Amber M32 Instruction Manual

M32 FLYWHEEL
INSTALLATION & MAINTENANCE
MANUAL
v2.0
March, 2018

Copyright 2018 by Amber Kinetics. All rights reserved.
ii
M32 FLYWHEEL - INSTALLATION & MAINTENANCE MANUAL
DISCLAIMER
The information contained herein is for informational
purposes only and is subject to change without notice.
While every precaution has been taken in the
preparation of this document, it may contain technical
inaccuracies, omissions, and typographical errors, and
Amber Kinetics, Inc. is under no obligation to update
or otherwise correct this information. Amber Kinetics,
Inc. makes no representations or warranties with
respect to the accuracy or completeness of the
contents of this document, and assumes no liability of
any kind, including the implied warranties of non-
infringement, merchantability or fitness for particular
purposes, with respect to the operation or use of
Amber Kinetics hardware, software, or other products
described herein. No license, including implied or
arising by estoppel, to any intellectual property rights
is granted by this document. Terms and limitations
applicable to the purchase or use of Amber Kinetics
products are as set forth in a signed agreement
between the parties or in Amber Kinetics Standard
Terms and Conditions of Sale.
©2018 Amber Kinetics, Inc. All rights reserved. Other
names are for informational purposes only and may be
trademarks of their respective owners.

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Copyright 2018 by Amber Kinetics. All rights reserved. M32 FLYWHEEL - INSTALLATION & MAINTENANCE MANUAL
Table of Contents
1 - Introduction ........................................................................... 1
1.1 - About this Manual .......................................................2
1.1.1 - Formatting Conventions ......................................2
1.1.2 - Organization ............................................................3
1.2 - About Amber Kinetics ............................................. 4
1.2.1 - Support Policy ....................................................... 4
1.2.2 - Features and Benefits ........................................ 4
1.3 - M32 Flywheel Description ......................................6
1.4 - Theory of Operation .................................................8
1.5 - Specifications & Performance ...............................9
1.6 - Safety Features .........................................................10
2 - Safety .....................................................................................11
3 - Installation ...........................................................................15
3.1 - Planning ....................................................................... 16
3.2 - Equipment & Tools ................................................. 17
3.3 - Site Preparation ....................................................... 18
3.4 - Capsule Placement ................................................. 19
3.5 - M32 Flywheel Preparation ..................................20
3.6 - M32 Flywheel Placement .................................... 23
3.7 - Electrical Connections ......................................... 25
3.8 - Completing the Installation ................................ 29
4 - Testing and Commissioning .........................................31
4.1 - Pre-Commissioning Steps ....................................32
4.2 - M32 Flywheel Spin-up ..........................................33
5 - Maintenance .......................................................................35

Copyright 2018 by Amber Kinetics. All rights reserved.
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M32 FLYWHEEL - INSTALLATION & MAINTENANCE MANUAL
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Copyright 2018 by Amber Kinetics. All rights reserved.
1
1 - Introduction
Welcome! This chapter introduces the M32 flywheel by Amber Kinetics by
providing the following general information:
•About This Manual: Layout and organization of this Installation Manual.
• About Amber Kinetics: Company information.
•Features and Benefits: Why the M32 flywheel compares well to batteries.
•Description: Key components of the M32 flywheel.
•Theory of Operation: How the M32 flywheel stores and discharges energy.
•Specifications: Basic mechanical and electrical specifications.
•Safety Features: How the M32 flywheel incorporates safety by design.

Copyright 2018 by Amber Kinetics. All rights reserved.
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M32 FLYWHEEL - INSTALLATION & MAINTENANCE MANUAL
1.1 - About this Manual
This section describes the formatting conventions and
information contained in this manual.
1.1.1 - Formatting Conventions
This manual uses several formatting conventions to
present information of special importance.
Lists of items, points to consider, or procedures that
do not need to be performed in a specific order
appear in bullet format:
• Item 1
• Item 2
Procedures that must be followed in a specific order
appear in numbered steps:
1. Perform this step first.
2. Perform this step second.
Specific keyboard keys are depicted in square
brackets and are capitalized, for example: [ESC]. If
more than one key should be pressed simultaneously,
the notation will appear as [KEY1]+[KEY 2], for
example [ALT]+[F4].
Interface elements such as document titles, fields,
windows, tabs, buttons, commands, options, and icons
appear in bold text.
WARNING: WARNINGS INDICATE THE
POSSIBILITY OF DEATH OR SERIOUS
BODILY INJURY, INCLUDING
ELECTROCUTION HAZARDS.
CAUTION: CAUTIONS INDICATE THE
POSSIBILTY OF EQUIPMENT DAMAGE
AND/OR DATA LOSS.
Note: Notes provide helpful information.

