All‑In‑One Energy Storage System

05Electrical Installation41Installation Requirements41Earthing the Cabinet43Cable Connections4406Commissioning66Start-Up and Shut-Down66Operating Status6807Maintenance and Troubleshooting78Maintenance78Fire-Protection System Inspection79Alarms and Troubleshooting8108Disposal and Support86Disposal86Technical Support86

Document

This manual covers the safety instructions, product description, transport, storage, installation, electrical connection, commissioning, maintenance and troubleshooting of the All-In-One energy storage system.

The All-In-One is manufactured by Solinteg. It combines a Solinteg E2BR outdoor air-cooled battery cabinet (the "cabinet" in this manual) with a Solinteg M2HT 25–50 kW hybrid inverter mounted on the side of the cabinet. The model (AIO-25K to AIO-50K) sets the inverter power, and the cabinet sets the storage capacity:

Who This Manual Is For

This manual is for licensed electrical workers who install, operate and maintain the cabinet. Anyone working on the cabinet must:

• understand electrical, cabling and mechanical work, and how battery energy storage systems operate
• be trained in installing and commissioning electrical equipment
• know the electrical standards and regulations that apply on site. In Australia these include AS/NZS 3000, AS/NZS 5139 and AS/NZS 4777.1
• hold the licences required in the state or territory where the work is done.

Only people who meet all of these requirements may install, maintain or troubleshoot the cabinet.

Safety Symbols

This manual uses the following symbols. Read and follow every instruction they mark.

Danger

Indicates a hazard with a high level of risk that, if not avoided, will result in death or serious injury.

Warning

Indicates a hazard with a medium level of risk that, if not avoided, could result in death or serious injury.

Notice

Indicates a hazard with a low level of risk that, if not avoided, could result in minor or moderate injury, or damage to equipment.

Note

Extra information to help you use the equipment efficiently. Notes are not safety warnings.

About This Edition

This manual is based on Solinteg's E2BR user manual. AERL has rewritten the text for clarity and adapted it for Australia. The product specifications are Solinteg's. Illustrations are for reference only and may differ from your product. The manual may be updated as the product changes. Download the latest edition from aerl.com.au.

Nothing in this manual excludes, restricts or modifies any right or remedy you have under the Australian Consumer Law.

1.1Warranty Exclusions

Before you transport, store, install, operate or maintain the equipment, read this manual carefully and follow it, the labels on the equipment and every safety instruction in this manual.

The manufacturer's warranty does not cover damage caused by:

• improper transport
• incorrect storage, installation or use
• installation or use by unqualified or untrained people
• failure to follow the instructions and safety warnings in this manual
• operation in an environment that does not meet the requirements of this manual
• operation outside the limits in the technical specifications
• unauthorised disassembly or modification of the product or its software
• unauthorised opening of the equipment covers, or removal or replacement of internal components
• abnormal natural events (force majeure), such as lightning, earthquake, fire or storm
• installation or operation that does not comply with local standards and regulations
• a product that is outside its warranty period.

1.2Personal Safety

To avoid injury, death or damage to the equipment, read these precautions before you start work.

• Only trained and licensed electrical workers may install the equipment.
• Remove watches, bracelets, rings, necklaces and other conductive items before you install or operate the equipment, to avoid burns from electric shock.
• Never work on the equipment while it is energised. Sparks and arcs from connecting or disconnecting live cables can cause fire or injury.
• Wear suitable personal protective equipment (PPE) during installation and operation.
• If you need a ladder, use a timber or insulated ladder.
• Before you operate the cabinet, make sure it is securely anchored. The cabinet has a high centre of gravity and can tip over, causing injury and damage.
• Some parts of the equipment can exceed 60 °C during operation. Keep away from vents, the cooling system and other hot surfaces.
• Install the equipment where children and animals cannot reach it.
• Do not use the backup supply of this equipment for:
  • life-support or other medical equipment
  • equipment or precision instruments that may malfunction or be damaged by a power failure or fluctuation.

