INTILION scalebloc energy User manual

6140203064 - scalebloc energy/power/power boost operating manual - V1.0 DE
OPERATING MANUAL
(original operating manual)
INTILION GmbH
Dr.-Sinsteden-Straße 8
D-08056 Zwickau
Telephone [phone]
Fax [phone]
E-mail [email protected]
Internet www.intilion.com
Store for future use!
INTILION | scalebloc energy
INTILION | scalebloc power
INTILION | scalebloc power boost

AC-coupled lithium-ion battery storage system in an
IP55 outdoor housing
Year of construction: 2021
Version 1.0
Edition: February 2021
© INTILION GmbH
This operating manual and all of the illustrations contained within are copyright-protected. Any use that
goes beyond the limits of copyright law without the prior written consent of the publisher is
impermissible and punishable by law. This applies in particular to reproduction, translations,
microfilming, storage and processing using electronic systems.

Contents
INTILION scalebloc I
Contents
1Introduction ......................................................................................................................................7
1.1 Means of representation ..........................................................................................................8
1.1.1 Section-relevant warnings ..........................................................................................8
1.1.2 Incorporated warnings................................................................................................9
1.1.3 Other means of representation...................................................................................9
1.1.4 Symbols used in this manual......................................................................................9
1.2 Warranty and liability..............................................................................................................10
1.3 Performance guarantee .........................................................................................................11
1.3.1 Information on the performance guarantee..............................................................11
1.3.2 Determining the State of Health ...............................................................................11
1.4 Copyright protection...............................................................................................................12
1.5 Service/customer service.......................................................................................................12
2Safety...............................................................................................................................................13
2.1 Intended use ..........................................................................................................................13
2.1.1 Structural changes to the battery storage system....................................................14
2.1.2 Foreseeable misuse .................................................................................................15
2.2 Personnel requirements.........................................................................................................16
2.2.1 Responsibilities.........................................................................................................17
2.2.2 Obligations of personnel...........................................................................................17
2.2.3 Unauthorised persons ..............................................................................................17
2.2.4 Training.....................................................................................................................18
2.3 Personal protective equipment ..............................................................................................18
2.4 General safety information.....................................................................................................19
2.5Safety measures for environmental protection ......................................................................20
2.6 Special warnings....................................................................................................................21
2.6.1 Symbols used on the battery storage system ..........................................................21
2.6.2 Danger due to electrical energy................................................................................22
2.6.3 Danger due to lithium-ion batteries..........................................................................24
2.6.4 Dangers due to hot surfaces ....................................................................................25
2.6.5 Dangers due to working at height.............................................................................25
2.6.6 Dangers due to noise ...............................................................................................26
2.6.7 Dangers due to the use of incorrect spare parts ......................................................26
2.7 Safety and protective devices................................................................................................27
2.8 Information regarding emergencies.......................................................................................27
2.9 Obligations of the operating company ...................................................................................28
2.10 Obligations of the system manager .......................................................................................29
3Description of the battery storage system..................................................................................30
3.1 Functional description............................................................................................................30
3.2 Overview................................................................................................................................31
3.2.1 Overview of functional elements...............................................................................31
3.2.2 Overview of safety devices.......................................................................................33
3.2.3 Type plate.................................................................................................................34
3.2.4 Safety devices ..........................................................................................................36
3.2.4.1 Smoke detector.........................................................................................36

