Wiring Guide

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SimpliPhi Wiring Guide

1.0 – Online Resources

The Product Documentation section of SimpliPhi’s web site (https://simpliphipower.com/product-

documentation/) includes Specification Sheets, Warranties, Installation & Operator’s Manuals, and Integration

Guides for all SimpliPhi’s current and legacy products.

SimpliPhi’s YouTube channel (https://www.youtube.com/channel/UCcuCaLT_G3Hhumteh-pI5yg/videos) has

instructional videos, including:

How to connect a lug to the terminals on a SimpliPhi Power battery:

https://www.youtube.com/watch?v=63hwvoZC0Zc

Paralleling PHI Batteries with Threaded Studs Using Battery Cables:

https://www.youtube.com/watch?v=Xk_tuVukUx0

Connecting a busbar to terminals on a SimpliPhi battery:

https://www.youtube.com/watch?v=7PamjYbd8TQ

Paralleling PHI Batteries using Busbars: https://www.youtube.com/watch?v=l_ABYDNfE74

2.0 – Technical Support

SimpliPhi Technical Support (805-640-6700 x 1, techsupport@simpliphipower.com) is available to take any

questions regarding this Guide or general installation questions.

3.0 – General Safety Instructions

• Do not operate if the PHI Battery has been damaged in any way during shipping or otherwise.

• To reduce the chance of short-circuits, always use insulated tools when installing or working with PHI

batteries or other electrical equipment.

• Remove personal metal items such as rings, bracelets, necklaces, and watches when working with PHI

batteries and electrical equipment. Wear insulated gloves and rubber shoes.

•

PHI Batteries pose some risk of shock or sparking during the installation and initial wiring and connection

process. This is consistent with all other battery-based storage formats. For batteries with threaded stud

connections, be sure the built-in breaker is in the “OFF” position to minimalize the risk of shock or sparks

during the installation and commissioning of the system.

• To avoid a risk of fire and electric shock, make sure that existing system wiring is in good condition and

that the wire is not undersized. Do not operate the PHI Battery in conjunction with damaged or

substandard wiring.

4.0 – Parallel Wiring

CAUTION: PHI Batteries are designed to serve at fixed voltages and cannot be wired in

series to increase the battery bank’s voltage. Wiring the PHI Batteries in series will result in

damage to the PHI Battery’s protective circuitry and will Void the Warranty. PHI batteries are

designed for parallel wiring only to increase the battery bank’s storage capacity.

Summary of content (16 pages)

