1. INTRODUCTION
   

Congratulations on purchasing a high quality BlueNova® product.

This document covers product assembly & installation, troubleshooting, safety & maintenance instructions, storage guidelines as well as emergency & first aid procedures.

Please do not discard this document as it contains valuable information that might have to be referenced at a later stage.

Should you have any queries, kindly contact BlueNova® Technical Support:

 Office: +27 21 205 2000  E-mail:  support@bluenova.co.za

B.  FRONT PANEL LAYOUT

The master panel has the following components: 

C.  TERMINAL CONNECTION

Connecting another battery in parallel should be done in one of the following two ways:

D.   PARALLEL CONFIGURATION: Without Serial Interface communication (excl. CAN bus Communication)

BlueNova batteries with firmware version 5.4 and higher include MultiCap™ functionality. The procedure below

describes how to correctly enable this functionality on parallel connected batteries:

1.   Switch off all batteries.

2.   Interconnect (daisy-chain) all batteries with standard RJ45 network cables.

3.   Wait at least 5 seconds in between switching on consecutive batteries. This allows each battery to assign itself a communications slot on the CAN bus.

4.   To reconfigure the number of units expected to run in parallel, switch on and briefly press the CTRL button during startup initialisation (within about 5sec of startup).  This triggers a once-off prompt to ask how many units are expected to run in parallel. This screen looks as follows:

 The current selection is shown on the 3rd line on the left (01 in the example), 

5.   To add batteries, press the CTRL button to increment the value to the total number of batteries that will be installed in parallel. To confirm the selection, hold the CTRL Button for 3 seconds. The following message should then be displayed:

  The 3rd line on the display will now show the new value.

The battery stores this configuration and will not ask for it when power is cycled in future, unless the above steps are repeated from (1), except if the Scroll Button is pressed during any of the connected batteries’ startup sequence.  Therefore, whenever the number of physically connected batteries change, the installer should re-configure ALL batteries with the new number by following the procedure above, from step 1.

For example, if 5 batteries are running in parallel and one needs to be disconnected for maintenance, the remaining 4 should be reconfigured with P.Bat=4. This can be done one at a time to avoid critical loss of power between the inverter and batteries.

Please note: After correctly configuring parallel-connected batteries with MultiCap™ functionality, switch each connected battery on. The inverter output should be disabled and not be connected to the load at this point.
Shortly after completing automated self-diagnostic each battery will perform a pre-charge of the DC bus capacitors and then they will close almost simultaneously. 

E.   PARALLEL CONFIGURATION: With Serial communication interface (incl. CAN bus Communication)

From version v5.4 onwards, batteries in parallel communicate their state, operating parameters etc. with each other via CAN bus. A straight through network cable connection (RJ45) should be used to daisy-chain all batteries and colour control / inverter on a single bus.

Batteries in parallel will automatically be configured with their Parallel Operation (PO) mode according to information shared on the CAN bus. Possible modes are Prime, Non-prime and Startup.

Only one battery on the bus will be prime, normally the one with the highest capacity. 

The Prime will consolidate all batteries' operating parameters and transmit this combined info to the Inverter and/or colour control etc.

Parallel Operation status is shown on the 2nd last page on the display. See example below:

The 3rd line of the display in this example should be understood as follows:

             123BMS installed, status = 3 (OK). Parallel Operation configured for 2 x batteries in

parallel. This one has been assigned Prime.

F.  INTEGRATION: No serial communication interface / VOLTAGE-BASED

If the battery is not connected to hardware that has a serial interface, the following highlighted values have to be set on the inverter/charger. Note: Disable equalisation.

Parameter	Cell V	Value	12V Eq	Comment
V high set	3.51 V	56.2 V	14.1 V	100% SoC. Constant voltage set point. This  is also known as the BULK or ABSORB set point.
V float	3.47 V	55.5 V	13.9 V	This is the FLOAT set point .
V reconnect	3.20 V	51.2 V	12.8 V	The inverter output is switched ON again.  Connection to grid is disconnected at this point.
V low set	3.00 V	48.0 V	12.0 V	Inverter must switch off the load. Switching back to Grid or starting the generator  at the voltage

High Voltage Battery Disconnect: > 3.9V on any cell.  

The Battery Management Systems is designed to protect each cell against a potential over charge situation. Once the voltage on any cell exceeds 3.9V the battery will open the main contractor and disconnect the battery from the Inverter / Charger. 

Low Voltage Battery Disconnect: < 2.85V on any cell.  

The Battery Management Systems is designed to protect each cell against a potential over discharge situation. Once the voltage on any cell falls below 2.85V the battery will open the main contractor and disconnect the battery from the Inverter / Charger. 

IMPORTANT: Voltage calibration

Experience has shown that some inverter/charger voltage measurement circuits are inaccurate. Compare the voltage values displayed by the inverter/charger with that of a calibrated voltmeter.

If the actual voltage differs by more than 100mV from that measured by the inverter/charger, apply this difference to the highlighted values above (i.e. if actual voltage = 56V while inverter voltage = 56.5V,

the voltage difference = 0.5V should be subtracted from each of the set values above).

G.  OPERATING INSTRUCTIONS

1.   Recovery from over-discharge

Should the battery reach its low voltage cut-off point at any time, the latching relay will open to protect the cells from being damaged. The recovery procedure is detailed below:

∙ Check the battery’s fuse(s) & terminal connections to the inverter/charger.

∙ Ensure that the inverter/charger is set to start charging the battery, once switched on.

∙ Ensure that the power button on the battery’s Control panel is switched on.

