X4 Terminals L1 and N,
conductor cross-section: 1.5 mm² ... 2.5 mm²
F
Battery temperature sensor
measuring cable
Sunny Island: Connection BatTmp
Only Lead-acid batteries require connection of a battery temperature
sensor. The battery temperature sensor must be mounted in the
middle of the battery array, in the upper third of the battery cell.
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24
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G
Control cable for the
tie-breaker
Sunny Island: Connection Relay1 Terminals C and NC, switching device:
Connection X4 Terminals 1 and 2. The contactor of the coupling switch
engages when the multifunction relay engages.
Conductor cross-section: 1.5 mm² ... 2.5 mm²
H
Control cable for contactors
Q4 and Q6
Sunny Island: Connection Relay2 Terminals C and NO, switching device:
Connection X5 Terminals 1 and 2, Contactor Q4 engages when the
multifunction relay engages.
Conductor cross-section: 1.5 mm² ... 2.5 mm²
I
Measuring cable for
monitoring the tie-breaker
Sunny Island: Switching unit connections DigIn+ and BatVtgOut+:
Connection X5 Terminals 3 and 4, Use a separate cable as the measuring
cable for monitoring the tie-breaker. This prevents interference in
the transmission of signals.
Conductor cross-section: 0.2 mm2 ... 2.5 mm2
Connect the DigIn − and BatVtgOut − connections within
the Sunny Island inverter.
K
Sunny Remote Control data
cable
Sunny Island: Connection Display
L
Speedwire network cable
Sunny Island: Connection ComETH
The Speedwire data module (SWDMSI-NR 10) must be installed in the
Sunny Island in order to connect the router/switch (see Installation
instructions for the Speedwire data module SWDMSI-NR 10).
The ComETH connection is located on the data module.
M
Battery management data
cable
Sunny Island: ComSync In
Batterie: CAN SMA
SMA, SUNNY ISLAND and SUNNYPORTAL are registered trademarks of SMA Solar Technology AG in many countries
N
Data cable for internal
communication within the
Cluster
Sunny Island: ComSync Out connection
Internal communication bus connection from Slave 1
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Connection Slave 1 und Slave 2
+
_
+
_
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Position
Description/Note
Description
A
Battery connection
Conductor cross-section: 50 mm² … 120 mm²
Cable diameter: 14 mm … 25 mm
Tightening torque: 12 Nm
cabel DC –
cabel DC +
C
D
AC power cable
Sunny Island: Connection AC2 Gen/Grid Terminals L, NTT and PE
Switching device: Connect Slave 1 to X3 Terminals L2, N and PE. Connect Slave 2
to X3 Terminals L3, N and PE. Conductor cross-section: 10 mm² … 16 mm²
B
Measuring cable for voltage
measurement
Sunny Island: Connection ExtVtg Terminals L and N
Switching device: Connect Slave 1 to X4 Terminals L2 and N. Connect Slave
2 to X4 Terminals L3 and N. Conductor cross-section: 1.5 mm² … 2.5 mm²
E
Data cable for internal
communication within the
Cluster
Sunny Island: ComSync In connection
For Slave 1: Internal communication bus connection from the Master
For Slave 2: Internal communication bus connection from Slave 1
F
Data cable for internal
communication within the
Cluster
Sunny Island: ComSync Out connection
For Slave 1: Internal communication bus connection to Slave 2
For Slave 2: Leave the termination resistor plugged in. Slave 2 is only
connected to Slave 1.
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8.2 Battery storage TESVOLT TS
The battery modules and the APU are delivered on pallets separate from the battery rack. The scope of delivery should be checked
against the delivery note and the requirements under point 4 “Transport at end-customer site” and point 5 “Installation location”
must be observed.
Always use insulated tools and gloves to provide protection against electric shock during installation.
8.2.1 Installation diagram TESVOLT TS
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INFORMATION
Enclosed documents: All battery cabinets come with installation instructions and a wiring plan for the
respective model.
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Samsung SDI Cell
8.2.2 Connections APU SMA SI
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WARNING!
Installation and servicing may only be performed by qualified personnel. Only authorised TESVOLT GmbH personnel are permitted to open
the APU-Unit. Improper use or incorrect configuration may damage the APU-Unit.
Labeling
Charger +
Description
DC connection for the positive pole of the Sunny Island
Charger -
DC connection for the negative pole of the Sunny Island
Battery +
DC connection for the positive pole of the 1st battery module
Battery -
DC connection for the negative pole of the 1st battery module
Switch
On/off switch for the battery
E-Stop
Two-pin plug for the optional connection of an emergency off switch.
