Alpha ESS T100 Page 1 Installation & Operation Manual Download

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Installation & Operation Manual

Energy Storage System (ESS)

T50/T100

V02

Summary of Contents for T100

Page 1: ...Installation Operation Manual Energy Storage System ESS T50 T100 V02 ...

Page 2: ...lpha ESS Co Ltd with all rights reserved Please keep the manual properly and operate in strict accordance with all safety and operating instructions in this manual Please do not operate the system without reading through the manual Version Information Version Date Content V1 0 July 16th 2018 First edition V1 1 Aug 2nd 2018 Some grammar modified V02 Aug 24nd 2018 Format improved ...

Page 3: ...7 Manual Keeping 7 Operator Requirements 7 Protection of Warning Sign 7 Setting of Warning Sign for Safety 7 Live Line Measurement 7 Measuring Equipment 8 Electrostatic Protection 8 Moisture Protection 8 Operation After Power Failure 8 Minimum Personal Protection Equipment 8 3 Product Description 10 Product Appearance 11 Product Characteristics 12 Parts Parameters 12 Container 12 PCS 13 Battery Sy...

Page 4: ... Switch on 27 Check Before Operation 27 Power on Procedures 27 Switch off 29 Dry Contact Description 29 Diesel Generator Control 30 Online Monitoring 31 Register 31 Registering License 32 Generator Control Setting On Server 33 PV Junction Box Data Check 34 Emergency Stop 34 6 Routine Maintenance 35 Maintenance Plan 35 Routine Inspection 35 Routine Maintenance 38 Notes 41 7 Troubleshooting 43 Batte...

Page 5: ...erms 1 Lithium iron phosphate cell LiFePO4 Basic unit constituted by electric poles and electrolytes Each cell is independent and closed Notes Paralleled cell cannot be regarded as an independent cell even packed again 2 Lithium iron phosphate pack Combination made up of battery monitoring circuit battery equalization circuit electrical connectors communication interfaces thermal management device...

Page 6: ..._____________ Alpha ESS Co Ltd Page 6 of 45 Your Smart Energy Combination made up of a bidirectional converter and a battery system unit which can be used as an independent load or be controlled directly by monitoring system in an energy storage power station ...

Page 7: ...charged It is strictly prohibited for any maintenance when equipments are on or charged Protection of Warning Sign The warning sign contains important information for the system to operate safely and it is strictly prohibited to be torn or damaged Ensure that the warning sign is always clear The signs should be replaced immediately when damaged Setting of Warning Sign for Safety While instructing ...

Page 8: ...er Power Failure The battery system belongs to energy storage system and it keeps fatal high voltage even the DC side is disconnected so touching the output of the battery is strictly prohibited The PCS keeps fatal voltage even both the DC or AC side are disconnected so it must be tested by multimeter for safety before operation Minimum Personal Protection Equipment For the safety of operators to ...

Page 9: ...otective equipments are required No Item Notes 1 Work clothes 2 Protective shoes 3 Protective glasses 4 Insulated gloves For touching live parts Note When replacing modules the stacking machine should be used carefully in case that the modules may fall down All workmen are suggested to wear high safety and high strength protective shoes to protect their feet ...

Page 10: ...y generated by the PV will be stored in the batteries The stored energy can be used when the PV is not generating enough energy for self consumption at a certain time or to shave off peak usage and fill valley usage The overall system connection diagram is as follows Figure 3 1 System application diagram If your system without container the overall system connection diagram is as follows Figure 3 ...

Page 11: ...ge 11 of 45 Your Smart Energy Product Appearance Figure 3 3 is the layout diagram of the container storage system Figure 3 3 Container layout diagram Figure 3 4 T50 T100 without container Item Components 1 Battery system 2 Fire extinguishing system 3 Air conditioner 4 PWG2 50 100 PCS 1 2 3 4 ...