∙ Press & hold both CTRL button until the latching relay closes. Keep the CTRL button depresses until the voltage rises to either 12V, 24V, 36V or 48V depending on this battery type being used. 

2.   Local monitoring

Press the CTRL button to scroll to each page below:

PAGE1:   Battery voltage.

Charge/discharge current. Negative value = discharging.

State of charge percentage.

PAGE 2: The total amount of energy that has been stored in the battery.

This value will increase throughout the entire service life of the battery.

PAGE 3: The total amount of energy that has been discharged from the battery.

This value will increase throughout the entire service life of the battery.

PAGE 4:  Total voltage (actual) of the battery.

 Operating voltage range maximum.

 Operating voltage range minimum.

PAGE 5:  Charge / discharge current (actual). Negative value = discharging.

 Maximum continuous charge current limit.

 Maximum continuous discharge current limit.

PAGE 6:  Ambient temperature (actual) inside the master enclosure.

 Operating temperature range maximum.

 Operating temperature range minimum.

PAGE 7:  Nominal cell voltage.

 Highest cell voltage.

 Lowest cell voltage.

PAGE 8:  Cell 1 voltage (actual).

 Cell 2 voltage (actual).

 Cell 3 voltage (actual).

PAGE 9:  Cell 4 voltage (actual).

 Cell 5 voltage (actual).

 Cell 6 voltage (actual).

PAGE 10:  Cell 7 voltage (actual).

 Cell 8 voltage (actual).

 Cell 9 voltage (actual).

 Cell 11voltage (actual).

 Cell 12 voltage (actual).

 Cell 14 voltage (actual).

 Cell 15 voltage (actual).

PAGE 13:   Cell 16 volatge (actual).

H. TROUBLESHOOTING

Every BlueNova® product contains integrated circuitry as a safety measure against possible damage from electrical malfunction. Under such conditions, the Error or the current fault will be displayed on the OLED.

Before troubleshooting any errors, first check the following:

• Check DC circuit breaker
  
• Ensure that the signal cable and busbars are tightly connected.
  

The table below illustrates various error messages that might be encountered, and the necessary steps required to resolve each of these:

Display	Description/cause	Troubleshooting steps
State |   Err |   BmsCRCfail |	BMS internal	Please contact BlueNova Technical Support. This error is used during production for debugging, and should not be encountered in the field.
State |   Err |   BmsCelComs |   |	BMS communication error	Please contact BlueNova Technical Support. This error is used during production for debugging, and should not be encountered in the field.
State |   Err |   BmsCommsTO |	BMS communication not present	Please contact BlueNova Technical Support. This error is used during production for debugging, and should not be encountered in the field.
State |   Err |   BmsBadData |	Data out-of-range or corrupt	Please contact BlueNova Technical Support. This error is used during production for debugging, and should not be encountered in the field.
State |   Err |   Vcell OVER |   |	Over-charge	Check inverter/charger settings. Check & note all cell voltages on the battery display. Contact BlueNova Technical Support.
State |   Err |   VcellUNDER |	Over-discharge	Check inverter/charger settings. Check & note all cell voltages on the battery display. Contact BlueNova Technical Support.
State |   Err |   +I_i2tOVER |	Max. charge current exceeded	Check inverter/charger settings. Contact BlueNova Technical Support.
State |   Err |   -I_i2tOVER |   |	Max. discharge current exceeded	Check inverter/charger settings. Contact BlueNova Technical Support.
State |   Err |   Tcell HIGH |	Temperature range max. exceeded	Check inverter/charger settings. Contact BlueNova Technical Support.
State |   Err |   Tcell LOW |	Temperature range min. exceeded	Check inverter/charger settings. Contact BlueNova Technical Support.
State |   Err |   VprechFAIL |   |	Pre-charge failure	Check fuses & connections. Disconnect inverter(s) / charger(s) from AC input & output. Disconnect MPPT’s. Switch battery on to check. Reconnect inverter(s) / charger(s).
State |   Err |   Fuse Error |	Fuse error	Check external fuses & connections. Switch the battery off, then back on.

I. SAFETY & MAINTENANCE

1.   Do not short circuit the battery terminals.

2.   Do not use the battery without a BlueNova® approved integrated BMS solution.

3.   Do not disassemble, pierce, cut or in any way physically alter any part of the battery.

4.   Do not burn, incinerate or otherwise subject the battery to extreme heat.

J.  BATTERY STORAGE GUIDELINES

1.   Ensure that the battery is switched off when stored.

2.   Disconnect the communication cable.

3.   Always store batteries in a cool and well-ventilated area – ideally 25°C ± 3°C.

4.   Store away from moisture and heat.

5.   Do not store batteries upside down for overly long periods.

6.   Check the open circuit voltage of stored batteries at least once per month. Recharge batteries sufficiently and frequently enough to prevent the open circuit voltage falling below 40V.

7.   Ensure that the stored battery’s state of charge is above 50% at all times. 100% SOC is optimal.

K.   EMERGENCY & FIRST AID

1.   In case of fire

a.   Evacuate danger zone. Open ventilation in the room. b.   Extinguish fire with a CO2 fire extinguisher.

c.   Immerse any remaining smoking cells completely in water.

2.   Skin contact

a.   Wash immediately with soap and water.

b.   If irritation persists, seek medical attention.

3.   Eye contact

a.   Rinse eyes immediately with clean water for at least 15 minutes. b.   Seek medical attention immediately afterwards.

4.   Ingestion

a.   Refrain from taking any emetic or vomit-inducing medicine. 

b.   Seek medical attention immediately.

L.   DATA SHEET

M.   NOTES