APU Fuse (F1)
Fuse element to protect the APU
CAN SMA
CAN port for communication between the battery and the Sunny Island.
Connection to the Sunny Island (master) ComSyncIn (single-cluster) or connection
to the Sunny Island (slave 2) ComSyncOut (multi-cluster)
LAN
When connecting to an existing network with DHCP, the battery
can be monitored using BatMon. The master/slave communication occurs
over the LAN connection.
Address
Rotary switch for adjusting the battery’s master/slave connections.
Further information can be found under point 11.1
BAT COM
Communication link to the battery module. Connect the BAT COM of the APU
to the BAT COM IN of the first battery module.
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8.2.3 Installation steps
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Step
1
Description/Note
Position the battery cabinet in the installation location, taking into account the requirements listed under point 5
2
Open the door to the battery cabinet using the included control cabinet key, which can be found
on the outside of the door.
3
Mount the APU on the upper slide rail and use screws to fix it in place at the four fastening points.
The two-pin plug for the e-stop connection to the APU must be plugged in upon delivery.
Until this is plugged in, the APU remains inactive.
4
Mount the battery modules in the slide rails provided – starting from the top to the bottom
5
Remove the side cover of the battery module’s ABO and carefully break out the area for the copper rails
along the pre-determined breaking points
6
Connect the DC copper rails, always bearing in mind that in the 48V variant, the positive pole must touch the
positive pole and the negative pole must touch the negative pole. Tighten the 13mm screws using 12nm of torque.
7
Reattach the side covers of the ABO to the battery module.
8
Lay the communication cable for the BAT COM using the included patch cable. Start by running the cable
from the APU (BAT COM) to the BAT COM IN of the battery module installed below the APU. From there,
run the cable from the BAT COM OUT to the BAT COM IN of the next module, etc.
9
Plug in the rack balancing plugs. The plug with an internal bridge from 1 to 4 is plugged into Rack Balancing In.
The plug with an internal bridge from 1 to 2 is plugged into Rack Balancing Out.
10
Connect the DC cable from the Sunny Island to the APU (CHARGER). If you do not use pre-assembled cables
from TESVOLT, it is important that an earth leakage and short-circuit protected cable (such as NSGAFöU)
be used.
11
Connect the communication cable from the Sunny Island (ComSyncIn) to the APU (CAN SMA)
WARNING!
Installation and servicing may only be performed by qualified personnel. Only authorised TESVOLT personnel are
permitted to open the APU-Unit. Improper use or incorrect configuration may damage the APU-Unit.
Opening the APU voids the warranty.
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9 Commissioning
Prerequisites:
The SMA Flexible Storage system must be installed according to the interconnection diagram specified by SMA
The Sunny Island power circuit breaker in the distribution system must be open
In a 3-phase system, the Sunny Remote Control must be connected to the Master
Procedure:
Check the wiring of the SMA and battery. See the Sunny Island Installation Instructions from SMA
Close all components. This protects all live components from accidental contact.
Close the DC fuse in the BAT BREAKER (if used).
Tap the screen on the battery to activate the display. The number of recognized battery modules will be displayed on the
screen. If this is correct, confirm by tapping twice. Otherwise check the BAT COM cabling.
Once the number of battery modules has been confirmed, the light on the switch will begin to flash. The batteries are now in
pre-charge mode (PRECHG). Once pre-charging has completed, the light on the switch will remain on. On the battery display,
the status will be indicated as OK. Now the battery is ready for use.
For systems with one Sunny Island, press the power button.
For systems with three Sunny Islands, press and hold the power button on the master until you hear a signal tone.
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WARNING!
Battery damage many owner due to incorrect configuration. The parameter settings influence the charging behaviour
of the Sunny Islands. It is therefore important to make the correct settings before commissioning the system.
online
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When the Sunny Remote Control (SRC) shows <Init System>, press and hold the button
on the SRC.
An audio signal tone is emitted 3 times and the SRC shows the "Quick Configuration Guide" (QCG).
Turn the button on the SRC and select New System.
Press the button. This selects the New System entry.
Set Y and press the button.
Set the Date.
Set the Time.
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Set OnGrid
Set the battery type to LiIon_Ext-BMS
Set the Battery capacity (see storage system data sheet).
Set the Country data record
(only possible within the first 10 operating hours).
Set the operating mode: SelfConsOnly (self-consumption optimisation only), BackupOnly (backup power supply only),
SelfConsBackup (self-consumption optimisation with backup power supply function).