Contents
II INTILION GmbH
3.2.4.2 Door contact switch .................................................................................. 36
3.2.4.3 Alarm ........................................................................................................ 37
3.2.4.4 Emergency stop contacts......................................................................... 37
3.2.4.5 Network and system protection................................................................ 38
3.2.4.6 Fire protection housing............................................................................. 38
3.2.4.7 Smoke degasification duct ....................................................................... 38
3.2.5 Operating modes ..................................................................................................... 39
3.3 Technical specifications ........................................................................................................ 40
3.3.1 INTILION scalebloc battery storage system ............................................................ 40
3.3.2 Battery modules....................................................................................................... 41
4Transport and storage .................................................................................................................. 42
5Installation...................................................................................................................................... 43
5.1 Information regarding hazards during installation................................................................. 43
5.2 Selecting the installation site................................................................................................. 44
5.3 Preparatory measures........................................................................................................... 46
5.4 Disassembling the transport pallet........................................................................................ 46
5.5 Securing the battery storage system onto the foundation .................................................... 47
5.5.1 Safety....................................................................................................................... 48
5.5.2 Permissible transport aids........................................................................................ 48
5.5.3 Attachment points .................................................................................................... 49
5.5.4 Unloading and positioning the battery storage system and securing in place......... 50
5.6 Earthing the battery storage system ..................................................................................... 52
5.7 Installing the alarm ................................................................................................................ 53
5.8 Inserting the battery modules................................................................................................ 55
5.9 Battery module power cabling............................................................................................... 59
5.10 Connecting the communication, control and power cables................................................... 64
5.11 Final measures...................................................................................................................... 66
5.12 Establishing the mains connection........................................................................................ 68
5.13 Connecting the energy meter................................................................................................ 69
5.14 “Setpoint specification” communication connection.............................................................. 72
5.15 Parallel switching of multiple battery storage systems.......................................................... 73
6Commissioning.............................................................................................................................. 75
6.1 Preparatory work and information......................................................................................... 76
6.2 Commissioning the energy meter ......................................................................................... 80
6.3 Filling in the commissioning log ............................................................................................ 84
6.4 Switching on the battery storage system .............................................................................. 84
6.5 Settings in the web visualisation ........................................................................................... 85
6.6 Fitting the panels................................................................................................................... 94
6.7 Contacting the Hoppecke Service team................................................................................ 96
7Operation........................................................................................................................................ 97
8Fault................................................................................................................................................ 98
9Maintenance................................................................................................................................... 99
9.1 Safety measures during maintenance work.......................................................................... 99
9.2 Inspection and maintenance work....................................................................................... 100
9.2.1 Maintenance intervals............................................................................................ 100
9.2.2 Preparatory measures ........................................................................................... 101

Contents
INTILION scalebloc III
9.2.3 Maintenance - annual.............................................................................................102
9.2.3.1 Battery storage system ...........................................................................102
9.2.3.2 Battery modules ......................................................................................102
9.2.3.3 Update the displayed State of Health .....................................................102
9.2.3.4 AC unit.....................................................................................................103
9.2.3.5 Smoke detector.......................................................................................103
9.2.3.6 Doors.......................................................................................................103
9.2.4 Special maintenance intervals................................................................................103
9.2.4.1 AC unit.....................................................................................................103
9.2.4.2 Inverter....................................................................................................103
9.2.4.3 Electrical equipment................................................................................103
9.2.5 Maintenance of additional third-party components.................................................103
9.2.6 Remote software updates.......................................................................................104
10 Decommissioning and disassembly ..........................................................................................105
10.1 Decommissioning.................................................................................................................105
10.2 Disassembly.........................................................................................................................106
10.2.1 Information regarding hazards during disassembly................................................106
10.2.2 Disassembly work...................................................................................................107
10.2.2.1 Discharging the battery modules.............................................................107
10.2.2.2 Disassembling the panels .......................................................................107
10.2.2.3 Disassembling the communication, control and power cables ...............108
10.2.2.4 Disassembling the panels for the battery management system (BMS) and
the inverter ..............................................................................................109
10.2.2.5 Disassembling the panels for the fire protection housings .....................109
10.2.2.6 Disassembling the cables from the battery modules ..............................110
10.2.2.7 Removing the battery modules ...............................................................111
10.2.2.8 Removing the earthing points .................................................................112
10.2.2.9 Preparing the battery storage system for loading...................................113
10.2.2.10 Loading the battery storage system....................................................114
10.3 Disposal ...............................................................................................................................116
11 Applicable documents.................................................................................................................117

