Avalon AFB2 User manual

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PRODUCT / MODEL NUMBER
AFB2
DOCUMENT TITLE
Installation and Operation Manual, DC Battery
DOCUMENT NUMBER
SPC00138
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COPYRIGHT
Unless stated otherwise, copyright in this document (including content and design) is owned
by Avalon Battery Corporation or used under licence.
You may not reproduce, adapt, modify, communicate to the public, reproduce or otherwise
use any part of this document (in particular for commercial purposes) except as set out
below, or otherwise with the express written permission from Avalon Battery Corporation.
Copyright © Avalon Battery Corporation, 2018.
DISCLAIMER
Avalon Battery Corporation and its subsidiaries makes no representations or warranties with
respect to the contents hereof and specifically disclaims any implied warranty or
merchantability or fitness for any particular purpose.
Avalon Battery has made every effort to ensure that content within this manual is accurate
but disclaims liability for any inaccuracies or omissions that may have occurred.
Information in this document is subject to revision without notice.
TRADEMARK
Product names used in this manual are the properties of their respective owners and are
acknowledged.
SUPPORT
For any additional support, please contact Avalon Battery at the following:
Avalon Battery Corporation
426 17th Street, Suite 700
Oakland, CA 94612
Via email: [email protected]
On the web: www.avalonbattery.com
Phone: [phone]

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1.0 Introduction
The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed
for power and energy management. The AFB2 is comprised of Avalon’s vanadium flow
battery, electrical and controls system that provide a DC Battery source for DC coupled, grid
interactive or microgrid energy provision and management.
Figure 1 – AFB2 Vanadium Flow Battery.

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1.1 Abbreviations
AC Alternating current
AHJ Authority having jurisdiction
AWG American wire gauge
BMC Battery management controller
BMS Battery management software
DC Direct current
EMS Energy management system
HVDC High voltage direct current
NEC National Electrical Code
NFPA National Fire Protection Association
NPT National pipe taper
PC Personal computer
PCS Power conversion system
PE Protective earth
PPE Personal protective equipment
PSU Power supply unit
SDS Safety data sheet
SOC State of charge

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1.2 Product Specifications
Battery Specifications
Model
AFB2.10
AFB2.5
Energy Storage Capacity, Rated
30 kWh
Continuous DC Power, Max
11 kW
5.5 kW
DC Power, Rated
10.5 kW
5.25 kW
Energy Storage Duration, Nominal
3 hours
6 hours
Energy Storage Ampacity, Nominal
55 Ah
Operating Voltage, Nominal
550 DC V
Energy Storage Capacity, Annual Degradation1
< 0.5% per year
Battery Energy Efficiency, Round-Trip (DC)
> 75%
Energy Efficiency, Annual Degradation1
< 0.1% per year
Discharge Voltage Range
440 to 600 DC V
Charge Voltage Range
500 to 600 DC V
Continuous Discharge / Charge Current, Rated
20 DC A
10 DC A
Internal Fuse Rating
30 DC A
15 DC A
Physical
Battery Dimensions (L x W x H), not including Power
Converter 1.77 m x 1.07 m x 1.79 m
[69.7” x 42.3” x 70.4”]
Mass (flooded)
3000 kg [6600 lbs]
Electrolyte Volume, Nominal
1460 L
Environmental
Ambient Operating Temperature Range
–5 to 45°C
Extended Ambient Operating Temperature Range,
with Optional Cold Weather Kit
–25 to 45°C
Storage Temperature Range
–25 to 50°C
Cooling
Integrated, forced air
Certification / Standard Compliance
Safety
UL 19732
1On the basis of 130 full depth-of-discharge cycles per year
2Pending

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1.3 Description
Avalon’s AFB2 is a direct current (DC) energy storage system composed of components
that comprise two key functions: the battery function which provides electrochemical energy
storage and the electrical and controls function that responds to external power requests
and provides the requested DC power.
1.3.1 Battery Function
Housed within the enclosure of the system are all components of the battery, including the
cell stack(s), electrolyte processing system, electrolyte storage (including the electrolyte)
and the thermal management system. Integrated as part of the enclosure is a secondary
containment vessel, lined with an electrolyte-resistant coating to prevent electrolyte from
escaping the system in event of any internal leak.
These components are accessed behind the removable plastic front Avalon cover and the
internal metal access panel. Given the presence of potential hazards within the battery
enclosure, only authorized personnel should ever access the inside of the battery enclosure.
1.3.2 Electrical and Controls Function
Within the battery enclosure and located between the
two stacks is a panel frame that houses the electrical
and controls components. This panel frame houses
two bi-directional DC-DC converters, the battery’s
power supply unit (PSU) and the battery management
controller (BMC).
Given the presence of high voltage components within
the enclosure, only authorized personnel should ever
touch or service these components.
Figure 2 – Inside view of AFB2 battery compartment.
Figure 3 – Internal view of electrical components.