1.3Electrical Safety

• Operate the equipment strictly in accordance with this manual.
• Make all electrical connections in accordance with local regulations. In Australia, comply with AS/NZS 3000, AS/NZS 5139, AS/NZS 4777.1 and the requirements of the local network service provider.
• Isolate the power supply before you install the equipment. Never work on live equipment.
• Connect the protective earth before anything else. When removing the equipment, disconnect the protective earth last.
• Select cables in accordance with local regulations and this manual.
• Connect cables securely and tighten terminal screws to the specified torque.
• A damaged cable must be replaced by a qualified person.
• Isolate the power supply before connecting power and communication cables.
• Do not open the internal covers of the cabinet. Except for the terminal wiring described in this manual, opening covers or replacing internal components may cause injury or damage and will void the warranty.
• Before working on the battery terminals, open the battery circuit breaker or isolator. The battery is at high voltage.

1.4Installation Requirements

• Before installation, check that all parts, tools and materials are present. After installation, count them again to make sure nothing has been left inside the equipment. Install every part (except optional parts) as this manual requires.
• Do not drill holes in the equipment. Drilling can damage it and affect its performance.
• Install the equipment in a well-ventilated area away from other heat sources, so the cooling system can work properly.
• Keep the vents and heat-dissipation paths clear at all times. Heat build-up can damage the equipment or cause a fire.
• Do not open the cabinet door in rain or high humidity. If you must, protect the inside of the cabinet from water.
• Never install or operate the equipment where there is flammable or explosive gas or smoke.
• Do not install the equipment in a low-lying area. Keep it away from drains, air-conditioner outlets, vents and anywhere water may leak, so that liquid cannot enter the equipment.

1.5Battery Safety

• Check battery polarity carefully. Never short-circuit the positive and negative terminals. A short circuit produces very high current and heat, and can cause leakage, smoke, flammable gas, thermal runaway, fire or explosion.
• Never work on the battery while it is energised.
• Never stand or lean on the battery, or allow people or equipment to press against it.
• Do not expose the battery to high temperature or humidity. Keep ventilation and heat dissipation unobstructed.
• Never disassemble, modify, shake, drop, strike, crush or puncture the battery, or subject it to pressure shock. Damage can cause leakage, smoke, flammable gas, thermal runaway, fire or explosion.
• Never weld, grind or do other hot work near the battery. Sparks or arcs can start a fire.
• Never mix battery models or brands.
• Never use second-hand or damaged batteries.
• Before working on the battery, check for any pungent or burning smell around it.
• Batteries must be handled and maintained only by qualified people wearing PPE (including goggles, rubber gloves, a respirator and protective clothing) in accordance with local requirements.
• A battery damaged by puncture, impact, crushing, external heat or overcharging can go into thermal runaway, leak, or release toxic and flammable gas. Take safety measures on site, in accordance with local requirements, to prevent fire, protect people and avoid damage.
• Install and commission the battery in accordance with local laws, regulations and standards, and provide fire-protection equipment.

• During storage and transport, keep the outer packaging intact. Place or stack batteries the right way up, as marked on the box. Never place them upside down, on their side, on end or tilted.
• Inspect the equipment regularly for loose connections, rust, corrosion and foreign objects, and fix any problem promptly. A loose screw connection causes a voltage drop that can overheat and burn the battery at high current.
• Recharge the battery promptly after it is discharged, to avoid damage from over-discharge. A battery stored for more than six months must be inspected and tested by a qualified person before use.
• Do not charge the battery when the ambient temperature is below the minimum operating temperature.
• If a battery is swollen or its case is dented or broken, stop using it immediately and contact the installer or a qualified service person to remove and replace it. Keep a damaged battery away from other equipment and from flammable and explosive materials, and keep unqualified people away.

2.1Product Overview

The All-In-One is a commercial energy storage system, manufactured by Solinteg. Its Solinteg E2BR cabinet combines a high-capacity battery, a high-voltage box, an electrical compartment and a fire-protection system. With the Solinteg M2HT hybrid inverter mounted on its side, it forms an outdoor energy storage system that is easy to install and expand. It suits a wide range of commercial and industrial applications.

2.2Dimensions

The cabinet alone measures 1050 × 2262 × 1140 mm (W × H × D). With the inverter fitted the system is 1376 mm wide, and with the rain shelter 1468 mm. The lifting eyes add 93 mm to the height (2355 mm).

2.3Components

* Mounting feet can be fitted on any of the four sides. Fit them on the left and right, or front and rear, to suit the site.

** The cabinet provides a mounting position for one inverter, which makes installation and wiring easier. In the illustrations, the inverter is mounted on the side of the cabinet.