Page 12: ...hnology between strings in case of circulating current or unbalanced power The system has relatively developed thermal management technology so that the consistency of system environment can be ensured The system has both remote monitor function and local control function The system realizes flexible scheduling of electric power system through communication among BMS PCS and monitoring system The ...

Page 13: ... the loads The DC DC module can charge batteries by using the PV panels generated electricity The DC AC module is bidirectional so the grid electricity can also through this inverter charge the batteries 3 3 2 2 Appearance Instruction No Description No Description 1 Power indicator 7 PCS module 2 Normal indicator 8 STS module 3 Fault indicator 9 PV DC switch 4 Scram button 10 Battery switch 5 Disp...

Page 14: ...ltage Range 500 900 V 16 Max Long Term Operation Current 110 A 17 Max Stable Operation Power 55 kW General Data 18 Max Efficiency 0 96 19 Dimensions W x H x L 800 x 2160 x 800 mm 20 Weight 500 kg 21 Altitude 3000 m 22 Ingress Protection IP20 23 Noise 70 dB 24 Operation Temperature 25 55 25 Cooling Concept Forced Air 26 Humidity 0 95 Non Condensing 27 Communication Interfaces Ethernet RS485 CAN2 0 ...

Page 15: ... Energy storage capacity According to the project situation Ambient temperature is 30 measured at DC side 3 Continuous discharge current 1C continuous 4 Direct voltage 250 520 V 5 Communication interface RS485 CAN2 0 3 3 3 1 M48112 S Figure 3 5 Battery appearance Figure 3 6 Battery front cover Battery interface definition No Description No Description 1 Battery negative pole 5 Dip switch 2 Battery...

Page 16: ...harge current 1C 6 Nominal stored energy 5 737 kWh 7 Work power consumption 0 4752 W 8 Dormant power consumption 1 52 mW Battery dormant state 9 Max charge discharge current 112 A Constant current mode 10 DC internal resistance 20 mΩ Factory default 11 Transportation storage temperature range 20 45 12 Charge work temperature range 0 50 13 Discharge work temperature range 10 50 14 Communication mod...

Page 17: ...ical parameter Remarks 1 High voltage control box HV900112 2 Working voltage range 200 900 V 3 Rated current 112 A 4 Dimensions W x D x H 450 520 162 5 mm 5 Weight 20 kg 6 Power consumption 10 W 3 3 3 3 Top BMU Box with EMS Through the TOP BMU Box with EMS the functions such as remote monitoring remote upgrade etc can be realized Figure 3 8 Front cover of TOP BMU box with EMS Top BMU box with EMS ...

Page 18: ...tem Technical parameter 1 Dimensions W x D x H 215 x 623 x 436 mm 2 COM RS 485 4 Ethernet 10 100 1000Mbps 1 3 Internal storage CF card 4 GB 4 Events diary Recent one month happenings 5 Work voltage 24 V 6 Power consumption 10 W 3 3 3 4 Junction box Wiring definition No Description No Description 1 DC IN INV 4 DC OUT 2 DC IN INV 5 Handle 3 DC OUT Technical parameters No Description Technical parame...

Page 19: ...ct and the cylinder will spray gas to fill the container in a short time The accident indication lamp starts to warn personnel to keep away from the container As soon as the cylinder acts the PLC will get signal from the fire monitoring device send it to power station control system and trip all PCS AC circuit breakers at once When the power supply of fire extinguishing system is missing either DC...

Page 20: ...n Precautions The following sites are not allowed for installation Sites which are salty and where humid air can penetrate Flooded areas Earthquake areas additional security measures are required here Sites that are higher than 3000 meters above the sea level Sites with explosive or potentially explosive atmosphere Sites with extreme change of ambient temperature Sites with highly flammable materi...

Page 21: ...o it s better that the height is not less than 1600mm changeable according to the real situation 6 Pay attention to the drainage of the inlet outlet holes and the foundation 4 2 1 2 Container Hoisting Step1 Hoist the container to the corresponding foundation as the lifting plan NOTE The lifting rope is fixed on the upper corner of the container B B B B and the length of the four ropes are equal Th...

