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SUNSYS HES L - 551697A - SOCOMEC

113

18. UL9540A TEST REPORT

The SUNSYS B-Cab L was tested according to UL 9540A - Test Method for Evaluating Thermal Runaway Fire Propagation
in Battery Energy Storage Systems, 4th edition.

Document:

4789764715

Date Issued:

April 27, 2021

Testing organization:

Summary of Contents for SUNSYS HES L

Page 1: ...SUNSYS HES L USER MANUAL Energy Storage System EN UL...

Page 2: ...EMS 24 3 8 2 The PMS 25 4 TRANSPORT STORAGE HANDLING 26 4 1 Transport 26 4 2 Inspection 26 4 3 Storage 27 4 4 Handling and Moving 27 4 5 Forklift or Pallet truck handling 28 4 6 Overhead lifting 29 5...

Page 3: ...C Power connections 61 8 4 3 4 Auxiliary power connection 62 8 4 4 Communication and signal connections 66 8 4 4 1 Control Box Connections 66 8 4 4 2 Aux interface box connection 67 8 4 4 3 Connection...

Page 4: ...01 13 4 1 Battery unit 101 13 4 2 Coolant 102 13 4 3 Battery disposal and recycling 103 13 5 Capacity and efficiency measurements of the Battery System 104 14 TROUBLESHOOTING 105 15 GRID SUPPORT UTILI...

Page 5: ...SUNSYS HES L 551697A SOCOMEC 5 EN...

Page 6: ...e 23 Vertical load spreader 30 Figure 24 Concrete depth SDS 2 5 31 Figure 25 Concrete space around the equipment 32 Figure 26 Clearance distances 36 Figure 27 In line installation 37 Figure 28 Back to...

Page 7: ...connections 81 Figure 67 Location of the fuses inside the C Cab 82 Figure 68 MSD covers installed in the battery modules 83 Figure 69 MSD diagram 84 Figure 70 MSD cover inserted in the receptacle 84...

Page 8: ...C Cab Extension Cabinet in parallel with C Cab Master EMC Electro Magnetic Compatibility EMS Energy Management System ESS Energy Storage System HMI Human Machine Interface IM Islanding Mode IoT Inter...

Page 9: ...up to 2 units in parallel per system to reach 550 kVA system design limit B Cab Lithium ion battery LFP technology 186 kWh nameplate rack 176 kWh useable rack Liquid cooling thermal management Integr...

Page 10: ...ation contained in the present manual This inverter complies with Part 15 of the FCC Rules Operation so it may not cause harmful interference and must accept any interference received including interf...

Page 11: ...t be in accordance with the indication of the present manual CAUTION Any use other than the specified purpose will be considered improper The manufacturer supplier shall not be held responsible for da...

Page 12: ...result in unsafe conditions WARNING California proposition 65 warning Product range Energy storage system This product can expose you to chemicals including lithium ions Styrene and glycol which are...

Page 13: ...sal of batteries is required Refer to your local codes for disposal requirements The battery installation must be done in accordance with the storage battery rules of the Canadian Electrical Code Part...

Page 14: ...s which minimizes the cabinet flow through air volume facilitating internal environmental control using filtered normal environmental air The battery requires tighter temperature control for life and...

Page 15: ...SUNSYS HES L 551697A SOCOMEC 15 EN CHILLER SWITCHES BATTERY MODULES Figure 02 SUNSYS B Cab L composition...

Page 16: ...s Frame 1 one SUNSYS C Cab L Master from 50kVA to 300kVA modulo 50kVA Frame 2 one SUNSYS C Cab L Master one SUNSYS C Cab L extension from 350kVA to 600kVA modulo 50kVA Figure 03 View of Frame 1 Figure...

Page 17: ...protection of the DC input line 6 UPS Yes Yes UPS for auxiliary line For protection of the auxiliary supply line during service interruptions 7 Insulation monitor RCD Yes Yes Residual Current Detector...

Page 18: ...SUNSYS HES L 551697A SOCOMEC 18 EN Automation box detailed in Figure 7 Figure 06 View of the dedicated components inside the C Cab Figure 07 Detailed view of the Automation box...