Set the Number of Sunny Islands in the system.
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1 Battery module
2 Battery modules
3 Battery modules
4 Battery modules
5 Battery modules
7 Battery modules
8 Battery modules
9 Battery modules
10 Battery modules
11 Battery modules
12 Battery modules
13 Battery modules
14 Battery modules
15 Battery modules
16 Battery modules
Single Phase: System with one Sunny Island3 Phase: System with three Sunny Islands
Asymmetric: One PV inverter feeds
single-phase. Set the phase that is
connected to the Sunny Island.
Symmetric: Either the installation location
is outside Germany or all PV inverters
symmetrically feed 3-phases.
Confirm the initial configuration with Y.
Confirm the initial configuration with Y.
Wait until the upper LED on Slave 1 flashes
and the SRC displays To identify Slave 1
press TSS on the Slv. Press the Start-Stop
button on Slave 1.
Press the Start-Stop button on Slave 1.
Wait until the upper LED on Slave 2 flashes
and the SRC displays To identify Slave 2
press TSS on the Slv.
Press the Start-Stop button on Slave 2.
Initial configuration is now completed.
The SRC displays Do not remove MMC/SD card.
In the distribution system, close the power circuit breaker and residual current circuit
breaker of the Sunny Island and leave the Sunny Island switched on but do not restart it.
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SMA, SUNNY ISLAND and SUNNYPORTAL are registered trademarks of SMA Solar Technology AG in many countries
E.IA..ENG-TSA.6
After commissioning using the QCG "Quick Configuration Guide", the following parameter settings must be checked using the
Remote Control. You must switch to the Expert mode in order to set these parameters. To do this, turn the rotary knob clockwise
until reaching the Password menu item, then confirm with Set and enter the digit summation of the Runtime (operating hours)
value.
Digit summation example: Runtime 1.234 h 1+2+3+4=10 digit summation = 10
The following settings must be made in the 700.01 ActLev parameter menu in the Expert mode.
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WARNING!
Only qualified technical specialists are permitted to set system parameters, otherwise incorrectly set parameter
values can result in system failures.
Number und DescriptionParameters
261.03 Saisonenable
The battery is discharged to a lesser extent
during seasons with less sunlight
No (deactivated) / Yes (activated)
Explanation
262.01 ProtResSOC
Area for deep discharge protection
3%
262.02 BatResSOC
Area for deep discharge protection
2% (own consumption only)
10% (backup power supply function)
262.03 BUResSOC
Area for emergency power function
0-90%
262.04 PVResSOC
Area to maintain the charge state
5%
262.05 MinSlfCsmpSOC
Area for self consumption optimization
on the shortest day of the year
0-90% recommendation of
80%, without Backup power supply)
100%
SMA, SUNNY ISLAND and SUNNYPORTAL are registered trademarks of SMA Solar Technology AG in many countries
E.IA..ENG-TSA.6
10 Decommissioning
1.
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WARNING!
Risk of electric shock, due to the auto-scheduled discharge of the energy storage
system. Please wait 15 minutes after switching off the storage system.
WARNING!
Remove the on/off switch plug from the BMS-Unit unit switch connector to
prevent the unit from being unintentionally switched on again! Apply the
supplied "REMOVE before commissioning" sticker to the APU-Unit unit switch
connector to prevent the unit from being unintentionally switched on again.
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Stop the Sunny Island (press and hold the
Start/Stop button on the Sunny Island until
the inverter LED lights up orange).
2.Switch off the Sunny Island (press and hold the
Switch-off button on the Sunny Island until an
audio signal tone is emitted).
3,Switch off the battery (press the green
illuminated pushbutton switch on the door of
the battery cabinet, the green LED must go
out).
REMOVE BEFORE
START OPERATION
11 Storage system expansion
The energy and the charge/discharge power of TESVOLT systems can be expanded.
11.1 Power expansion by SMA battery inverter
System with one Sunny Island (single-phase)
System with three Sunny Islands (3-phase)
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Max. 2,3 kW 1 x SI 3.0M
Max. 3,3 kW 1 x SI 4.4M
Max. 4,6 kW 1 x SI 6.0H
Charge/Discharge power per
Cluster
Charge/Discharge power per
Cluster
Max. 6,9 kW 3 x SI 3.0M
Max. 9,9 kW 3 x SI 4.4M
Max. 13,8 kW 3 x SI 6.0H
Max. 18,0 kW 3 x SI 8.0H
On-Grid expandable up to 4 clusters.