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Copyright 2018 by Amber Kinetics. All rights reserved. 1 - OVERVIEW
1.1.2 - Organization
This manual contains the following chapters:
1 - Introduction: Introduces the M32 flywheel by
describing its key features, components, operation,
specifications, and safety features.
2 - Safety: Provides important safety information that
must be followed when installing, commissioning,
operating, and maintaining the M32 flywheel.
3 - Installation: Detailed installation procedures that
include site planning and preparation, physical
installation, and the various electrical and monitoring
connections.
4 - Testing and Commissioning: Describes how to test
the M32 flywheel and commission it for regular
service.
5 - Maintenance: Contains scheduled maintenance
procedures that will maximize the operating life of
your M32 flywheel(s).

Copyright 2018 by Amber Kinetics. All rights reserved.
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M32 FLYWHEEL - INSTALLATION & MAINTENANCE MANUAL
1.2 - About Amber Kinetics
Amber Kinetics, Inc. was founded in anticipation of the
enormous worldwide demand for competitively
priced, safe, environmentally sustainable, multi-hour
energy storage. Our mission is to accelerate global
adoption of energy storage by commercializing our
advanced, cost-disruptive flywheel technology to
provide a lower cost and higher performing
alternative to fossil fuel generation.
1.2.1 - Support Policy
Amber Kinetics support is available via either phone or
email Monday to Friday from 8:00AM to 5:00PM
Pacific time (holidays excluded).
You may contact Amber Kinetics via the following
methods:
1.2.2 - Features and Benefits
Amber Kinetics, Inc. was founded in 2009 to develop
and bring to market breakthrough flywheel energy-
storage technology. Although flywheel storage is a
mature technology, it has been limited to short-
duration discharges.
The M32 flywheel by Amber Kinetics is the world’s first
cost-effective energy storage system that safely and
reliably provides up to four hours of continuous power
for the following applications:
• Demand reduction
• Energy arbitrage
• T&D deferral
• Flexible capacity
• Renewable firming
• Ancillary services
Address 32920 Alvarado Niles Blvd
Suite 250
Union City, CA 94587
Phone [phone]
Email [email protected]

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Copyright 2018 by Amber Kinetics. All rights reserved. 1 - OVERVIEW
The M32 flywheel offers the following key benefits
over traditional chemical batteries:
• >86% round trip efficiency (DC),
includes self-discharge
• No daily cycling limitations
• No degradation over time
• No HVAC required
• Operates in hot and cold environments (-40°F to
122°F; -40°C to 50C°)
• Fast response time (<1 second)
• Recyclable all-steel design
• Minimal operations and maintenance
• 30-year design life
• 10-year manufacturer warranty

Copyright 2018 by Amber Kinetics. All rights reserved.
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M32 FLYWHEEL - INSTALLATION & MAINTENANCE MANUAL
1.3 - M32 Flywheel Description
The Flywheel Module (FM) consists of the Flywheel
Housing that contains the primary electric and
mechanical components of the M32 flywheel, an
Electronics Enclosure mounted on the top of the
Flywheel Housing, and a Passive Vacuum Pump that is
also mounted to the Flywheel Housing.
This assembly functions as a “mechanical battery.”
Like a chemical battery, it is charged by an input of DC
electrical energy and discharged by an output of DC
electrical energy. To charge, the DC power is inverted
to variable frequency AC power that powers a Motor/
Generator to spin up a rotating mass, which stores the
electrical power as mechanical energy. To discharge,
this process is reversed. The rotor group operates in a
vacuum to minimize rotational losses during storage.
The M32 flywheel and Capsule are installed in an
excavated hole in the ground, and a protective
Capsule Lid is then placed on top of the Capsule to
protect the M32 flywheel and electronics from rain
and debris.
Figure 1 displays the major components that make up
the components within and attached to the Flywheel
Housing:
Figure 1: M32 flywheel components
Note: This drawing is intended for
general information only. It is not to
scale, and the actual appearance and/or
location of components may vary from
those shown.