Page 19: ...is possible to access to all the devices and ports available on the front of the machine These devices are described in the figures below Some of them are optional and may not be present as explained...

Page 20: ...le batteries or from the external commands of a device called Energy Management System EMS which is not a part of this manual The EMS is provided by a third party and has full control over the Energy...

Page 21: ...Mode The ESS may import active power from Area EPS while charging and may export active power to the Area EPS while discharging Import Only Mode The ESS may import active power from the Area EPS for...

Page 22: ...on in an outdoor environment at the specified temperature ranges and up to 100 humidity non condensing However the converter and batteries have different environmental control strategies described as...

Page 23: ...ime the machine is completely de energized and restarts Please note that if the system restarts within 20 minutes after the UPS stopped the 3h drying will be skipped If it restarts between 20 minutes...

Page 24: ...eat value in the 715 model it must change every second To control the DER we use the models 715 for ON OFF controls The DER set points are defined by the model 704 To control the battery we use the mo...

Page 25: ...he PMS derives its operational intelligence to operate the system based on the following Modbus TCP SunSpec communication to the converter for control operational data Modbus TCP communication to exte...

Page 26: ...te that for transport the batteries have to travel in a separated container for security reasons This container has to respect the following requirement Transport for hazardous material The transport...

Page 27: ...shipping and physical transfer The unit must remain in a vertical position during all shipping and handling operations Ensure that the floor is strong enough to support the weight of the unit Carry th...

Page 28: ...adall forklift with the C Cab remove the front and rear panels as shown below Figure 18 Panels to remove from the C Cab Figure 19 Handling of the unit using pallet truck with 1 30m long forks screen s...

Page 29: ...4 lifting lugs are on the top of the unit The radius of the hole on the lifting lug is 11mm 0 43in Warning The title angle should be smaller than 5 during hoisting Figure 20 Lifting lug on the top of...

Page 30: ...but basic ones you will need to use a vertical load spreader not supplied as illustrated below for handling Figure 23 Vertical load spreader CAUTION While lifting it is important to ensure that even...

Page 31: ...f a minimum capacity of 3000psi or 20 68MPa respect a solid and perfectly levelled ground in order to ensure the correct drainage of the water and avoid its stagnation respect the flatness unevenness...

Page 32: ...used must sustain the following characteristics SDS Cabinet Bolt diameter Load Tension Shear 2 5g C Cab 0 5inch 2282 lbs 10151 N 1118 lbs 4973 N B Cab 0 625inch 2954 lbs 13140 N 2911 lbs 12494 N 1 5g...

Page 33: ...ystem is at minimum as required by SOCOMEC please find distance required below 3 Please provide a photo of the all installation overviem front side 4 Please provide a photo of the all installation ove...

Page 34: ...connection od the C Cabinet 4 Please provide a photo of the Auxiliaries Cable connection od the C Cabinet 5 Please provide a photo of the DC and auxiliaries Cable connection od the B Cabinet 6 For Is...

Page 35: ...nts for electrical installation These requirements may include but is not limited to Input upstream overcurrent protection will be required by code specified by the engineer of record for the site for...

Page 36: ...vable back fence this fence can be installed at 500mm 20in enough for the ventilation and once removed we should have again the requested space to operate 6 3 Environmental conditions SUNSYS HES L has...

Page 37: ...d before putting the cabinet in place Positioning of all cabinets is critical to ensure proper installation with the cable troughs from each battery cabinet Refer to the template provided to prepare t...

Page 38: ...of the drilling template mounted 7 2 1 Installation with only 1 C Cab no extension Mark the 4 holes shown below note 1 3 3 2 2 1 1 1 1 c cab2 REAR FRONT c cab2 Holes to drill Figure 31 Holes to drill...

Page 39: ...les already drilled with these Figure 33 Holes to drill for the B Cab installation If the battery is not the last one to be installed on the left side you need to directly prepare the holes for the ne...