Page 22: ...2 of 45 Your Smart Energy Step4 Remove two sides of iron sheet 1 2 Battery Installation If you don t need the container you can only see this chart to install the storage system a Check the cluster No on the battery cover Battery cluster No number Cluster No number Battery gear No Battery SN No ...

Page 23: ...installed batteries have the same cluster No and whether the gear No is consistent f Use the screws in packing list to fix each battery Battery Side Wiring Table 3 Parts in package required by battery wiring No Item Description No Item Description 1 Screw M6 16 Battery package 5 Power cable Black black 2500mm 2 Nut M6 4 Battery package 6 Power cable Red red 130mm 3 Power line Red black 130mm Batte...

Page 24: ...ay from the LMU internet access of HV900112 and insert it into the top battery COM port of one battery cluster You can see the detailed information in the battery picture c Connect the comminucation cables to the LMU port of HV900112 control box as the following diagram shows Figure 4 1 Battery side communication cables connection HV900112 Top battery of one battery cluster ...

Page 25: ...ction positions are in the bottom down position of the inverter cabinet The cables shall be passed through the hole on the base of cabinet into the cable trench Open the front door and remove the inner door you can see the wiring copper bar In view of the requirements of connecting cables single or multiple cables with suitable diameter shall be selected We suggest to use 35mm2 cables to connect b...

Page 26: ...tion Description Position Description 1 PV DC input positive pole 7 Load output phase B 2 PV DC input negative pole 8 Load output phase C 3 Battery input positive pole 9 Diesel input phase A 4 Battery input negative pole 10 Diesel input phase B 5 Ground connect 11 Diesel input phase C 6 Load output phase A 12 Neutral connect ...

Page 27: ...e in the OFF position you will a check whether the DC input wiring of the energy storage system and the AC output wiring are normal and whether the earthing is good b check whether the wire connection polarity is normal Power on Procedures The system shall be turned on in the correct sequence to avoid any damage A Turn on the plastic case breakers of HV900112 in each cluster respectively From left...

Page 28: ...e LED on the batteries and HV900112 starts flashing E After two minutes turn on the battery and PV switches of inverter by pushing up the switch handles the inverter will be powered on Figure 5 3 PV switch and battery switch in switch off satus F turn on the load and diesel switches by pushing up the switch handles Figure 5 4 Load switch and diesel switch in switch off satus G Normal system operat...

Page 29: ...ce Setting Password the initial password for installers is 1111 1 2 Enter Function menu INVcmd ModeOff yes 3 4 The inverter will be powered off Then switch off all of the breakers Note automatically power on if the system is still powered after 5 min Dry Contact Description 1 Connect DO_2 to the dry contact of the diesel generator port 2 and 3 is normally closed ...

Page 30: ...ts the Genset according to the genset controller Diesel Generator Control Enter into EMS menu Main interface Setting Password the initial password for installers is 1111 Enter function menu Generator allocation Table 4 Setting Parameter for Diesel Generator Control No Parameter Description 1 GeneratorEN Yes Diesel generator enabled No Diesel generator disabled 2 GeneratorMode Fix SOC mode 3 GCSOCS...

Page 31: ...or output rated power mode is selected the diesel generator will charge to the batteries with the rest power under the condition of satisfying load The rest power is Prest Poutput Pload You can also set the control mode on the website see 5 5 3 Online Monitoring Register You have to create a new account on our webserver for the normal monitoring In addition a part of our warranty is based on this ...

Page 32: ...ure 5 6 Register Interface In this form all blanks marked with an asterisk must be filled out you can choose End user or installer More detailed information can be obtained in Online Monitoring Webserver installation Manual Registering License Figure 5 7 Menu for Installer Click Install new system to register the license No ...

Page 33: ...rst please click Generator to enable it Choose SOC control to set SOC range If the SOC drops below the lower limit of the configured SOC range the diesel generator will start when it raises beyond the upper limit the diesel generator will then be turned off If you set the battery charge power it will charge the batteries with the configured battery charge power If you set the Generator output powe...

