Alpha ESS T100 User manual

Installation & Operation Manual
Energy Storage System (ESS)
T50/T100
V02

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Copyright Statement
This manual is under the copyright of Alpha 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

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Content
IMPRINT..........................................................................................................1
Copyright Statement......................................................................................2
Version Information.......................................................................................2
Content ...........................................................................................................3
1. Introduction..............................................................................................5
Brief Introduction ..............................................................................5
Explanation of Terms ........................................................................5
2. Safety Instructions ..................................................................................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 System..........................................................................................15
Fire Extinguishing System........................................................................19
Air Conditioner ..........................................................................................19
Distribution Box.........................................................................................20

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4. Installation..............................................................................................20
Installation Precautions..................................................................20
Installation........................................................................................20
Container Installation................................................................................20
Battery Installation ....................................................................................22
Battery Side-Wiring...................................................................................23
Inverter Side-Wiring..................................................................................25
5. Operation................................................................................................27
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
Battery and BMS troubleshooting..................................................43
Error Type .................................................................................................43
Emergency Handling Plan........................................................................43
EMS Troubleshooting......................................................................44

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1. Introduction
Brief Introduction
This manual applies for Storion T50/T100 Li-ion battery energy storage system, mainly
includes:
(1) Safety introduction
Introduces the product use, operating notes and qualification of operators of T50/T100 Li-
ion battery energy storage system.
(2) Product description
Describes product appearance, product characteristics, system composition and major
functions of T50/T100 Li-ion battery energy storage system.
(3) System installation
Introduces the installation of T50/T100, including attentions.
(4) Operation
Introduces the operation of T50/T100 system.
(5) Routine maintenance
Introduces items in maintenance of T50/T100 kWh Li-ion battery energy storage system,
including attentions.
(6) Trouble-shooting
Introduces the faults of T50/T100 Li-ion battery energy storage system, reasons to faults,
and processing method.
Explanation of Terms
(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 devices and multiple Lithium
iron phosphate cells(Notes: For packs from same company, all the details such as physical
size, working performance and interface specification should be consistent in order that all
the packs are interchangeable).
(3) Battery management system
Electronic equipment collection formonitoring the operating information of cells, packs and
system units (such as voltage, current, temperature, protective parameter of batteries),
evaluating the state of charge (SOC), the state of health (SOH) and cumulative
processed energy, protecting batteries for safety, etc.
(4) Battery system unit
Combination made up of batteries through series parallel combination inside and a battery
management system (BMS) in which accesses to DC side of a bidirectional converter.
(5) Storage unit

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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.

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2. Safety Instructions
Manual Keeping
This manual contains important information about operating the system. Before operating,
please read it very carefully.
The PCS should be operated in strict accordance with the description in the manual, in
case that it causes damage or loss to equipment, personnel and property.
This manual should be kept carefully for maintenance and reparation.
Operator Requirements
The operators should get a professional qualification, or be trained.
The operators should be familiar with the whole storage system, including compositions
and working principle of the system.
The operators should be familiar with the Product Instruction.
While maintaining it must ensure that two operators are in the field, and they cannot
operate any equipment until all of them are powered off and fully discharged.
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, maintaining and repairing, in case of preventing unrelated personnel
nearby to cause incorrect operation or accident, the opinions below should be followed:
Obvious signs should be set at front switch and rear-level switch in case of accidents
caused by false switching.
Warning signs or tapes should be set near operating areas.
Keys of the system must be pulled out after maintenance or operation.
Live Line Measurement
High voltage in the container which may cause vital electric shock when touching by
accident.
Equipment protection must be taken in live line measurements (e.g.: insulation gloves).
The measuring equipment should be connected and used correctly to ensure personnel
safety. When measuring, at least two workers are needed.