Page 40: ...tallation Then put the drilling plate as shown below overlapping 2 holes note 1 that you already marked and mark 2 note 1 additional ones 3 3 2 2 1 1 1 1 c cab2 REAR FRONT c cab2 3 2 2 1 1 1 1 c cab2...

Page 41: ...to right and plus minus 0 25in for horizontal direction front to back Note It is important for the unit to be leveled to ensure proper installation with the cable troughs from each battery cabinet Pu...

Page 42: ...ab connection kit back part Item 2 C Cab connection kit cover part Item 3 B Cab connection kit middle and right back part Item 4 B Cab connection kit cover part Item 5 B Cab connection kit left back p...

Page 43: ...SUNSYS HES L 551697A SOCOMEC 43 EN Item 8 Straight angle bottom parts and covers for back batteries Item 9 Back plate for C Cab for back to back installations...

Page 44: ...it Step 1 Remove the front panel of the base of the C CAB Figure 38 C Cab front panel removal Step 2 Place the C Cab connection kit back part item 1 under the C Cab Put it on top of the shims or direc...

Page 45: ...cab C cab Figure 40 Specific connection parts for back to back installations This connection is composed of 4 parts Fix them on the floor using Tapcon bolts Use 1 4 Tapcon bolts Figure 41 Details of...

Page 46: ...he shims or directly on the concrete pad whichever applies and screw every notch with stud M6 Figure 42 Installation of the B Cab back part connection kit Figure 43 Connection of C Cab and B Cab parts...

Page 47: ...ing of the DC cables the internal Ethernet communication and the battery communication cables and chiller and auxiliaries power supply cables All these cables are supplied with the system Start from t...

Page 48: ...3 2 Recommended Torques for imperial dry zinc plated bolted class 5 fasteners Bolt Nominal dia in Threads per inch Tensile stress area sq in Clamp load lbs Torque in lbs K 0 15 K 0 17 K 0 20 1 4 20 0...

Page 49: ...strated after Figure 47 Location of isolation switch QS and breakers QF1 QF2 8 4 1 Battery Cabinet Interconnections DANGER Risk of electrical shock including high short circuit current as batteries ar...

Page 50: ...M10 10 mm 2 95 mm2 3 0 AWG AC auxiliary connection X40 1 35 mm2 2 AWG 2 5Nm 1 8ft lb Screw in terminal block AC optional auxiliary connection X107 1 2 5 mm2 14 AWG N A Push in terminal block CATL B Ca...

Page 51: ...SUNSYS HES L 551697A SOCOMEC 51 EN Protection of single C Cab with external line on X107 see 8 4 3 4 Auxiliary power connection page 62 Protection of 2 C Cabs with 2 separated AC protections suggested...

Page 52: ...ed AC voltage System power Overcurrent protection rated current Maximum short circuit current Size Circuit breaker type RCD Residual Current Device Vout 480V Vout 480V Single C Cab 480 V 3 ph N 60Hz 5...

Page 53: ...A 400 A 250 kVA 500 A 300 kVA 600 A N 2 C Cabs in parallel 570 V 860 V 350 kVA 700 A 400 kVA 800 A 450 kVA 900 A 500 kVA 1000 A 550 kVA 1100 A 600 kVA 1200 A Size of AC auxiliary input protection Auxi...

Page 54: ...Screws of the plastic panel The bottom part of the machine is provided with 4 metal plates that are used for the passage of cables This part is located inside the C Cab as shown on the below figure I...

Page 55: ...ix them to the baseplate 5 Start to fix the cables For each cable follow this procedure A insert the cable inside the cable gland B fix the cable to the power terminal C fix the gland with the proper...

Page 56: ...SUNSYS HES L 551697A SOCOMEC 56 EN Suggested layouts for cable glands positioning Layout for single C Cab up to 300kW Layout for 2 C Cabs in parallel 350kW to 600kW I I N L1 L2 L3 COM PE AUX BATT AUX...

Page 57: ...taller shall mark the C Cab with the following wording or equivalent located on or adjacent to the DC wiring compartment DANGER HIGH VOLTAGE Or DANGER 860V CAUTION The AC output circuits are isolated...