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Copyright 2018 by Amber Kinetics. All rights reserved. 1 - OVERVIEW
The M32 flywheel components are as follows
(numbers correspond to the callouts in Figure 1 on the
preceding image):
•Flywheel Housing (1): Vacuum vessel that houses
the components numbered 2 through 9.
•Passive Vacuum Pump (2): Canister of molecule-
adsorbing desiccants that maintain the appropriate
vacuum environment within the Flywheel Housing
(1).
•Bearing Caps (3): Cover and provide access to the
upper and lower Bearings (4). There is also a jack
screw underneath the lower Bearing Cap that
lowers the Flywheel Rotor (7) onto internal
supports to protect the Bearings (4) from damage
during shipping. You will remove the lower Bearing
Cap and adjust this jack screw during installation.
•Bearings (4): Support the Flywheel Rotor (7).
•Electronics Enclosure (5): Houses a number of
electronic components, including the electrical
powertrain, instrumentation, communications, and
control.
•Offloader (6): Electromagnet that reduces loads on
the Bearings (4) by providing a lifting force for the
Flywheel (7).
•Flywheel Rotor (7): Rotating mass that stores
mechanical energy for conversion into electricity.
•Motor/Generator (8): Converts electrical energy to
mechanical energy when the Flywheel Rotor is
charging, and vice-versa when the Flywheel Rotor
is discharging. The Motor/Generator also contains
the current-carrying conductors that route power
to and from the Electronics Enclosure (5).
•Feet (9): Support the Flywheel Housing (1) and
other components.
•Capsule (not shown): Encloses the M32 flywheel
and other components within the excavated hole.
•Capsule Lid (not shown): Covers the Capsule to
prevent rain and debris from falling into the
Capsule.

Copyright 2018 by Amber Kinetics. All rights reserved.
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M32 FLYWHEEL - INSTALLATION & MAINTENANCE MANUAL
1.4 - Theory of Operation
The M32 flywheel stores kinetic energy in a massive
rotating disk. The amount of energy stored is defined
by the equation E=½Jω2, where:
• J is the moment of inertia (related to the mass and
size of the disk)
•ωis the rotational speed.
The rotational speed of the M32 flywheel accurately
characterizes the state of charge of the system, and
this speed will vary slowly between its minimum and
maximum limits over the course of a 4-hour charge or
discharge period. Unlike batteries, the M32 flywheel
exhibits no capacity fade over time.
As described in “M32 Flywheel Description” on page 6,
the Motor/Generator assembly within the M32
flywheel converts the kinetic energy of the Flywheel
Rotor to and from electrical energy. This 3-phase
electric component is driven by a Pulse Width
Modulation (PWM) voltage-source inverter within the
Electronics Enclosure. Both the Motor/Generator
assembly and M32 flywheel inverter are capable of
providing both positive and negative watts to the
Flywheel Rotor, which allows the M32 flywheel to
accurately track any continuously variable charge/
discharge profile that falls within its maximum power
and energy ratings.
Multiple M32 flywheels can be connected in parallel to
meet desired power and energy requirements. The
inverter in each M32 flywheel connects to a common
DC bus, as shown in Figure 2.
Figure 2: DC bus connection
A third-party grid-tie inverter (not shown) interfaces
between the DC bus and the AC line. A single central
grid-tie inverter can serve many parallel M32
flywheels. Please contact Amber Kinetics as described
in “Support Policy” on page 4 for information on grid-
tie inverter requirements.