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2.0 Important Safety Instructions
SAVE THESE INSTRUCTIONS! This manual contains important instructions
related to the installation, operation and maintenance of Avalon Battery’s
AFB2. This manual should be retained throughout the life of the product.
Product failures or decreases in performance resulting from an act in
contravention of the operation manual shall be excluded from the product
warranty.
Hazard voltages are present within the AFB2. Installation and maintenance
should only be conducted by qualified personnel familiar with this manual and
with proper precautions in place.
Hazardous voltages can remain on the battery even when fully disconnected.
Proper precautions MUST be taken to avoid direct contact with HV & LV DC
components AT ALL TIMES. A service event that requires potential exposure
to one more DC components, shall only be undertaken by specially-training
personnel with proper PPE.
Electrolyte is corrosive and acutely toxic. Avoid all contact with skin and eyes.
When working with or conducting a procedure that results in potential
exposure to electrolyte, all necessary personal protective equipment must be
worn. This includes safety glasses, sleeves, gloves, lab coat or apron and
may include boots and respirator.
During the course of charging and discharging or in a fault condition,
flammable gases can be generated within the battery. Gas ventilation system
must be properly installed where required.
All necessary precautions MUST be taken when attempting to service within
the battery or electrolyte tanks, this includes:
•personal flammability meters to safe gas levels – do not access or
continue service if gas concentration above 25% LFL
•proper ventilation and purging
•non-sparking tools

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The following precautions shall be followed at all times:
•Installation shall conform to federal, state and local regulations regarding hazardous
material.
•All personnel (installers, operators, etc.) that may come into contact with electrolyte
must be trained and have read and are familiar with the safety data sheet (SDS) for
electrolyte. Electrolyte SDS can be found in appendix of all manuals.
•All wiring connections to system shall be compatible with specifications identified in
this document and completed in accordance with local codes and NFPA 70 (NEC).
•Electrical grounding shall be in accordance with code requirements & NFPA 70
(NEC).
•External electrical systems must be operated within the stated voltage, current and
power limitation as stated on the product specs. The system is intended to be
installed with a field installed Manual DC Disconnect.
•The system shall not be connected to any electrical equipment that is not explicitly
called out in the manual or sales agreement. This includes installations or
connections that in any way deviate from the procedures and connections explicitly
allowed in the manual.
•System shall only be operated in accordance with this manual.
•The system shall not be operated outside of the stated environmental conditions.
•Air flow path shall be unrestricted, ensuring sufficient air flow to the system.
•The battery shall not be operated with any external enclosure panels removed. The
enclosure panels protect against rain, dust and debris ingress, electric shock and
electrolyte egress in the unlikely event of a leak.
•No person shall attempt to service, modify or alter the product (including software) in
a way not explicitly allowed by this installation and operation manual or the service
manual.
•Only authorized personnel should attempt to service the system. Personnel should
be familiar with all product documentation prior to conducting service.
•Do not bypass or make any changes to plumbing or any electrical connections.
•Use extreme care when servicing the unit with tools to avoid accidental shorts.
•In the event of an electrolyte leak the system should be powered down via the DC
disconnect. If uncontained, i.e. outside of secondary containment, measures must be
taken to control and contain leak. Refer to site specific emergency response
instructions completed in accordance with local, state and federal regulations.
•The system is not intended to be installed in a marine environment.
•Systems intended for outdoor use shall be mounted on a non-combustible surface,
such as a concrete pad, that extends a minimum of 91.4cm (3ft) on all sides.