PAGE 1
SimpliPhi Wiring Guide 1.0 – Online Resources The Product Documentation section of SimpliPhi’s web site (https://simpliphipower.com/productdocumentation/) includes Specification Sheets, Warranties, Installation & Operator’s Manuals, and Integration Guides for all SimpliPhi’s current and legacy products. SimpliPhi’s YouTube channel (https://www.youtube.
PAGE 2
Storage Capacity and total available Amperage is increased incrementally with the number of units wired in Parallel. For example, two PHI 3.8 kWh-51.2Vnominal (75Ah) Batteries wired in parallel are rated at a combined 7.6 total kWh, 51.2 Volts DC and 150Ah. Each PHI 3.8 kWh-51.2Vnominal Battery also has a maximum continuous discharge rate of 37.5 Amps DC and paralleling two of these batteries incrementally increases the maximum continuous charge and discharge rate. The two paralleled PHI 3.8 kWh-51.
PAGE 3
Modified from Schneider Electric’s Conext XW PRO Installation Guide. Wiring differs when Conext Battery Monitor is included in the system. All Battery-to-DC Busbar cables are the same length and gauge. Figure 2.0 – Twelve PHI Batteries Paralleled in a MidNite Solar MNLBC Lithium Battery Combiner Box with a single Positive Output and a single Negative Output leaving the Combiner Box, to the BoS Photo courtesy of Mike Swenson (Schneider Electric). SimpliPhi Power, Inc.
PAGE 4
2. Method #2: Busbars are attached directly to the terminals of multiple PHI Batteries (see Figure 3.0). Battery cables then connect between these positive and negative busbars and the positive and negative DC busbars, plates, or terminal blocks. If the DC busbars, plates, or terminal blocks are located somewhere other than the paired inverter’s power panel (see Figure 4.0), additional connections may be required between a battery combiner box or terminal blocks and the BoS equipment (see Figure 5.0).
PAGE 5
Figure 5.0 – Six Total PHI Batteries are Directly Bussed in Two Sets of Three, then Paralleled Using Cabling to a Single Positive Terminal Block and a Single Negative Terminal Block 6.0 – Cable or Busbar Ampacity Ratings PHI battery cable leads are typically sized at 4 AWG. This sizing is according to the battery’s 80ADC built-in breaker and therefore assumes a maximum current of 80 Amps flowing to or from an individual battery.
PAGE 6
7.0 – Cable Wiring Batteries with Threaded Studs (Wiring Method #1) When parallel wiring PHI batteries using cables (from individual PHI Batteries to DC busbars or plates or terminal blocks), make sure all wires from each PHI battery to common busbars, plates, or terminal blocks are the same length and gauge. Matching cable lengths and gauges balances the load across (all) PHI Batteries in the installation. Figure 8.0 – Two PHI Batteries in Parallel Figure 9.
PAGE 7
CAUTION: Identical wire lengths and identical wire gauges from each PHI Battery in a PHI Battery bank is a critical feature of parallel power storage systems that must be adhered to throughout all parallel wiring instructions. Failure to properly wire the PHI Batteries in parallel will Void the Warranty. 3/8” (10mm) lugs fit on the terminal posts of batteries with threaded studs (such as PHI 3.8, PHI 2.9, etc.). Battery cables can often be ordered to include these 3/8” lugs.
PAGE 8
• • MidNite Solar produces the MNLB Lithium Battery Combiner (rated at 250 Amps MAX) and the MNBCB 1000/50 Battery Combiner (rated at 1,000 Amps MAX). If wiring battery cables directly to the inverter’s panel (as in Figure 1.0), consult the inverter manufacturer regarding negative wiring to a DC Negative Busbar versus a DC shunt. Refer to the thirdparty manufacturer’s product documentation for guidance regarding acceptable wire sizes and torque specifications when wiring to that manufacturer’s equipment.
PAGE 9
PHI Batteries can be paralleled using common bussing directly attached to the batteries’ terminals. Best practice involves wiring the battery leads to opposite ends of the busbars, as illustrated in Figure 12.0 below. All groups of interconnected battery “strings” within a single PHI battery bank must include the same number of batteries per “string.
PAGE 10
Helpful Tips: • • SimpliPhi’s two-PHI battery busbars (SKU #BB-2) with a 50°C rise are rated at 455 ADC. Positive (red) and negative (black) busbars measure 9.37” x 1” x 3/16”. SimpliPhi’s three-PHI battery busbars (SKU #BB-3) with a 50°C rise are rated at 455 ADC. Positive (red) busbars measure 21.5” x 1” x 3/16” and negative (black) busbars measure 19.5” x 1” x 3/16”. CAUTION: Again, no material (such as a washer) should be placed between the current carrying terminal and the interconnecting busbars.
PAGE 11
Appendix - Cable or Busbar Ampacity Ratings A variety of factors are considered when sizing battery cables and/or busbars: • Local electrical codes • Ambient temperature • Voltage drop • Percentage of raceway filled • The draw of the connected load(s) This Guide puts aside the variables associated with local electrical codes, ambient temperature and voltage drop. Heavy gauge, high strand copper wire is the industry standard due to its stability, efficiency and overall quality.
PAGE 12
Also assume Inverter AC Output Power Watts is 6,800 WAC and inverter efficiency is 93%. 𝑀𝑀𝑀𝑀𝑀𝑀 𝐷𝐷𝐷𝐷 𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 = 6,800 𝑊𝑊𝑊𝑊𝑊𝑊 + (0 𝑊𝑊𝑊𝑊𝑊𝑊) = 7,312 𝑊𝑊𝑊𝑊𝑊𝑊 0.93 𝑀𝑀𝑀𝑀𝑀𝑀 𝐷𝐷𝐷𝐷 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 = 7,312 𝑊𝑊𝑊𝑊𝑊𝑊 = 152.3 𝐴𝐴𝐴𝐴𝐴𝐴 48 𝑉𝑉𝑉𝑉𝑉𝑉 2. Maximum current potentially charging the battery bank The Conext XW PRO inverter in Figure 1.0 (specification sheet linked here) includes a 140 ADC charger and the Conext MPPT charge controller in Figure 1.0 has a 60 ADC maximum charge current rating.
PAGE 13
Example 2: Examine Figure 2.0 and assume the following in this example regarding the 12-PHI 3.8kWh48V battery bank. Assume: DC Loads = 0 Watts, Two Conext XW+ 5548 inverters are used with AC Power Rating = 5,500 W each and efficiency of 93%, Inverter Charger Rating = 110 ADC per inverter, and two MPPT Charge Controllers are used each with Maximum Output = 80 ADC. 1. Maximum current liable to be drawn from the battery bank 𝑀𝑀𝑀𝑀𝑀𝑀 𝐷𝐷𝐷𝐷 𝑊𝑊𝑊𝑊𝑊𝑊𝑊𝑊 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 = 2 × 5,500 𝑊𝑊𝑊𝑊𝑊𝑊 + (0 𝑊𝑊𝑊𝑊𝑊𝑊) = 11,828 𝑊𝑊𝑊𝑊𝑊𝑊 0.
PAGE 14
In Section 6.0 – Cabe or Busbar Ampacity Ratings of this Guide, battery cables are sized at 4AWG according to the battery’s 80ADC built-in breaker. As illustrated in previous examples of this Appendix, battery cables do not always need to be sized according to this maximum surge rating. However, using smaller gauge wires decreases overall battery system efficiency and makes the system less robust. SimpliPhi Power, Inc. | 3100 Camino Del Sol | Oxnard, CA 93030, USA | (805) 640-6700 | info@simpliphipower.
PAGE 15
2.0 –Battery Busbar Ampacity Sizing Example 1: Examine Figure 4.0 (complete installation video linked here) and consider the busbar sizing required for the group of 3 PHI 3.4kWh-24V batteries. The paired inverter is a Magnum MS4024 rated at 4,000 Watts AC continuous output and 93% efficiency. The paired charge controllers are two MidNite Solar Classics rated at a maximum 94 Amps output per controller. Also assume that the system includes no DC Loads. 1.
PAGE 16
The Sol-Ark-12K includes a 185A charger. In Sol-Ark’s combined (inverter and dual charge controller) unit, 185 ADC is the maximum charging current the equipment can use to charge the batteries, whether from an AC or DC power source. 3. The greater of the two values from Steps 1 and 2 is used to size the cables: 209.4 ADC. From each individual battery to the terminal blocks: 209.4 𝐴𝐴𝐴𝐴𝐴𝐴 = 104.7 𝐴𝐴𝐴𝐴𝐴𝐴 2 𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 4.