2.3.1 Side cable panel

Note

The cabinet door key is stored here. Remove it after unpacking.

2.3.2 Cabinet base

2.3.3 Electrical compartment

2.3.4 Control power supply

2.3.5 High-voltage box

2.3.6 Battery pack

2.3.7 Air conditioner

Danger

Keep the air-conditioner drain line clear. Water pooling in the cabinet from a blocked drain can damage the unit. Do not change the air-conditioner controller settings. Incorrect settings can stop it controlling the cabinet temperature and humidity, and damage the batteries.

Note

Run the end of the drain hose out through the air-conditioner drain port. We recommend running it to a drain, so that water does not collect under the cabinet.

2.3.8 Fire-protection system

Notice

The door switch at the top right of the cabinet tells the high-voltage box when the door is open. Close the door when you finish work, to keep out moisture and small animals. The cabinet light switches on automatically when the door opens. Leave the light switch in its normal position. The light switches off 30 seconds after the door closes.

Battery pack protection. Each battery pack has its own aerosol extinguishing module. It discharges when a fire triggers its thermal fuse line (170 °C).

Cabinet protection. As standard, the cabinet also has a separate aerosol fire module with smoke and temperature detectors. The system automatically detects a fire, activates the extinguishing module and discharges the agent, reports the discharge to the BMS through a dry contact, and disconnects the main power circuit.

2.3.9 Inverter

The All-In-One inverter is a Solinteg M2HT 25–50 kW hybrid inverter. It is packed separately from the cabinet and mounted on the side of the cabinet during installation (section 4.2.3). The illustration below is for reference only. See the inverter manual for details.

2.4Electrical System

• In normal operation, the system supplies the loads.
• If the cabinet fails, you can isolate it and keep the loads supplied from the grid with the bypass switch.
• If both the PV and storage system and the grid fail, the UPS keeps the high-voltage box and the cabinet lighting powered for up to 2 hours. The UPS does not supply the site loads.

Bypass operation

In normal operation, leave the bypass switch in the left-hand (normal) position, as shown below.

If the grid is healthy but the cabinet has a fault, switch to bypass supply:

1. Switch off QF6-1 on the left of the bypass switch.
2. Slide the interlock in the middle to the left.
3. Switch on QF6-2 on the right of the bypass switch.

Note

In bypass, the cabinet cannot supply the loads and the inverter cannot start. The auxiliary circuits (high-voltage box, air conditioner, door switch and sockets) keep running.

3.1Unpacking

Notice

Inspect the outer packaging before you accept delivery. Unpack only if it is intact. If the packaging is damaged, contact your supplier immediately. The parts box is inside the cabinet. Open the cabinet door to remove it after unpacking. After unpacking, remove the decorative panels from around the cabinet and refit them as described in section 4.2.

You will need two adjustable spanners, a claw hammer, a flat-blade screwdriver, pliers, a ladder at least 1.5 m high, gloves and other PPE. The cabinet is more than 2 m tall, so use the controls required for working at height.

1. Use the screwdriver, pliers and claw hammer to lever up and straighten the clips on the top of the crate, then lift off the lid.
2. Lever up and straighten the clips around the crate, then remove the side panels. Have a second person hold the panels so the crate does not fall.
3. Open the front and rear cabinet doors. Use an adjustable spanner to remove the bolts that fix the cabinet to the pallet.

3.2Transport

Danger

Protect the equipment from water during transport, avoid impacts, and never transport it upside down. Damage can lead to fire or explosion. Before transport, check the packaging for damage, odour, leaks and other abnormalities. Never transport damaged goods: they may cause fire or explosion.

Notice

Follow the warning labels on the packaging and the cabinet, and all transport requirements. Secure the cabinet so it cannot tip during transport and handling. Keep the tilt angle at 10° or less. Choose a transport method that suits the equipment and protect it during transport. The cabinet contains lithium-ion batteries (Class 9 dangerous goods). The carrier must be licensed to carry dangerous goods and must comply with the regulations that apply. In Australia, this is the Australian Dangerous Goods Code.

3.2.1 Lifting

1. Lift in strict accordance with local laws. The crane operator and dogger or rigger must hold the required high risk work licences, and be trained and competent.
2. The lifting equipment must meet local regulations and be tested and certified. The crane must have a lifting capacity of at least 2 t and a working radius of at least 2 m. Fit the lifting eyes securely so they cannot loosen or come off.