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3.0 Internal Protections
The AFB2 includes primary self-protection functions described in the following sections.
These functions are embedded with the battery internal hardware and protects the battery
from mis-operation and potential damage.
3.1 Over-Current / High Voltage DC (HVDC) Fuse
A fuse is located at the first connection point to the battery on the positive wiring to act as
over-current protection on the high-voltage line. This is a replaceable midget-style fuse.
Voltage
Rating
Min. 600 DC V
Size
10 x 38 mm
Type
Fast-blow
Current
Rating
30 A (AFB2.10)
15 A (AFB2.5)
Examples
Littlefuse
SPF030 / SPF015
Mersen
HP10T30 / HP10T15
Figure 4 – Fuse details and location, adjacent to the
landing distribution block for external HVDC wiring
3.2 Over-voltage
The AFB2 possess multiple levels of overvoltage protection, with ultimate protection
integrated within the DC-DC converters.
3.3 Over-charge
Hardware protection has been built into the battery management controller (BMC) to prevent
ensure over-charge.
3.4 Current Limiting Devices on Sub-components
The motor drives and fan power supplies have current limiting hardware protection built into
the controller for protection in the event of shorting of the pump motor or fan power cable
harness.
3.5 Secondary Containment
The AFB2 has integrated secondary containment built into the lower enclosure of the
system, in the event of an internal system leak in the plumbing, stacks, or primary tanks.
This containment consists of an internal coating of an elastomeric polyurethane coating on

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the inside of a continuously welded steel enclosure. This coating has proven chemical
resistance to continuous exposure of concentrated acids including 50% sulfuric acid. The
capacity of the secondary containment (including the primary tanks), is capable of holding in
excess of 130% of AFB2 electrolyte capacity. In addition, all of the plumbing, stacks, and
primary containment tank are designed within the footprint of the secondary containment so
any leak is designed to remain within the secondary containment.
In the event of an internal system leak (tanks, stack or plumbing), the tank level will
eventually drop below the pump supply hose from the tank (nominally 5% electrolyte loss),
at which point, the pumps will stop operating and a fault will be generated by the system.

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4.0 Unpacking
Upon receiving the battery, the packaging shall be carefully inspected and any damage shall
be noted and reported to the shipper and Avalon Battery before continuing with installation.
All packaging materials shall be removed and properly disposed. All equipment shall be
inspected for signs of damage. Avalon Cover panels are typically shipped on top of system
and should be carefully removed and set aside until ready for installation.
If received as components, components should be unpacked carefully and inspected for any
signs of damage. Personal protective equipment (PPE), including eye protection and gloves
should be worn while unpacking any electrolyte containing components (e.g. cell stacks) in
event of any electrolyte leakage that may have occurred during transport. If any leaked
electrolyte is found, installation shall be stopped and reported to Avalon Battery.
4.1 Shock & Tilt Detectors
If installed on packaging or equipment, the state of the shock and tilt indicators should be
recorded at the time of receiving the equipment from the shipper. A photo should be taken of
each indicator and associated with the position of each. Any indication of excessive shock or
tilt shall be immediately reported to Avalon Battery.

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5.0 Handling
The AFB2 is designed to be handled with a fork lift using the pockets in the bottom of the
enclosure or via an overhead crane using the lifting points shown in Figure 5.
The AFB2 is shipped in upright position and MUST remain in an upright position while being
moved or handled.
5.1.1 Overhead Crane
To lift and/or move with a crane, the plastic cover panels shall be removed and attached to
the roof of the unit. Lift the system by utilising four M10 hoist rings installed into the
designated lifting lugs. Install four 2m (72’) lifting straps at each corner to hoist the battery.
The AFB2 is designed to be lifted and handled either via the fork lift pockets
at the base or via the lifting points located at the mid-point of the battery.
The top of the enclosure is NOT rated for lifting or strapping down and MUST
NOT be used as lifting point.
Figure 5 – Overhead lift points and example lifting arrangement.
5.1.2 Forklift
To lift and/or move with a forklift there are two jack pockets that must be used at the bottom
of the enclosure. Ensure the battery is centered over the fork lift.
Never attempt to lift or jack at any point that is not the hoist hook mounts or
jack pockets and always ensure lifting equipment is in good condition and
sufficiently rated to carry the desired load

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Figure 6 – Example of battery being handled via fork lift pockets.
5.2 Components
5.2.1 Cell Stacks
If shipped as a separate component, cell stack(s) will be shipped in a crate and designed to
be moved using a fork lift or pallet jack. To minimize potential handling damage, stacks
should remain on the pallet they are shipped upon while being handled. Please see the
service manual for information on stack installation or exchanges.
Flooded cell stacks weigh 120 kg each. Attempting to manually lift is NOT
recommended.
5.2.2 Electrolyte
If shipped as a separate component, electrolyte will be shipped in one or more UN
recognized intermediate bulk container (IBC) totes. Proper precautions and equipment
should be used to handle and move the totes. Please see the Service Manual for more
information on electrolyte loading
NOTE: The mass of a full 1000L tote is approximately 1400kg.
Electrolyte is corrosive and acutely toxic. Avoid all contact with skin and eyes.
When working with or conducting a procedure that results in potential
exposure to electrolyte, all necessary personal protective equipment must be
worn. This includes safety glasses, sleeves, gloves, lab coat or apron and
may include boots and respirator.