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Measuring Equipment
For ensuring the electrical parameters to match requirements, related measuring
equipment are required when the system is being connected or tested.
Ensure that the connection and use matches specification in case of electric arc or shock.
Electrostatic Protection
Contact or improper operation of the printed circuit board or other ESD sensitive
components may result in damage to the device. Unnecessary contact should be avoided.
Moisture Protection
Moisture intrusion may highly likely well damage the system.
Do not open the container door when the humidity is larger than 95%.
Repair or maintaining activities in wet weather should be avoided or limited.
Operation After Power Failure
The batterysystem belongs to energy storage system, and it keepsfatal 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 the system, when doing personal protective equipments are
required.
When stepping into the containers, as minimum the following protective equipments are
required:
No.
Item
Notes
1
Work clothes
2
Protective shoes
3
Protective glasses
When doing maintenance works such as checking cables or wires, measuring voltage,
replacing small electrical parts or cleaning modules and brackets, as minimum the
following protective equipments are required:
No.
Item
Notes
1
Work clothes
2
Protective shoes
3
Protective glasses
4
Insulated gloves
For touching live parts
Note: All metal tools during maintenance should be insulated.

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When replacing modules, the following protective 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.

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3. Product Description
The AlphaESS T50/T100 energy storage system is an off-grid system. The excessive
energy 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 3-2 System application diagram

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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

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Product Characteristics
LiFePO4 batteries produced byAlphaESS have longer lifespan and higher reliability, which
is able to satisfy the application of energy storage systems.
The system is highly modular designed, and it is easier toassemble, transportand maintain.
The system has a three-level BMS and is easier for system expansion.
The system adopts full time balancing technology so that the consistency of batteries and
modules can be well ensured.
The system is designed as a removable container which is tight, flexible, convenient for
installation and testing, suitable to the environment, and is able to satisfy different kinds of
application.
The system has current balance technology 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 system realizes emergency fireprotection by automatic alarming andfire extinguishing
system
Parts Parameters
Container
Battery Enclosure
Manufacture
AlphaESS
/
Model Name
10’GP energy storage
container
/
Dimensions (L x W x H in mm)
2991 x 2438 x 2591
Quantity
1
Ventilation
e.g. natural, air conditioned
Air conditioned
Access to all battery terminals
Yes
Yes
Racking of batteries
Horizontal or Vertical
Vertical
Enclosure shading details
Shell material details
SPA-H, t2.0; Thermal
insulation composite board:
stone wool
Foundation type
The fixed foundation of the
container is cement pile
Hold down method

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PCS
3.3.2.1 Product Instruction
T50/T100 INV is a hybrid inverter. It has DC/DC and DC/AC modules. It can transform the
DC electricity from PV panels into three-phase AC electricity to supply 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
Display screen
11
Load switch
6
Handle
12
Diesel switch
3.3.2.3 Technical Parameters
No.
Item
Parameter
AC Side Data

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1
Rated Power
50 kW
2
Max Output Power
52.5 kVA
3
Rated Voltage
400 V
4
Max Output Current
72 A
5
AC Connection
3P4W (Transformerless)
6
Operation Voltage Range
400 V ±15 %
7
Rated Frequency
50 Hz / 60 Hz
8
Frequency Range
50 Hz / 60 Hz ±2.5 %
9
THDI @ Rated Power
<3%
10
Power Factor
-0.8 ~ +0.8
DC Data (Battery Side)
11
Rated Power
50 kW
12
Max. Stable Operation Power
50 kW
13
Max Long Term Operation Current
160 A
14
DC Voltage Range
250 –520 V
PV Side Data
15
PV Voltage 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
< 70dB
24
Operation Temperature
-25 ℃~ +55 ℃
25
Cooling Concept
Forced Air
26
Humidity
0~95% (Non-Condensing)
27
Communication Interfaces
Ethernet‚ RS485‚ CAN2.0
3.3.2.4 Emergence Stop Switch
The converter stops working immediately after pushing down the button.
If you will restart the converter, please execute in the following order:
a) Conduct counter clockwise rotation on the emergency stop switch and then loosen the
locking status.
b) Push the AC breaker into “OFF” position, pull up the emergence button then turn the
AC breaker “ON”.