3. Before lifting, check that:
   • the lifting gear is complete, certified and secure, and the slings are attached safely so they cannot slip or break
   • the operators are trained, licensed and competent
   • the cabinet doors are closed and locked and everything inside is secure, so nothing can fall out
   • the weather is suitable: no rain, snow or strong wind.
4. After unpacking, take the lifting eyes and rubber washers from the parts box. Remove the waterproof plugs from the mounting holes on top of the cabinet, and screw the lifting eyes and washers in firmly, as shown below. If you do not need the lifting eyes, leave the waterproof plugs in place so the holes do not clog or corrode.

3.2.2 Forklift handling

1. Use a forklift rated for at least 2 t. The operator must hold a forklift high risk work licence.
2. A competent spotter must supervise the move.
3. Allow for the cabinet's centre of gravity, and strap it to the forklift so it cannot tip.
4. Use the forklift pockets shown below.

3.3Storage

1. For long-term storage, leave the cabinet in its original packaging and inspect the packaging regularly.
2. Store the cabinet as instructed by the warning labels and markings on the packaging.
3. Storage temperature: −20 to 45 °C.
4. Storage humidity: 5–95% RH.

Choose the storage conditions to suit the storage time:

Notice

The batteries are installed in the cabinet, so the battery storage requirements also apply.

Danger

Store batteries indoors, in an area that is out of direct sun and rain, dry and ventilated, away from heat and ignition sources, free of radiation, chemically safe, free of dust and conductive metal dust, and equipped with fire-protection equipment. Store batteries as instructed by the warning labels on the packaging. Do not store them with other electronic equipment, chemicals or anything else that may cause interference or a hazard. Limit stacking height so the lower layers are not crushed or deformed.

Warning

Long-term storage of batteries is not recommended. If it cannot be avoided, recharge the batteries regularly to prevent damage. A battery stored for more than six months must be inspected and tested by a qualified person before use.

3.4Packing List

4.1Installation Requirements

4.1.1 Site

Choose a site that meets the product requirements, local fire codes, and the laws and regulations that apply.

• Comply with local laws and electricity industry standards and regulations.
• The site must meet local fire codes and have fire-fighting equipment and a fire-water connection point.
• Avoid unstable ground that may deform or settle, and areas with corrosive pollution such as salt or alkali.

4.1.2 Foundation

The cabinet weighs up to about 1440 kg (S112) and the inverter 89 kg. Design the foundation for at least 2 t, the local seismic code and the ground conditions, so that it can carry the cabinet and the people working on it. Build the foundation from concrete, solid brick, steel or a similar material. Compact and level the base: the level tolerance is 3 mm and the slope must not exceed 5°. The foundation must not sag or tilt.

Provide cable trenches or conduit entries in the foundation, and avoid buried services when you build it.

The drawings below are for reference only. Design and build the foundation to suit the site and local requirements.

4.1.3 Environment

1. Keep the separation from homes, public places and other buildings required by local fire codes and standards. If the separation cannot be achieved, build a fire wall between the cabinet and the neighbouring building as the local fire code requires. We recommend a locked fence around the installation to keep out unauthorised people.
2. Keep the site away from heat, flames and other high-temperature sources; flammable or explosive materials; dust; corrosive substances and gases; strong electromagnetic fields; and strong vibration or noise.
3. The site must drain well. Do not install the cabinet where water collects. Provide drainage and flood barriers to suit local weather.
4. The site must also meet these conditions:
   • ambient temperature: −20 to 50 °C (discharging −20 to 50 °C, charging 0 to 50 °C)
   • relative humidity: 5–95% RH
   • altitude: 3000 m or less.

4.1.4 Clearances

Keep the clearances shown below around the cabinet.

4.1.5 Tools

You need at least the tools below. Use other tools as the site requires. All tools must comply with local requirements.

4.2Mechanical Installation

Take the mounting hardware out of the cabinet and check it against the packing list before you start, so you are not held up by missing parts.

Danger

Do not install, wire or operate the equipment outdoors in lightning, rain, snow or other severe weather. Before drilling, digging or other construction work, locate and avoid buried pipes and cables. Wear the PPE required by regulations. Cover the equipment, and the components inside the cabinet, during installation so that debris cannot get in. Clean the equipment when installation is complete.