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6.0 Installation
6.1 Siting
Prior to installation, the installer must verify that planned installation is in compliance with
local building and fire codes including necessary regulations related to hazardous material
storage and batteries / flow batteries. This typically requires an approved permit from the
authority having jurisdiction (AHJ).
Refer to table below for installation siting requirements for battery installation. Local
installation requirements shall supersede these guidelines where any conflict exists.
Installers shall always consult with local AHJ for applicable requirements.
Risk of physical damage If system is in a high traffic location, physical protection
(such as bollards, walls, etc.) shall be provided.
Surface load Surface shall be capable of supporting a minimum 60 kPa
weight load
Grade Installation surface shall be level within 25 mm [1 in] per
2.44 m [8 ft]
Air flow Installation location shall be such that air flow to front air
intake and rear panel exhaust is not obstructed. In addition,
hot exhaust streams from other equipment should not
directed towards air intake.
Indoor installation Indoor installations shall be in rooms with sufficient
continuous ventilation to ensure hydrogen gas that may be
evolved by the system shall not accumulate to beyond 25%
of LFL. When continuous ventilation cannot be provided, an
external vent line can be connected to the system to
provide for direct ventilation.
A minimum air exchange of 2 air changes per hour shall be
provided to ensure proper cooling.
Service access A minimum of 0.92 m [36 inches] unobstructed area shall
be reserved in the front of the battery. Any battery with
power conversion system (PCS) mounted to the side shall
provide required service access as defined by PCS
manufacturer or local codes.
Table 1 – Siting requirements.
6.2 Anchoring
The AFB2 is designed to be anchored to a concrete floor or pad. The design of the
anchoring system shall be completed in advance and in accordance with applicable seismic

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and civil requirements, per site location. In completing such design, an analysis shall be
conducted by an authorized professional engineer; including confirming sufficient bolt
strengths, concrete / floor bearing load, etc. Always refer to local building authority to
confirm such requirements.
Anchoring of the system is designed to be done with typical floor anchors (such as Hilti®
Concrete Anchors) or clamps. Anchors are to be drilled and installed after locating and
placing the system.
Alternative anchoring solutions, including mounting on driven piers or piles may be
considered at customer’s discretion but should be reviewed and approved by Avalon before
proceeding.
6.3 External Gas Vent
The system requires air flow and ventilation in all installed locations. If the system is installed
in a confined space with insufficient or non-continuous ventilation or otherwise requires an
external gas vent, one can be installed and connected via the gas vent on the rear panel.
Care must be taken when routing any external gas vent lines to avoid liquid
traps or other blockages from external material. Vent must also be routed
away from sources of ignition or building air intakes.
6.4 Mounting the Antenna
NOTE not all batteries will be shipped with an antenna installed. This is defined by the
factory configuration.
The antenna mount is shipped external to the battery in an upside-down orientation so that it
does not stick above the top of the enclosure. Prior to installation of the antenna – the
mounting bracket should be removed and turned around so that the antenna, when it is
attached to the top of the bracket, as shown in Figure 7, sits above the highest point of the
enclosure, and the bracket can be secured to the battery using the same two bolts it was
shipped with.
The antenna will either ship separately or be already mounted to the bracket. If shipped
separately, the antenna should be mounted to the two screw-hole placements at the top of
the antenna bracket. The antenna cable should be pulled through the cable gland and the
cable gland should be tightened. The BMC controller has a connection for the antenna at
the back of the controller. It is important to not that the antenna cable should be routed and
secured such that the lowest point of the cable is below the cable gland, reducing the
possibility that water will run along the cable, into the battery enclosure.

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Figure 7 – Antenna shown in shipping position (left) and in operating position (right).
If the PCS mounting bracket is also installed on the system then the antenna bracket should
sit on-top of the PCS bracket and utilise the same bolts.
6.5 Access & External Cover Panels
The AFB2 must NOT be left unattended without the access panel installed.
This is for electrolyte egress containment in the event of failure and rain/dust
ingress protection.
The exterior plastic access panels (aka “Avalon Cover Panel”) is shipped and uninstalled
and is to be installed when battery is left unattended. Identical panels are installed on both
the front and back of the battery.
The sheet metal access panel (aka “access panel”) is the removable panel installed on the
front of the battery. This panel serves many functions, including safety critical functions and
must be fully installed before operating the battery. The access panel is secured via
security screws to avoid tampering.
6.6 Mounting External Equipment
Do not attach components to the lower portion of the battery enclosure. The
lower section of the AFB2 enclosure serves as secondary containment. This
surface MUST NOT be perforated, drilled into, or damaged in any way. Any
modification to the lower enclosure will void product warranty.
External equipment including inverter / PCS, DC disconnect and/or antenna may be
mounted directly to the AFB2 and depending configuration ordered may already be factory
mounted and installed.