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Copyright 2018 by Amber Kinetics. All rights reserved. 1 - OVERVIEW
1.5 - Specifications & Performance
These tables provide basic mechanical, environmental,
and electrical specifications for the M32 flywheel.
*Round trip, excludes self-discharge.
** Average over charge/discharge cycle.
Mechanical
Weight 10,500lbs
(4,763kg)
Size (height/diameter) 52”x54”
(132cm x 137cm)
Installation below grade
Seismic rating 4 USUBC
Daily cycling limit none
Design life 30 years
Standard warranty 10 years
Environmental
Temperature
(storage)
-40°F to 140°F
(-40°C to 60°C)
Temperature
(operating)
-40°F to 122°F
(-40°C to 50°C)
Humidity 100% condensing
Greenhouse gases zero emissions
Electrical
Maximum power 8 kW (minimum)
Energy 32 kWh
Full-power response
time
<1 second
Discharge duration 4 hrs (minimum)
Efficiency (round trip) >86%*
Average self-discharge <100W**
Auxiliary power
(120 Vac)
<50 W (coasting)
<140W** (charge/discharge)
DC input/output 550 to 750 Vdc
DC current 15A (maximum)
Internal fuse 30A DC

Copyright 2018 by Amber Kinetics. All rights reserved.
10
M32 FLYWHEEL - INSTALLATION & MAINTENANCE MANUAL
1.6 - Safety Features
Amber Kinetics has developed a comprehensive, five-
step approach to flywheel safety. Our methodology
encompasses the entire spectrum from design to
manufacturing, testing, installation, and operation:
•Design: Each M32 flywheel is
designed using conservative peak
stress and cyclic fatigue margins
that are consistent with aerospace
engineering standards.
•Manufacturing: The material used
for the Flywheel Rotor is produced
using a commercially proven
manufacturing process that yields
the cleanest, highest-grade steel
available.
•Testing: Finished rotors are
scanned for both surface and bulk
defects. Each rotor is then spun
beyond its maximum rated
operating RPM before being
placed into service.
•Installation: As a redundant safety
measure, M32 flywheels are
installed either below grade or
behind surrounding earth berms.
•Operation: Each M32 flywheel is
monitored 24/7/365 by a health
monitoring system.

Copyright 2018 by Amber Kinetics. All rights reserved.
11
2 - Safety
This chapter contains important safety guidelines and advice that are intended
to help ensure a safe installation and operating environment. These directions
must be considered in addition to both standard and site-specific safety best
practices.
The order in which these guidelines appears is not intended to express or
imply any priority or relative importance.

Copyright 2018 by Amber Kinetics. All rights reserved.
12
M32 FLYWHEEL - INSTALLATION & MAINTENANCE MANUAL
• This manual is an integral part of the M32 flywheel
product. It contains important instructions that
must be followed when installing, commissioning,
and maintaining the M32 flywheel. Read this entire
manual, paying particular attention to all
WARNING, CAUTION, and Note callouts, before
installing or commissioning the M32 flywheel. Keep
this manual and all other documentation in a
convenient place for future reference.
• Read all of the instructions for all grid-tie
inverter(s), computers, routers/switches, and all
other components used in every installation,
paying particular attention to all safety-related
information.
• This manual does not and is not intended to
replace any local, state, provincial, federal, or
national laws, regulations, or codes applicable to
the installation and use of the M32 flywheel,
including without limitation applicable electrical
safety codes. All phases of M32 flywheel
installation, commissioning, and operation must
comply with all applicable codes and regulations
for the installation site,
• All US electrical installations must be performed by
an authorized electrician in compliance with both
National Electrical Code ANSI/NFPA 70 and OSHA
requirements, in addition to all local jurisdiction
requirements.
• The M32 flywheel weighs approximately 10,500lbs
(~4,763kg). The Capsule weighs approximately
WARNING: THIS MANUAL IS FOR USE
BY QUALIFIED PERSONNEL ONLY.
QUALIFIED PERSONNEL ARE THOSE
WHO HAVE RECEIVED TRAINING AND
HAVE DEMONSTRATED SKILLS AND
KNOWLEDGE IN THE INSTALLATION,
COMMISSIONING, AND OPERATION OF
THE M32 FLYWHEEL, AND WHO ARE
TRAINED IN MITIGATING HAZARDS
INVOLVED IN INSTALLING AND
OPERATING HIGH-POWER
ELECTRICAL DEVICES.
WARNING: FAILURE TO FOLLOW THE
INSTRUCTIONS CONTAINED IN THIS
MANUAL AND ANY OTHER M32
FLYWHEEL DOCUMENTATION, AND/
OR TO FOLLOW STANDARD AND SITE-
SPECIFIC BEST PRACTICES CAN
CAUSE SERIOUS INJURY OR DEATH
FROM A VARIETY OF ELECTRICAL
AND NON-ELECTRICAL HAZARDS.
CAUTION: FAILURE TO FOLLOW ALL
OF THE SAFETY INSTRUCTIONS IN
THIS CHAPTER, MANUAL, AND OTHER
APPLICABLE DOCUMENTATION CAN
RESULT IN EQUIPMENT DAMAGE AND
CAN VOID YOUR WARRANTY OR
WARRANTIES.