4.2.1 Installing the cabinet

1. Move the cabinet into position by crane (section 3.2.1) or forklift (section 3.2.2).
2. Fit the decorative panels around the cabinet with the 24 M5 × 10 countersunk screws from the parts box, as shown.

3. Take the four mounting feet, 12 M8 × 25 hex bolts and four M20 × 150 expansion anchors from the parts box. Choose front-and-rear or left-and-right mounting to suit the site, and mark out the holes as shown.

4. Drill the holes with a hammer drill: 25 mm diameter, 150 mm deep. Vacuum the holes clean.
5. Tap the M20 × 150 expansion anchors into the holes with a rubber mallet, and fix the feet to the ground. Do not tighten the anchors yet.
6. Bolt the feet to the cabinet with the M8 × 25 bolts, as shown. When all the bolts are in, tighten them evenly.

4.2.2 Installing the rain shelter

1. Take the rain shelter, five M6 × 16 bolts and waterproof washers from the parts box. Fit a washer on each bolt.
2. Bolt the rain shelter to the mounting area above the right-hand side of the cabinet, as shown.

4.2.3 Installing the inverter

1. Fix the inverter mounting bracket to the right-hand side of the cabinet with four M8 × 16 bolts from the parts box, as shown.
2. Lift the inverter with suitable equipment and hang it on the bracket.
3. Tighten the M6 screws on both sides to secure the inverter, as described in the inverter manual.

Notice

Read this manual before you start, so you understand all the installation requirements. Make sure the mechanical installation is complete and no parts or tools have been left in the cabinet. Check the seals on the cable entries before you start. Leave the waterproof plugs in unused cable entries. When installation is complete, seal the cable entries as local requirements specify.

5.1Installation Requirements

5.1.1 Tools

Wiring tools: wire strippers, side cutters, crimping tool, RJ45 crimping tool, multimeter (DC range above 1100 V), screwdrivers and hex keys.

5.1.2 Materials you supply

Supply the following materials, selected to the recommended specifications and the site conditions.

Note

If the cable is smaller than the recommended diameter, seal it with the gland sealing ring or the fire-stopping putty from the parts box.

5.2Earthing the Cabinet

Danger

Connect the cabinet earth first, as soon as the cabinet is installed. When removing the cabinet, disconnect the earth last. A faulty earth is a danger to people and equipment. Keep the cabinet earth in good condition during commissioning and operation.

1. Using two M8 × 16 hex bolts from the parts box (torque 8 N·m), connect the earth point on the right of the cabinet to the site earthing system with 40 × 4 mm hot-dip galvanised flat bar or 50 mm² PE cable, as shown.
2. Paint any cut ends of the flat bar with anti-corrosion paint.

5.3Cable Connections

Danger

Make sure every power switch is off before you connect any cable, to avoid injury and short circuits. Make sure the cabinet earth is reliably connected before you connect any cable. Failure to do so can cause injury or death. Secure every cable terminal so it cannot loosen over time. A loose terminal can damage the equipment.

Notice

The cables between the cabinet and the inverter are supplied, with one end already connected inside the cabinet. After unpacking, check the cables for damage, then connect the other ends to the inverter as described below.

5.3.1 Inverter wiring

Connect the cables as shown in the diagram below and as the inverter manual requires. When all the wiring is done, tighten the gland compression nuts on the side cable panel.

Inverter on-grid AC cable

Loosen the compression nuts of the glands on the side cable panel, as shown below. Pull the inverter on-grid and back-up cables out far enough to reach the inverter terminals.

1. The connector accepts cables of 22–40 mm outside diameter. Remove seal insert parts to suit the cable: above 24.5 mm remove part 1; above 28.5 mm also remove part 2; above 32.5 mm also remove part 3.
2. Thread the cable through the locknut, seal insert and housing, in that order.
3. Fit the lugs to L1, L2 and L3 in order, and tighten the screws to 3.8 ± 0.1 N·m.

4. Fit the insulating spacer into its hole in the connector insert.
5. Fit the insulating spacer at the N/PE end into its hole.
6. Fit the N and PE lugs, and tighten the screws to 3.8 ± 0.1 N·m.

7. Push the housing onto the connector insert, then tighten the Phillips screws.
8. Tighten the nut with an open-ended spanner to 10.0 ± 0.1 N·m.
9. Feed the excess cable back through the cable entry, then refit and tighten the gland compression nut.