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In event field installation requirements mounting one or more piece of external equipment, a
location to mount a bracket for the DC Disconnect and the recommended Ideal Power
Converter (if required by project) is provided on the left side of the battery enclosure. There
are eight M8 threaded bolt connection points (max 16mm length) provided for this purpose.
If necessary, components may be mounted on the upper portion of the enclosure. This may
only be done under the written approval of Avalon Battery. Care must be taken to ensure not
to penetrate into components located within the battery. Any penetrations must be sealed
completely with a sufficiently weather resistance component, rated NEMA Type 3R or
higher.

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7.0 Equipment Wiring
7.1 Pre-install Requirements
Prior to commissioning the AFB2, local code compliant conduit should be run to the final
installation location. A watertight conduit hub or cable gland, of NEMA Type 3R or higher,
shall be installed in each of the knockouts in the enclosure that are used for cable passage.
Knockout
Location Trade Size Number of Knockouts Sheet Metal Thickness Intended for Passage of
Left-Hand
Side 1-1/4” 1 0.060” [1.5mm] Main DC + Ground Cables
Left-Hand
Side 3/4” 1 0.060” [1.5mm] PCS Comm. cables and 24V
supply
Right-Hand
Side Drilled as required N/A 0.060” [1.5mm]
DC connections for unit 2 through
6 within string of up to (6)
batteries.
Table 2 – Electrical knock-out details.
An external DC disconnect shall be installed with the battery in some jurisdictions to be able
to disconnect the battery from the DC supply or load or external inverter. Disconnect must
open all ungrounded conductors and must be readily available and accessible without need
of special tools to access or operate. A mounting location is located external to the battery
for this purpose as it is recommended that this disconnect be located near to the battery.
Figure 8 – Knockout locations on the AFB2 battery. 1-1/4” and 3/4” knockouts shown on the left, and panel
allocated on the right shown in the middle for any required pass throughs, and the same panel modified to connect
with additional batteries shown on the right.
7.2 Mounting the Inverter/PCS
Depending upon the battery configuration ordered, it may be required to install the
inverter/PCS in the field. In such case, an inverter specific mounting bracket must be first
installed on the battery, either ordered as part of a factory configuration or field installed.
Refer to PCS and AC battery installation for detailed instructions on installation.

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Figure 9 – PCS mounting bracket, installed.
7.3 Power / HVDC Connection
If required by configuration, main HVDC and protective earth (PE) connections to the AFB2
are made thru the distribution blocks located at the lower left side of the upper enclosure.
The HVDC landing distribution block is shown in Figure 10, where the positive connection is
shown passed through to the fuse of the battery.
Figure 10 – Main HVDC landing Distribution Block.

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Installation and Operation Manual, DC Battery
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Commercial Confidential
Figure 11 – Main DC connection label to system
The PE wiring is to land on the ground terminal on the stack rail, as shown in Figure 12. The
PE wire is to be routed behind the stack rail, as shown in the left image of Figure 12, in
order to allow the stack to be removed without having to disconnect the PE wire. These
same connection points are where battery 2 through 6 will have their HVDC and ground
wiring landed for multi-battery arrays of up to 6.
Figure 12 – Groud terminal for PE wiring. Note correct routing of PE wire is behind the
stack rail (shown on left), in order to allow stack to be removed for servicing. Routing
the PE wire over the stack rail (shown on right) will require removal of PE during stack
servicing, posing a potential safety risk.
Wire
Cable Size
Wire Type
Torque
Tightening Tool
HVDC (+) 4 to 10 AWG 75°C,
Copper 4 to 6 AWG: 45 lb-in 8 to 10 AWG: 35 lb-in Flat head screwdriver
HVDC (-) 4 to 10 AWG 75°C,
Copper
4 to 6 AWG: 35 lb-in
8 AWG: 25 lb-in
10 AWG: 20 lb-in
Flat head
screwdriver
PE 8 AWG Copper 125 lb-in 8 mm hex drive
Table 3 – DC connection wire details.