13
Copyright 2018 by Amber Kinetics. All rights reserved. 2 - SAFETY
1,200lbs (~550kg). The Capsule Lid weighs
approximately 400lbs (~200kg). Always use an
appropriately rated crane/hoist along with
appropriately rated equipment (such as straps,
chains, shackles, and/or hooks) when hoisting any
of these components.
• Remain well clear of any component during any
hoisting operation to prevent serious injury or
death in the event of any hoist failure. Never use
any body part to position or align the components,
such as when lowering the M32 flywheel and
Capsule into the hole, Instead, use one or more
tagline(s) while remaining well clear of the
components.
• The installation hole and protruding Capsule pose
various tripping and/or falling hazards. Remain
clear of all installation holes and be aware of your
surroundings at all times.
• The M32 flywheel produces hazardous voltages
and currents when the Flywheel Rotor is spinning
at any speed, even when the utility grid and/or
other power sources are lost or disconnected.
• All wiring and connections may have hazardous
voltages and currents at any time. Only qualified
and authorized personnel may install and/or
maintain the M32 flywheel and associated
components.
• Be sure to use safety lockout devices on all
affected circuit breaker(s) and/or power shut-
off(s) when working on the M32 flywheel or
associated components to prevent accidental
power-on and death from electrical shock,
• The M32 flywheel contains no user-serviceable
parts. Under no circumstances should you open the
Flywheel Housing or perform any other servicing or
repair aside from that explicitly described in this
manual. Always contact Amber Kinetics for any
maintenance or repair that is not described in this
manual.
• Only use the M32 flywheel in accordance with the
information provided in this manual, any other M32
documentation, and all locally applicable standards
and directives. Any other use or application may
cause death, personal injury, and/or property
damage.
• Altering the M32 flywheel, such as (but not limited
to) modifications or conversions, is only permitted
with the express written permission of Amber
Kinetics, Inc. Unauthorized alterations will void all
guarantee and warranty claims and will usually void
the operation permit. In no event shall Amber
Kinetics be held liable for any damage caused by
such changes.
• The M32 flywheel can continue to spin for up to 15
days following removal of DC power. Contact
Amber Kinetics for assistance before approaching
any M32 flywheel while it is still spinning.
• The Capsule lid must be in place at all times while
the Flywheel Rotor is spinning.

Copyright 2018 by Amber Kinetics. All rights reserved.
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M32 FLYWHEEL - INSTALLATION & MAINTENANCE MANUAL
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Copyright 2018 by Amber Kinetics. All rights reserved.
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3 - Installation
This chapter describes the installation procedure for the M32 flywheel. This
process begins with planning the installation, gathering the needed equipment
and tools, and then preparing the site. Next, the M32 flywheel is installed in the
ground and electrical connections are made. Finally, a vacuum pump is
connected to the M32 flywheel(s) to ensure a proper level of vacuum inside
the Flywheel Housing, and the site-wide wiring is completed.

Copyright 2018 by Amber Kinetics. All rights reserved.
16
M32 FLYWHEEL - INSTALLATION & MAINTENANCE MANUAL
3.1 - Planning
When planning a multi-M32 flywheel installation:
• The total DC capacity will be 8kw times the number
of M32 flywheels in the installation.
• Each block of M32 flywheels consists of two rows.
• Figure 3 displays the minimum clearance
requirements between individual M32 flywheels,
blocks, and the site perimeter.
Figure 3: Clearance requirements at a multi-M32 flywheel site