Page 58: ...he cable into the rear of the gutter Note ensure the cable is laid straight without any excessive slack g Connect to the positive terminal and bolt using the provided hardware and torque h Identify th...

Page 59: ...COMEC 59 EN 2 In like manner repeat the above procedure for each battery cabinet using the appropriate table to identify the cable sets for each cabinet cable run GND B CAB1 Master DC DC HV HV Figure...

Page 60: ...h B Cab to the termination compartment these are supplied by Socomec In the instructions below B Cabs are referred relative to their position from the C Cab WARNING Ensure that there is no power appli...

Page 61: ...ab to connect up to 2 185mm 2 350MCM on each pole The lugs needed are M12 For ease of connection if possible depending on the number of cables you are using connect the phases in quincunx As shown on...

Page 62: ...AC aux connection Fix the wires L1 L2 L3 to the connection terminals 208 Vac Ph Ph 60 Hz The neutral wire is not connected The maximum possible size of the cables is AWG 1 or 42 4mm For information f...

Page 63: ...Do not connect more than 1 B Cab per connector Figure 55 C Cab connector for B Cabs aux power supply Pin Function 1 HVAC supply 2 3 Aux supply 4 Shall you have only a master C Cab or a master extensio...

Page 64: ...SUNSYS HES L 551697A SOCOMEC 64 EN B CAB1 Master B CAB2 JXH1 JX3 JX2 JXH1 JX3 JX2 Battery Aux power supply Figure 56 Connection of the B Cabs aux power supply from the C Cab...

Page 65: ...is chapter replace the power supply connection to the X40 terminals previously described which is always required and necessary Connector Pin Function Description X107 1 L AC optional auxiliary voltag...

Page 66: ...e present chapter Note that not all the devices described may be present depending from the options installed see List of options Figure 57 Location of the communication and signal connections in the...

Page 67: ...internal contactor It has to be connected to a normally open dry contact Input state Action Open None Close Contactor force off Pin 2 4 Input EPO Emergency Power Off This input is used to switch off...

Page 68: ...t 5 6 Emergency stop output 7 8 Emergency stop output 9 10 Emergency stop output X5 10 pin plug in connector 1 2 Input IX1 1 reserved for PMS functionalities 3 4 Input IX1 2 reserved for PMS functiona...

Page 69: ...ge 1 5mm2 2 5mm2 16 12 AWG Eth 10 C Cab In the C Cab master this port is connected to Eth 3 of Control Box this cable is pre installed DC DC GND Ethernet internal communication Go from Eth10 in the Au...

Page 70: ...more than 1 B Cab the cable will then go out of B Cab1 through JX2 and enter B Cab2 through JX3 and so on When you reach the last B Cab JX2 is connected to the terminal resistor connector B CAB1 Mast...

Page 71: ...o switch off the power of the C Cab and of other C Cabs in parallel to the first one Each output shall be connected to the EPO input of the Aux interface box see Connections to Aux interface box X8 X9...

Page 72: ...S L 551697A SOCOMEC 72 EN 8 4 5 Connection path The Ethernet cables need to go through the cable duct on the side wall of the machine as per the following procedure 1 Remove the cable duct cover on bo...

Page 73: ...HES L 551697A SOCOMEC 73 EN 2 Pass the cables inside the cable duct 3 The cables shall pass under the metal covers in the lower corners 4 Put the cover back in place covering all the cables inside th...

Page 74: ...rent powers can be one of the following SOCOMEC reference DIRIS DIGIWARE U 30 4829 0102 DIRIS DIGIWARE I 35 4829 0130 DIRIS B 30 4829 0000 DIRIS A 40 4825 0501 The associated current sensors can be se...

Page 75: ...the probes follow the procedure below open the probe by releasing the locking system pass the probe around the AC power cables each probe shall embrace all the cables of the associated phase L19 phas...

Page 76: ...parallel without using an additional external DC coupling cabinet 8 7 1 DC Power Connection It is mandatory to connect half of the B Cabs to the C Cab Master and the other half to the C Cab Extension...

Page 77: ...section of Electrical installation chapter for details on sizing of cables that can be connected to copper bars The cables from the user s plant shall be sized according to the total power of the sys...