Inverter back-up AC cable

Notice

Do not confuse the back-up connector with the generator connector.

1. If the cable is larger than 24 mm outside diameter, remove part 1 of the connector seal insert.
2. Strip 95–100 mm of the outer sheath, and 15 mm of insulation from each L1, L2, L3, N and PE core.
3. Thread the stripped cable through the locknut and housing, in that order. Fit bootlace ferrules to multi-strand copper cores.
4. Insert the cores into the connector insert, matching the markings. Tighten the terminal screws to 5 ± 0.1 N·m.
5. Push the housing onto the insert until it clicks, then tighten the nut with an open-ended spanner to 10.0 ± 0.1 N·m. It clicks three times when it is fully tightened.
6. Feed the excess cable back through the cable entry, then refit and tighten the gland compression nut.

Battery cables

Before connecting the battery, open the grid-side AC breaker and the battery-side breaker, and turn the inverter DC switch to OFF.

Note

Before connecting to the inverter, measure the battery terminal voltage with a multimeter. It must not exceed 840 V. Before connecting the battery terminals, check that the cable polarity is correct.

1. Loosen the compression nuts of the glands on the side cable panel, as shown below. Pull the battery cables out far enough to reach the inverter battery terminals.
2. Plug the positive and negative connectors into the inverter battery terminals. They click when they are fully engaged.
3. To unplug a connector, press its release button with a screwdriver, then pull it out.
4. Feed the excess cable back through the cable entry, then refit and tighten the gland compression nut.

Communication cable (BMS)

Note

Do not earth an unused communication cable or connect it to other equipment.

Notice

Use the inverter's BMS 1 port. The BMS 2 port is not used. All the inverter COM3 connections are RJ45.

1. Loosen the gland of communication port B (inverter comms) on the side cable panel and remove its sealing ring. Pass one end of the communication cable through the gland and sealing ring.
2. Plug the cable into communication port B of the cabinet, then refit the sealing ring and compression nut.
3. Crimp an RJ45 plug onto the inverter end of the cable, wired to the BMS 1 pinout below.
4. Pass the RJ45 plug through the inverter COM3 swivel nut and into the open side of the rubber seal. Plug it into the matching RJ45 socket in the inverter COM3 connector.

Emergency stop cable

The inverter emergency stop uses the following pins.

The inverter COM2 connector has push-in (screwless) terminals and an RJ45 socket. The steps below are for the push-in terminals.

1. Loosen the nut of emergency stop port C on the side cable panel and remove its sealing ring. Pass the end of the cable without crimped terminals through the nut and sealing ring.
2. Plug the emergency stop cable into port C, then refit the sealing ring and compression nut.
3. Pass the other end of the cable through the inverter COM2 swivel nut and housing. Strip 55 mm of sheath and 8 mm of insulation. The cores are 0.5–1.5 mm².
4. Twist each multi-strand core by hand and crimp a pin ferrule onto it.

5. Following the COM2 terminal definitions in the inverter manual, press down the release on top of each terminal with a flat-blade screwdriver, insert the core and let go.
6. Tug each core to check it is secure. Push the terminal block into the connector until it clicks.

PV cables

Choose the DC cable to suit the site. The recommended specification is:

For the PV wiring itself, follow the inverter manual.

Cable cover

We recommend fitting the cable cover after all the cables are connected and the system is commissioned.

1. Tie the cables to the cable tie bar.
2. Take side plates 01 and 02, six M6 × 16 and four M8 × 16 hex socket bolts from the parts box. Assemble the cable cover with the M6 × 16 bolts, as shown.
3. Fix the cable cover to the right-hand side of the cabinet with the M8 × 16 bolts.

5.3.2 Battery pack DC cables

Note

Before connecting the battery terminals, check that the cable polarity is correct.

If the cabinet is to be stored or transported, unplug the main positive and negative battery pack cables first, then close the cabinet.

1. Take the key from the side cable panel.
2. Slide the waterproof cover on the lock to the left, insert the key and turn it to the right. Lift the handle and turn it to the left to open the door. Open the door fully: the door stay locks it open.

3. Remove the battery pack cover at the upper left of the cabinet with a screwdriver.
4. Take off the protective caps and plug the main positive and negative battery connectors into the battery pack terminals, as shown. They click when fully engaged. Refit the battery cover.