Page 34: ...top button EPO on the cabinet door turn off the diesel engine switch load switch PV switch and battery switch In order to prevent personal injury if you want to repair or open the machine after power off please measure the voltage at the input port with the multimeter at the first Before the relevant operation please confirm that there is no grid electric supply The upper cover plate cannot be ope...

Page 35: ...or rusting or damage Once 6 months No rusting or damage on container surface Work cloth Protective shoes Container door Check the container door for damage Once 6 months The doors should be opened and closed normally Work cloth Protective shoes Indicate light Check the indicator lights outside the container for damage Once 6 months No flashing lights or ringing bells outside Work cloth Protective ...

Page 36: ...ce 6 months The equipments should be on without any alarms and the pressure of gas tank should be normal by checking the indicator needle green means OK Work cloth Protective shoes Bracket surface Check the brackets for rust or damage Once 6 month No rusting or damage Work cloth Protective shoes Bracket fixing Check the fixing of brackets between brackets and ground of the container Once 6 months ...

Page 37: ...cuit breakers Once 6 months The circuit breaker function should be OK When breaker is off no voltage is allowed Work cloth Protective shoes Wrenches Insulated gloves PCS display Check the PCS screen Once 6 months All data on PCS including voltage power and current is OK Work cloth Protective shoes PCS inside temperatur e Check inside temperature of PCS including module temperature and cabinet temp...

Page 38: ...loose Turn the fan to check if it is smooth and if there is any abnormal noise Visually check if the drainage mouth is blocked Check the cleanness of the condenser and clean it with compressed air Battery system Painting on brackets Work clothes Protective shoes Anticorrosive paint 6 months Corresponding color number Fixing on brackets Work clothes Protective shoes Wrench 6 months Fixing between b...

Page 39: ... Wrench 3 months Use multimeter to test grounding Battery capacity calibration Work clothes Protective shoes 6 months Whole discharge charge discharge cycle Battery data analyze Work clothes Protective shoes 6 months Analyze BMS data recorded by Alpha staff Junction box Junction box cable terminal fixing Work clothes Protective shoes Wrench 6 months All bolts are tight PCS Operating status and env...

Page 40: ...connection of power circuit Work clothes Protective shoes 6 months Check whether the power cable is losse and fasten it with the torque Check whether there are damages on power cable and control cable especially the cable skin contacts with the metal surface Check whether the insulated ribbon is stripped from the electric cable s wiring terminal Connection of terminal and winding displaceme nt Wor...

Page 41: ... be followed in operation and maintenance Disconnect all the electrical connections so that the equipment would not be powered on Wait at least 15 minutes after disconnection in case that the residual voltage of capacitors down to safe voltage Use a multimeter to ensure the equipment is completely uncharged The amount of maintenance staff should be not less than two while maintaining The equipment...

Page 42: ...ay cause warnings of sensor but it will not trigger fire system If the fire spreads into the container the temperature sensor would work and the whole system would start For single cell it is better to be sank into water to block burning The batteries need to be charged to 30 50 SOC rate when the whole system is static that is the batteries has not been charged for two weeks or longer for a long t...

Page 43: ...service Cell under volt fault Cell Low Volt Contact with Alpha service Insulation resistan fault IR_Fail Cut off BMS at the first then operate in power sequence when power the system LMU Communication fault Commu_fail_LMU Check communication connection between batteries LMU and LMU battery and HV900112 LMU and BMU Cell over temperature fault Cell Ov Temp Contact with Alpha service BMU Communicatio...

Page 44: ...lity of danger Water or other liquid is not recommended Just keep all doors closed and the fire system will automatically work Under this premise the emergency button should be pressed down in order that the DC breaker will trip As battery cell contains little Oxygen inside and all cells have got explosion proof valve explosion hardly happens EMS Troubleshooting Alarm Displayed in EMS Processing m...

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