Max. 4,6 kW 1 x SI 8.0H
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The charging and discharging capacity can be increased by increasing the number of Sunny Islands. The number of Sunny Islands is
increased in steps of 3. 1, 3, 6, 9 and 12 Sunny Islands can be operated in grid-parallel mode.
If more than one Sunny Island is connected to the battery, a battery fuse unit (Bat breaker) must be connected between the Sunny
Islands and the battery. This distributes the power across the Sunny Islands via fuses. In a Cluster of three Sunny Islands, one Sunny
Island functions as the Master that controls the other two Sunny Islands functioning as Slaves.
11.2 Energy expansion by TESVOLT storage system
Battery capacity can be expanded in 4.8kWh increments as required. Each APU can control up to 16 battery modules. If the capacity per
cluster exceeds 76.8kWh, a further APU is required, which can control up to 16 additional battery modules. Up to 4 APUs per cluster may be
connected in parallel using the master/slave principle.
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IMPORTANT!
Up to 4 battery cabinets per
Cluster can be connected in
parallel using
the Master / Slave principle.
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Example with 2 different clusters:
Cluster 1: 3 x Sunny Island 6.0H (13,8 kW) with TS 40 Battery (up to 38,4 kWh)
Cluster 2: 3 x Sunny Island 8.0H (18,0 kW) with 4 x TS 40 Battery (up to 153,6 kWh)
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Up to four battery cabinets of the same type can be connected in parallel using the Master / Slave principle. Clusters with different
types of Sunny Islands can be used together. However, the same Sunny Island type must be used within a given Cluster.
Different batteries can also be connected to each Cluster.
12 Remote monitoring via Sunny Portal
The storage system data can be queried locally using the SMA Remote Control and also remotely via the Sunny Portal from SMA
(www.sunnyportal.com). Please observe the Portal operating instructions from SMA for this. This can be downloaded from
www.sma.de.
The System Setup Wizard at the Portal page (www.sunnyportal.com) must be executed in order to register a Home Manager system.
All further steps are described in detail on the website. You will need the information on the type plate of the Sunny Home Manager
for this.
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SMA, SUNNY ISLAND and SUNNYPORTAL are registered trademarks of SMA Solar Technology AG in many countries
E.IA..ENG-TSA.6
13 BMS Monitoring (BatMon) menu structure
The battery parameters are password
protected. Since these parameters directly
affect the battery, only TESVOLT certified
technical specialists are permitted to
configure these parameters. You can obtain
the password by directly requesting it from
TESVOLT GmbH.
The value indicates the percentage to which the battery has been charged. 100%
refers to a fully charged battery. SoCs above 100% may occur since the batteries
have higher capacities upon delivery. The BMS-Unit can use the measured
parameters to determine the state of charge of a single cell, or cell stack, and stop
the charging process if necessary. This prevents overcharging. The software
also has the same functions for monitoring the discharge process in order to
prevent unnecessary discharging of the cells. The system stops discharging of the
battery when a defined minimum state of charge is reached.
This value indicates the health of a cell. Precise monitoring allows the system to
detect pe rfor mance di ffer ence s betw een in dividual cel ls and th us
detectdamaged/defective cells. The system switches off if necessary and notifies
the Sunny Island.
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Battery
Output
Battery voltage
Battery temperature
Charge/Discharge
Cells
Balancingmode
Charging cycle (kWh)
SoC (state of charge)
SoH (Health)
Warning - Time
Cell temperature
Cell voltage
Serial Port
SoC (cell)
SoH (cell)
Events
Event Logbuch
Parameter
Battery
System
Current errors
Firmware Update
SOH – State of Health – Alterungszustand
SOC – State of Charge – Ladungszustand
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F929 / W945
Switch
Contactor
W 947
BMC internal
Faulty Internal Controller Restart the battery.
F933/W 949
Static Switch
Temperature High
Upper temperature limit
for Static Switch
Switch off the battery and allow it to cool down to at
least 25°C.
Event
Fault correction
Description
–
Storage system fails
to start
Check the functionality of the 4 A BMS Fuse (F1)
microfuse mounted on the front side of the BMS-Unit
and replace it if necessary.
W920 / W936
General
General errors in the
Battery
Restart the APU-Unit by actuating the On/Off pushbutton.
Check the Sunny Island parameter settings.
F921/W937 -
Battery
High Voltage
Overvoltage of a
single cell
F922/W938 -
Battery
Low Voltage
Undervoltage of a
single cell
The active battery management system equalises the cell voltages.