5.3.3 Grid and load cables

Choose cables to suit the site, using the recommended specifications in section 5.1.2.

1. Remove the sealing plate under the electrical compartment with a screwdriver.
2. Remove the nuts and sealing rings from the grid and load cable glands, and take out the waterproof plugs, as shown.

If the cable is smaller than the recommended diameter, seal it with the M42-26 gland sealing ring or the fire-stopping putty from the parts box. Fit the M42-26 sealing ring to suit the cable outside diameter (22–44 mm):

3. Thread the grid and load cables through the glands, seals and compression nuts in the base plate, as shown. Pull out enough cable to reach the terminals.

Note

If threading is difficult, remove the base mounting plate as shown below, and refit it after the cables are connected.

4. Strip 95–100 mm of the outer sheath, and 20–25 mm of insulation from each L1, L2, L3, N and PE core.
5. Take the lugs from the parts box: four SC50-8 for the grid cable (12 N·m), four C45-25 for the load cable (3.5 N·m) and two SC16-8 for PE (12 N·m). Crimp them onto the cores.
6. Connect the lugs to L1, L2, L3, N and PE, as shown.

7. Refit the lower cover plate.
8. Refit and tighten the compression nuts. If there is a gap between a cable and its entry, seal it with a sealing material that meets local electrical and fire requirements.
9. Lift the locking pin of the door stay and close the door to the right.

5.3.4 Fire alarm signal

The cabinet's fire-activation signal is a dry contact. Wire it only if the site needs to monitor fire activation remotely.

1. Remove the nut and sealing ring from the cable gland in the base of the cabinet, as shown.
2. Pass the fire signal cable through the gland, seal and compression nut in the base plate. Pull out enough cable to reach the terminals.
3. Strip 55 mm of sheath and 8 mm of insulation. Twist each multi-strand core by hand and crimp a pin ferrule onto it (0.5–1.5 mm²).
4. Press and hold the release above each terminal with a flat-blade screwdriver, insert the cores into terminals 1-A and 2-A, and let go. Tug the cables to check they are secure.
5. Tie the cables, then refit and tighten the compression nut.

6.1Start-Up and Shut-Down

Start-up

1. Switch on grid breaker QF4. Grid power is applied and the white power indicator on the cabinet lights.
2. Switch on SPD breaker QF7. The surge protection is in service.
3. Switch on bypass breaker QF6-1. The AC system is in service.
4. Switch on the auxiliary main breaker QF8. The control circuits are powered.
5. Switch on air-conditioner breaker QF81. The air conditioner starts.

6. Switch on UPS breaker QF82. The UPS starts.*
7. Switch on controller PDU breaker QF821. The PDU control supply is on.
8. Switch on the high-voltage box main switch QF1. The BMS powers up.
9. Switch on the high-voltage box DC supply breaker QF3. The DC control supply is on.
10. Switch on the high-voltage box AC supply breaker QF2. The AC control supply is on.
11. The BMS runs a self-test. If there are no alarms, the red fault indicator on the high-voltage box stays off and the green running indicator on the cabinet lights.
12. Once the high-voltage box has started, the inverter runs its grid self-test and starts on-grid operation.
13. Check that the loads are ready, then switch on load breaker QF5. The system supplies the loads and start-up is complete.

Note

*The first time the UPS is powered, press its power button to start it.

Note

After start-up, check the cabinet status against the table below. If there is a fault alarm, follow section 7.3 or contact AERL support.

Shut-down

1. Switch off load breaker QF5. The supply to the loads stops.
2. Switch off the high-voltage box main switch QF1, AC supply breaker QF2 and DC supply breaker QF3, in that order. The DC system and inverter shut down, the high-voltage box control supply turns off, and the green running indicator goes out.
3. Switch off the auxiliary main breaker QF8 to turn off the control supply. Switch off the other breakers in the cabinet as needed.
4. Switch off bypass breaker QF6-1 to turn off the AC supply.
5. Switch off grid breaker QF4. The grid supply is off and the white power indicator goes out.

Note

In an emergency, press the emergency stop button on the door panel and switch off grid breaker QF4. If the site requires it, also switch off QF821 to cut the UPS output.

6.2Operating Status

Notice

After start-up, check that the cabinet is running. If it fails to start, the site may lose power.

