Safe Installation of LiFePo4 Batteries in Australia

AS/NZS 5139-2019 Compliance Guide for a 15kWh, 51.2V, 300Ah Lithium Battery with LiFePO4 Cells

All of our LiFePro Batteries are designed to comply with IEC62619 for installation to AS/NZS3001.2:2022 standard. Our Lithium batteries are designed to comply to IEC62619 and therefore can usually be installed in most applications.
We are currently working on the application and certificate of IEC62619 for a number of our batteries. You can reach out to find out more by calling us on (07) 4191 6815

Compliance vs. Certification

Compliance:

  • When a battery complies with IEC 62619, it means that the battery has been designed and manufactured to meet the requirements and criteria set out in the IEC 62619 standard.
  • This compliance could be based on internal testing and assessments conducted by the manufacturer to ensure that the battery meets the necessary safety and performance specifications outlined in the standard.

Certification:

  • Certification, on the other hand, involves a formal process where an accredited third-party testing organization tests and verifies that the battery meets the IEC 62619 standard.
  • This process includes rigorous testing under controlled conditions and results in an official certificate or mark that indicates the battery has been independently verified to meet the standard.
  • Certification provides a higher level of assurance and credibility to customers and regulators, as it involves independent validation.

Why Certification Matters

  • Market Acceptance: Many markets, industries, and customers require certified products to ensure safety and reliability. Certification can be a requirement for selling products in certain regions or for use in specific applications.
  • Liability and Compliance: Certification can protect against liability and regulatory issues, as it demonstrates that the product has been independently verified to meet recognized safety standards.
  • Customer Confidence: Certification provides customers with confidence in the quality and safety of the product, which can be a key differentiator in the market.

1. Introduction

AS/NZS 5139:2019 sets the standards for the safe installation of battery energy storage systems (BESS) in Australia and New Zealand. Compliance with this standard ensures the safety and reliability of your lithium battery system. This guide will help you meet these standards for your 15kWh, 51.2V, 300Ah lithium battery containing LiFePO4 cells. To ensure the safety and compliance of your 15kWh, 51.2V, 300Ah lithium battery system, it’s important to adhere to both AS/NZS 5139:2019 and additional regulations specified in AS/NZS 3000:2018

2. System Design

2.1 Battery Specification

  • Capacity: 15kWh
  • Voltage: 51.2V
  • Current: 300Ah
  • Chemistry: Lithium Iron Phosphate (LiFePO4)

2.2 Key Components

  • Battery Management System (BMS)
  • Inverter/Charger
  • Safety Enclosure
  • Circuit Protection Devices (Fuses/Breakers)
  • Cabling and Connectors

3. Installation Site Requirements

3.1 Location

  • Battery Location & Restrictions:
  • Install the battery system in a well-ventilated, cool, and dry area.
  • Avoid direct sunlight and ensure the location is away from flammable materials.
  • Batteries cannot be installed in restricted locations such as near gas appliances and gas cylinders. Specifically, there are exclusion zones for electrical installations near gas relief vent terminals to prevent ignition hazards (AS/NZS 3000:2018, Section 4.18)​ (GSES)​.
  • Ventilation and Environmental Requirements:
  • Ensure the installation site provides adequate ventilation to avoid overheating and accumulation of gases. The location should maintain temperatures within the limits specified by the manufacturer and control humidity levels to prevent condensation​ (Standards.govt.nz)​​ (GSES)​.

3.2 Access and Clearances

  • Ensure clearances around the battery system for maintenance and ventilation as specified by the manufacturer.
  • Allow at least 600mm clearance around the battery enclosure.

3.3 Environmental Conditions

  • Install the system within the environmental conditions specified by the manufacturer (e.g., temperature, humidity).

4. Safety Considerations

4.1 Battery Enclosure

  • Use a non-combustible, weatherproof enclosure with an IP rating appropriate for the installation location (e.g., IP65 for outdoor installations).
  • The enclosure should have ventilation to prevent the accumulation of gases.

4.2 Fire Safety

  • Install fire-resistant barriers as required.
  • Maintain a safe distance from ignition sources.
  • Ensure the system is equipped with a fire suppression system if required by local regulations.
  • Fire Safety and Hazard Protection:
  • Install fire-resistant barriers and maintain safe distances from potential ignition sources. A fire suppression system may be required depending on local regulations​ (Smart Energy Council)​(GSES)​.

