Avalon AFB2 User manual

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Commercial Confidential
PRODUCT / MODEL NUMBER
AFB2
DOCUMENT TITLE
Installation and Operation Manual, DC Battery
DOCUMENT NUMBER
SPC00138
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ISSUED
REVISION
004
TOTAL # of PAGES
27

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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.