The battery undervoltage system allows detection of defective cells.
If dangerous voltages are reached then the battery system opens the
DC relay and safety disconnects from the Sunny Island. If the APU-Unit
shows lower voltages than are actually present at the batteries then
check the white fuses on the pole circuit boards. For this, please
measure the white fuse on each respective pole circuit board.
The supplied circuit diagram shows the location of each respective
cell in the cell block.
F924/W940
Battery
Low Temperature
Lower temperature
limit of a cell has been
reached
Switch off the battery and increase the ambient
temperature to min. 5°C.
F923/W939
Battery
High Temperature
Upper temperature
limit of a cell has been
reached
Switch off the battery and allow it to cool down to at least 25°C. Check
the screwed connection at the pole of the affected cell. If temperatures
of 195°C are displayed this indicates a defect in the cables or the pole
circuit boards. Please check the respective connections for loose contacts.
F925/W 941
Battery
High Temperature
Charge
Upper temperature limit
for charging the battery
has been reached
Switch off the battery and increase the ambient
temperature to min. 5°C.
F926/W 942
Battery
Low Temperature
Charge
Lower temperature limit
for charging the battery
has been reached
Switch off the battery and allow it to cool down to at
least 25°C. Check the screwed connection at the pole
of the affected cell.
F927/W943 -
Battery
High Current
Charging current
too high
Switch off the battery and check the battery parameters
and the Sunny Island parameters. Restart the battery.
F928/W944
Battery
High Current
Charge
Excessive charging
current when charging
the battery
Switch off the battery and check the battery parameters
and the Sunny Island parameters. Restart the battery.
Faulty DC contactorRestart the battery.
14 Battery system error and warning messages
In the case of persistent errors please contact the TESVOLT Service Line.
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15 Maintenance and storage
The Lithium-Ion cells used by TESVOLT are maintenance-free. However, to ensure hazard-free operation, qualified specialists
should check all connections and screws and tighten them where necessary since temperature fluctuations may loosen the screws.
Check the tightening torque of the following screws:
Battery pole: 12 Nm
APU connection"Battery" und "Charger": 12 Nm
DC Battery conenction Sunny Island: 12 Nm
Using the BatMon software, check the SoC, SoH, cell voltages and cell stack temperatures for irregularities.
Please use a mist-dampened cleaning cloth for cleaning the battery cabinet. Prevent any moisture from coming into contact with
the battery connections.
Clean the Sunny Island ventilator and remove dust from its casing and other components. Check the Sunny Island connections (AC1,
AC2, DC cables).
16 Information on handling lithium batteries
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WARNING!
Carry out 'Decommissioning' steps on page 34 before any maintenance work.
ACHTUNG!
Please consult SMA Sunny Island operating instructions for cleaning and maintenance of the SMA.
E.IA..ENG-TSA.6
Do not open, dismantle, drill through or drop battery cells
Do not expose battery cells to high temperatures
Do not throw battery cells into fire
Do not short-circuit battery cells
Do not expose battery cells to rain or immerse in liquids
Do not expose battery cells to corrosive atmospheres (e.g. ammonia, salt)
Do not use defect or damaged batteries
Do not use any charge controllers other than SMA Sunny Island
Use class D fire extinguishers (dry powder)
Commission storage systems within 6 months of delivery
17 Disposal
TESVOLT products are integrated in a free of charge disposal return
system. Please contact TESVOLT in this regard. The batteries may only
be disposed of in accordance with the disposal regulations for old
batteries applicable at the time of disposal.
Immediately take any damaged batteries out of service and first contact
your installer or sales partner before disposal.
Ensure that the battery is not subjected to moisture or direct
sunlight.Organise quick removal by your installer or TESVOLT.
Do not dispose in household waste!
18 Contact
We are happy to support you in all questions relating to warning signs or error messages. Please contact us and have the following
information ready:
Serial number of the TESVOLT product
The error or warning messages shown in the display
Contact data:
TESVOLT GmbH Am Alten Bahnhof 10 06886 Lutherstadt Wittenberg Germany
tel.: +49 (0) 3491 87 97 - 100 email: support@tesvolt.com
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WE HAVE A THEN
FOR ANY WHEN
TESVOLT GmbH
Am Alten Bahnhof 10
06886 Lutherstadt Wittenberg
Deutschland | Germany
Tel. +49 (0) 3491 8797 - 100
Email support@tesvolt.com
www.tesvolt.com
Your certified TESVOLT partner
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