6.2.1 Cabinet indicators

The indicators on the cabinet door show its operating status.

If an alarm occurs, check the alarm details in the monitoring data to identify the fault.

6.2.2 High-voltage box indicator

6.2.3 Inverter indicators

6.2.4 Adding the system in the IntegHub app

Scan a code to install the free Solinteg IntegHub app, or search for IntegHub in Google Play or the App Store.

Get the IntegHub app

Android

Google Play

iPhone

App Store

1. Log in to the IntegHub app and create a plant by following the prompts.
2. On the Plants screen, open the plant you want to add devices to.
3. In the plant, tap Devices, then tap + at the top right.

4. Tap Scan to add and scan the QR code or serial number on the inverter rating plate.
5. Tap Enable Bluetooth to turn on your phone's Bluetooth. The app scans for nearby devices. (If you tapped Add devices manually in step 3, the app goes straight to this screen.)

6. The app lists the devices it finds. Select the device to add.
7. Choose how the inverter connects to the internet: Wi-Fi or LAN.

8. For Wi-Fi, select the network and enter its password. Tap Next to continue, or Setup later to do this later.
9. For LAN, DHCP is on by default. To set a static address, turn DHCP off and enter the IP address, subnet mask, gateway and DNS server. Tap Next to continue, or Setup later.

10. The app configures the network in three steps. If a step fails, the app shows the reason.

11. When configuration finishes, tap Complete.
12. You can now add the device. Tap the edit button to rename it, then tap Confirm.
13. Open the device to see its name, serial number, type, model, connection (Wi-Fi or LAN), IP address, MAC address, inverter firmware versions and the date it was connected.

7.1Maintenance

Inspect and maintain the equipment regularly so it keeps working properly. Where the environment or operating conditions are harsh, maintain it more often. Maintenance must be carried out by qualified people.

Paint repair

The cabinet paint may be damaged by knocks during handling, transport and installation. Repair it as follows.

1. Choose a paint or touch-up spray to match the colour code. Prepare brushes, sandpaper, anhydrous ethanol, cotton cloths, masking tape and plastic sheet.
2. Mask around the damaged area with tape and plastic sheet so paint does not get on the rest of the cabinet.
3. Lightly sand the damaged area to remove rust and dirt.
4. Wipe the area with a cotton cloth dampened with anhydrous ethanol, then wipe it dry.
5. Brush or spray paint evenly over the damaged area until it is completely covered.

Note

If the damaged area is large, contact a professional for repair.

7.2Fire-Protection System Inspection

Danger

Only qualified people may inspect the fire-protection system. A failed fire-protection system can cause injury, death or damage. Use proper fire-detection test equipment, so the smoke and temperature sensors are not contaminated. Before any fire-detection test, disconnect the fire test terminal in the cabinet. Otherwise the extinguisher will discharge and damage the equipment.

1. Lift the lever of the fire-detection quick-connect terminal at the top right of the cabinet and pull out the wire below it.
2. Following local fire-protection requirements, test the detectors with a combined smoke and heat tester until the trigger condition is reached.
3. The cabinet's audible and visual alarm should activate. If it does, the smoke and temperature detection is working.

7.3Alarms and Troubleshooting

Troubleshooting must be carried out by qualified people in accordance with local requirements. Where the table says to contact AERL support, call 1800 950 865 or email [email protected].

Codes starting with E are protection faults. The battery stops to protect itself. Codes starting with I are alarms and codes starting with W are warnings. The system keeps running, but the condition needs attention.

The following conditions each have three levels: protection (E), alarm (I) and warning (W).

8.1Disposal

The cabinet contains lithium-ion batteries. Do not dispose of it in general waste. Dispose of the cabinet and its batteries through a licensed e-waste or battery recycler, in accordance with the requirements of your state or territory environmental regulator. Contact AERL for advice on returning or recycling batteries.

8.2Technical Support

Contact AERL for help with installation, commissioning, alarms, warranty and spare parts for the All-In-One in Australia.

When you contact AERL, have the following ready:

• the All-In-One model (AIO-25K to AIO-50K), and the cabinet model and serial number from the rating plate
• the inverter model, serial number and firmware versions (in the IntegHub app, under device details)
• the alarm or fault codes shown, and when they occurred
• a short description of the problem and what you have already checked
• photos of the installation and indicators, if relevant.