4.3 Emergency Shutdown

  • Provide an accessible emergency shutdown switch.
  • Ensure clear labeling and instructions for emergency procedures.
  • Documentation should include detailed installation, operation, and maintenance instructions, along with clear labeling for emergency shutdown procedures​ (Standards.govt.nz)​​ (Clean Energy Council)​.

5. Electrical Installation

5.1 Circuit Protection

  • Install DC fuses or circuit breakers appropriately rated for your battery system to protect against overcurrent conditions. Proper cable sizing is essential to minimize voltage drop and prevent overheating​ (Standards.govt.nz)​​ (GSES)​.

5.2 Cabling

  • Use cables rated for the maximum current and voltage of the battery system.
  • Ensure cables are correctly sized to minimize voltage drop and heat generation.
  • Secure and protect cables against physical damage.

5.3 Earthing and Bonding

  • Earth the battery system according to AS/NZS 3000:2018.
  • Ensure all metallic parts are bonded to prevent electrical shock hazards.

5.4 Inverter/Charger Integration

  • Connect the battery system to the inverter/charger according to the manufacturer’s instructions.
  • Ensure the inverter/charger is compatible with the battery’s voltage and current specifications.

6. Battery Management System (BMS)

6.1 Functions

  • Overcharge/Over-discharge Protection: The BMS monitors the state of charge and prevents the batteries from being overcharged or excessively discharged, which can damage the cells and reduce their lifespan.
  • Temperature Monitoring and Control: The BMS tracks the temperature of the cells and the environment to prevent overheating. It can shut down the system or reduce the charge/discharge rates if temperatures exceed safe levels.
  • Cell Balancing: The BMS ensures that all cells in the battery pack are charged equally, preventing any single cell from becoming a weak link and reducing the overall capacity and lifespan of the battery.
  • Communication: The BMS communicates with external systems like the inverter/charger to provide status updates, alerts, and control signals.
  • Sound Alarm: The BMS must be equipped with an audible alarm to alert users in case of critical issues such as overcharge, over-discharge, overheating, or any other condition that might lead to a hazardous situation. This is part of ensuring that the system can provide immediate alerts to prevent accidents and enable timely intervention.

6.2 Installation

  • Manufacturer’s Instructions: Follow the specific installation instructions provided by the BMS manufacturer. This includes wiring, sensor placement, and configuration settings.
  • Configuration: Set up the BMS to match the parameters of your battery system. This might involve setting voltage thresholds, temperature limits, and other protective settings.

7. Documentation and Labeling

7.1 User Manual

  • Provide a detailed user manual including installation, operation, and maintenance instructions.

7.2 Labels

  • Clearly label the battery system with the following information:
    • Manufacturer name and contact details
    • Model and serial number
    • Electrical ratings (voltage, current, capacity)
    • Safety warnings and emergency shutdown instructions

8. Testing and Commissioning

8. Testing and Commissioning

8.1 Pre-Installation Testing

  • Component Testing: Before installing, test each component (battery cells, BMS, inverter/charger, etc.) to ensure they are functioning correctly. This includes checking for proper voltage, current, and any manufacturer-specific tests.

8.2 Post-Installation Testing

  • Inspection: After installation, perform a thorough inspection to ensure all components are correctly installed, all connections are secure, and there are no signs of damage.
  • Continuity and Insulation Tests: These tests check that the electrical connections are correct and that there are no unintended paths for current that could cause short circuits.
  • Functional Tests: Verify that the BMS and protective devices (fuses/breakers) operate correctly. Simulate fault conditions to ensure they respond appropriately.
  • Inverter/Charger Operation: Check that the inverter/charger correctly charges and discharges the battery and that it communicates effectively with the BMS.

9. Maintenance and Monitoring

9.1 Regular Inspections

  • Conduct regular inspections to ensure the system remains in good condition.
  • Check for signs of wear, corrosion, or damage.

9.2 Monitoring

  • Use monitoring systems to keep track of battery performance and health.
  • Regularly check BMS data for any anomalies or alerts.

10. Compliance and Certification

10.1 Certification

  • Obtain certification from a qualified electrical inspector to ensure the installation complies with AS/NZS 5139:2019.

10.2 Documentation

  • Keep records of all installation, testing, and maintenance activities.
  • Ensure all documentation is available for inspection by regulatory authorities.