Page 78: ...NSYS HES L 551697A SOCOMEC 78 EN DC DC GND DC DC GND Extension Master Extension Master C Cab paralleling connection XC6 A XC6 B XC6 A XC6 B Figure 64 Connection of the communication for the parallelin...

Page 79: ...e X9 connector of the C Cab Extension In the C Cab Extension the RS485 connection must be terminated with a 120 resistor provided with the cabinet Control box connection port Eth10 from the master is...

Page 80: ...SUNSYS HES L 551697A SOCOMEC 80 EN DC DC GND DC DC GND Extension Master Extension Master Ethernet RS485 Figure 65 Figure 66 Connection of the communication for the Digiware package...

Page 81: ...up to 6 Emergency Power Off outputs are available in the Automation Box of C Cab Master The C Cab Extension can be connected to the EPO input of the Aux Interface box connector X106 Figure 66 Locatio...

Page 82: ...1 10x38 CC 5A AC 230V Service Socket F18A F18B 2 10x38 CC 6A AC 230V Door Heaters F19 1 10x38 CC 12A AC 230V Heaters 2kW F20A F20F 12 10x38 CC 20A AC 230V B CAB 1 B CAB 6 F21A F21B F21C 6 10x38 CC 1A...

Page 83: ...Cabs 1 Ensure the isolation switch QS is in OFF state refer to Figure 47 2 Open the right hand side battery cabinet enclosure 3 Install the provided four MSD upper covers on the panel of each module...

Page 84: ...r Receptacle Figure 69 MSD diagram 5 Press the cover into the receptacle and rotate the handle downwards Figure 70 MSD cover inserted in the receptacle 6 Once the cover and the handle are installed pr...

Page 85: ...Open the right side door and cut the 7th and 8th dividers 2 1 2 1 3 4 5 6 7 8 Figure 72 Dividers of the right side door Step 3 Drill a hole in the front part of the roof 19mm 3 4in Figure 73 Hole dril...

Page 86: ...on the C Cab Step 5 Reinstall the cover by passing the cable inside the top hole Figure 75 Cable direction from antenna to inside the C Cab Step 6 Connect the cable to the antenna input of the automat...

Page 87: ...SUNSYS HES L 551697A SOCOMEC 87 EN 8 11 HMI installation 1 Unmount the support of the HMI from the door 4 screws M5 Wrench 7 mm 2 Mount the HMI on the support...

Page 88: ...SUNSYS HES L 551697A SOCOMEC 88 EN 3 Mount the support with the HMI back on the door 4 Wire the HMI with the existing cables...

Page 89: ...RESENTATION The status ledbar on the front of the C Cab replicates the ledbar on the Control Box indicating the status of the machine and the system Figure 77 View of the External HMI of the C Cab Sta...

Page 90: ...normal power up of the unit from a non operating state and for an initial power up The equipment doors must be opened to access the breakers and switches this is a normal operating situation Always e...

Page 91: ...reviously removed Figure 81 Reinstallation of the panel If an external supply line see AC aux from user s UPS is connected to the X107 connector this power line has to be switched on 4 Switch on AC an...

Page 92: ...wer Switch off Q3 by turning the handle in position 0 refer to Figure 78 4 Open the isolation switch QS and QF1 QF2 in all B Cabs refer to Figure 47 The unit is now isolated for service and the approp...

Page 93: ...the RCD options are configured with predefined settings During the commissioning trained and qualified service personnel may modify the predefined settings with others depending on the plant configur...

Page 94: ...es must be inserted from the bottom upwards and removed from the top downwards to ensure the unit remains stable WARNING The modules have to be moved individually Never handle more than one module Wei...

Page 95: ...SUNSYS HES L 551697A SOCOMEC 95 EN 1 2 3 4 5 6 Figure 85 Order of insertion of the modules Tighten the screws at 5 5 Nm 3 7 ft lbs to secure the module...

Page 96: ...s b Specific visits regular maintenance of specific components at specified periodic intervals 3 End of life refresh maintenance Before performing any maintenance activity the system must be switched...