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c) Launch the machine and run after the requirement
Battery System
Item
Description
Parameter
Remark
1
Nominal discharge power
50 kW / 100 kW
2
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 positive pole
6
COM port
3
Earthing point
7
Information label

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4
LED light
Battery technical parameters:
No.
Item
Technical parameter
Remarks
1
Battery model
M48112-S
2
Assembly method
16S2P
3
Nominal voltage
51.2 V
4
Voltage range
48～58 V
5
Nominal capacity
112 Ah
Max. charge / discharge
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 mode
CAN
15
Weight
70 ±2.0 kg
16
Size (W x D x H)
494.6 x 615.3 x 162.6
(±5) mm
17
Humidity
15%～85%
3.3.3.2 HV900112
Figure 3-7 HV900112 front cover

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HV900112 interface definition:
No.
Description
No.
Description
1
DCin+
7
DCout-
2
DCin-
8
AC input
3
Earthing point
9
AC Air switch
4
Plastic circuit breaker
10
BMU COM port
5
Information label
11
LMU COM port
6
DCout+
12
LED
HV900112 technical parameters:
No.
Item
Technical 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 interface definition:
No.
Description
No.
Description
1
BMU COM port
9
PCS COM port
2
BMU COM port
10
PV COM port
3
Ethernet
11
Dry contact
4
Reserve power supply
12
EMS display screen
17

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5
Dry contact
13
DB9 COM
6
Electricity meter
14
Storage card
7
EMS
15
Burning port
8
Air conditioner
16
COM pin board
17
DIP switch
Technical parameters：
No.
Item
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 parameter
1
Dimensions (W*D*H)
447x205x162 mm
2
Weight
7 kg
1
1
1
1
2
2
2
2
3
3
4
4
5
5

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Fire Extinguishing System
The container has fire detection, alarm, control and firefighting systems.Alarm bells will be
ringing once either the smoke detector or the heat detector is activated. When the smoke
detector and heat detector are activated at the same time, after confirming there is fire, the
fire monitoring device will give a signal to the fire control panel, audible and visual warning
signals are automatically generated and then the fire panel starts counting down.After that,
the fire extinguisher will start and spray gas.
When the alarming bells ring, the control system will send signal to cut off the DC
connectionof batteriesbytrippingallDC breakers.Aftertheaudibleandvisualalarmstarts,
the PLC will get signal and AC breakers will be tripped. Personnel in the container should
evacuate immediately, meanwhile the control system will start counting down and then
send signal to spray gas after the counting down. The electromagnetic valve will act 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, eitherDC or AC supply, the
fire panel will send a trouble signal to PLC and show that something is wrong with power
supply.
Air Conditioner
3.3.5.1 Introduction
A CC2000PA cabinet air conditioner consists of the following main components:
Compressor, condenser, temperature controller, capillary tube or expansion valve and fans.
It features compact structure, light, low energy consumption and low noise. The cabinet air
conditioneradopts AC power supply anduses the environmental-friendlyrefrigerant R134a
to achieve high efficiency, energy saving, safety, and reliability. The cabinet air conditioner
is equipped with RJ45 ports to implement communication and remote control.
Table 1 Air conditioner technical parameters:
No.
Project
Technical Parameter
1
Auxiliary power type
220 V, 50 HZ
2
Refrigerating capacity
2000 W
3
Rated power
616 W
4
Rated current
2.8 A
5
Maximum power
880 W
6
Maximum current
4 A

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Distribution Box
The distribution box (in the container) figure is shown as below:
Table 2 Distribution box swith discription
No.
Description
No.
Description
1
AC input
7
Exhaust fan
2
Air conditioner
8
BMS
3
PCS lighting
9
Container fan
4
Battery lighting
10
Camera
5
Socket
11
Camera
6
Emergency
4. Installation
Installation 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 materials or gases.
Installation
If you don’t need the container, please skip to 4.2.2 directly.
Container Installation
4.2.1.1 Base Requirements
1. This container has been made based on the new 10'GP mark TEU dimensions;
2991*2438*2591 (long * wide * high).