Page 97: ...air inlet and outlet of the fans Check and clean the drain on the floor drain when necessary using a vacuum cleaner usage of air compressor is forbidden Check in all the B Cabs for the operation of t...

Page 98: ...nside Automation Box Replace I O and Analog cards inside Automation Box Replace the DIRIS Replace all SPDs Replace DC AC capacitors PCB inside power modules Replace the varistors PCB Replace the contr...

Page 99: ...s on the frames around the filter and remove the frame Pull out the filter Inspect the sponge cloth filter if found to be exceptionally dirty it should be discarded and replaced Place the new sponge c...

Page 100: ...C Cab is normally equipped with an SPD on AC mains and SPDs on DC input and AC aux input Figure 89 Location of the SPDs inside the C Cab Each SPD has a fault indicator when the indicator turns red the...

Page 101: ...ution to clean the battery containers or lids These materials will cause permanent damage to the battery container and lid and will invalidate the warranty Follow the suggested maintenance schedule re...

Page 102: ...mpted and the coolant should be filled for the recommended level what is the level and how to check chiller debug tool For coolant filling and draining procedures see below CAUTION This procedure shou...

Page 103: ...1 Unbolt the six front cover screws M4 cross recessed countersunk head using an appropriate screwdriver and remove the cover 2 Connect one end of the hose pump to the valve position 7 shown in the fi...

Page 104: ...me less than the power defined in the Installation and Operating Manual 4 The energy used to charge the Battery System during charge cycle on the DC bus will be measured by the data log provided by th...

Page 105: ...ious alarm conditions that cause the unit stop These alarm conditions require a manual reset Alarm and warnings are divided into two categories System Alarms Warnings these alarms warnings relate to e...

Page 106: ...eshold Voltage of nominal voltage Clearing time s OV2 120 fixed 0 16 fixed OV1 110 110 120 13 0 1 0 13 0 UV1 88 0 0 0 88 21 0 2 0 50 0 UV2 50 0 0 0 50 2 0 0 16 21 0 15 2 Interconnection system respons...

Page 107: ...and get into the food chain damaging health and wellbeing Depleted batteries are considered as toxic waste When battery replacement becomes necessary only give rundown batteries to certified and licen...

Page 108: ...50 kVA 200 kVA 250 kVA 300kVA Width x Depth x Height 1000 x 1300 x 2160 mm 39 4 x 51 2 x 85 inches Width x Depth x Height with packaging 1100 x 1400 x 2500 mm 43 3 x 55 1 x 98 4 inches Module weight 2...

Page 109: ...Width x Depth x Height 1300 x 1300 x 2280 mm 51 2 x 51 2 x 89 8 inches Width x Depth x Height with packaging 1350 x 1350 x 2480 mm 53 1 x 53 1 x 97 6 inches Weight 2180 kg 4806 lbs Weight with packag...

Page 110: ...ary current overload 90 A 180 A 271 A 361 A 451 A 541 A Off grid short circuit current symmetrical fault 125 A 50 ms 250 A 50 ms 375 A 50 ms 500 A 50 ms 625 A 50 ms 750 A 50 ms Off grid short circuit...

Page 111: ...VA Max PCS heating consumption extreme climatic conditions 3 0 kW PCS auxiliary rated current w o battery racks 16 7 A Max CATL battery control circuits consumption 216 W 516 VA No 6 racks Max CATL b...

Page 112: ...upport utility interactive inverters and converters based upon IEEE 1547 2018 and IEEE 1547 1 2020 California RULE 21 Generating Facility Interconnections PG E May 31 2018 SCE April 8 2021 SDG E May 1...

Page 113: ...40A TEST REPORT The SUNSYS B Cab L was tested according to UL 9540A Test Method for Evaluating Thermal Runaway Fire Propagation in Battery Energy Storage Systems 4th edition Document 4789764715 Date I...

Page 114: ...551697A CORPORATE HQ CONTACT SOCOMEC SAS 1 4 RUE DE WESTHOUSE 67235 BENFELD FRANCE www socomec com...

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