Illustrations
IV INTILION GmbH
Illustrations
Illustration 1: Functional elements - view with closed door ...................................................................31
Illustration 2: Functional elements - view with open door......................................................................32
Illustration 3: Safety devices..................................................................................................................33
Illustration 4: Type plate –attachment location.....................................................................................34
Illustration 5: Type plate - INTILION scalebloc energy..........................................................................34
Illustration 6: Type plate- INTILION scalebloc power............................................................................35
Illustration 7: Type plate - INTILION scalebloc power boost.................................................................35
Illustration 8: Smoke detector................................................................................................................36
Illustration 9: Door contact switch..........................................................................................................36
Illustration 10: Alarm..............................................................................................................................37
Illustration 11: Emergency stop contacts...............................................................................................38
Illustration 12: Maintenance areas.........................................................................................................45
Illustration 13: Disassembling the transport pallet - removing the fixing screws...................................46
Illustration 14: Disassembling the transport pallet - removing the floor plates......................................46
Illustration 15: Base for base height of 100 mm (INTILION scalebloc energy only)..............................47
Illustration 16: Base for base height of 200 mm (INTILION scalebloc all versions) ..............................47
Illustration 17: Overview of the attachment points.................................................................................49
Illustration 18: Removing the covers over the attachment points..........................................................49
Illustration 19: Forklift attachment of the 200 mm base.........................................................................51
Illustration 20: Securing the foundation earthing system.......................................................................52
Illustration 21: Securing the earthing system for rack rails....................................................................53
Illustration 22: Icotek frame on the door of the AC unit .........................................................................54
Illustration 23: Installed alarm................................................................................................................54
Illustration 24: Battery module - on delivery ..........................................................................................56
Illustration 25: Battery module - opening the box..................................................................................56
Illustration 26: Battery module - removing from box..............................................................................57
Illustration 27: Battery modules - securing in the fire protection housing..............................................58
Illustration 28: Battery module - removing the safety caps....................................................................60
Illustration 29: Wiring diagram...............................................................................................................61
Illustration 30: Laying the cell connectors..............................................................................................62
Illustration 31: Icotek frame ...................................................................................................................64
Illustration 32: Icotek grommet - suitable for cable................................................................................65
Illustration 33: Icotek grommet - not suitable for cable..........................................................................65
Illustration 34: Securing the front panel.................................................................................................66
Illustration 35: Adjusting the AC unit......................................................................................................67
Illustration 36: Connection terminal -XD11 for connection to the sub-distribution ................................68
Illustration 37: Energy meter connection diagram.................................................................................69
Illustration 38: Ethernet port -XF14 for the connection of the energy meter. ........................................71
Illustration 39: Ethernet port “XF13” for the external control of the battery storage system..................72
Illustration 40: Feed-throughs (green) for communication and optional control cables ........................73
Illustration 41: Diagram showing the connection of multiple battery storage systems..........................73
Illustration 42: Ethernet ports for connecting the energy meter and the battery storage system..........74
Illustration 43: Control panel overview screen in Windows 10..............................................................77
Illustration 44: Network and Internet section of the control panel .........................................................77
Illustration 45: Network adapter settings ...............................................................................................78
Illustration 46: Options for the network adapter.....................................................................................78

Illustrations
INTILION scalebloc V
Illustration 47: Settings for the IP address, the standard gateway and the DNS server....................... 79
Illustration 48: Configuration software UCS - main menu..................................................................... 81
Illustration 49: Configuration software UCS - setting the IP address for the energy meter .................. 81
Illustration 50: Configuration software UCS - selecting the energy meter ............................................ 82
Illustration 51: Configuration software UCS - overview page for the energy meter.............................. 82
Illustration 52: Configuration software UCS - entering the transformer ratio ........................................ 83
Illustration 53: Configuration software UCS -- network settings for the energy meter.......................... 83
Illustration 54: Front view of the ControlShield...................................................................................... 85
Illustration 55: Overview of recommended settings .............................................................................. 86
Illustration 56: Login window of the web visualisation........................................................................... 86
Illustration 57: INTILION web visualisation ........................................................................................... 87
Illustration 58: INTILION web visualisation - user interface .................................................................. 87
Illustration 59: INTILION web visualisation - configuration interface..................................................... 88
Illustration 60: INTILION web visualisation - configuration interface (excerpt) ..................................... 88
Illustration 61: INTILION web visualisation - interface for optimisation of energy consumption........... 90
Illustration 62: INTILION web visualisation - interface for peak shaving............................................... 90
Illustration 63: INTILION web visualisation - interface for E-mobility.................................................... 91
Illustration 64: INTILION web visualisation - interface for entering the serial numbers........................ 92
Illustration 65: INTILION web visualisation - performance run.............................................................. 93
Illustration 66: Panel for the fire protection housing.............................................................................. 94
Illustration 67: Panel for the BMS, inverter, the ControlShield and the installation areas..................... 94
Illustration 68: Inserting the Icotek grommets into the panel for the fire protection housing................. 95
Illustration 69: Fastening the panel to the fire protection housing......................................................... 95
Illustration 70: Securing the panels for the ControlShield and the installation areas............................ 96
Illustration 71: Removing the front panel............................................................................................. 107
Illustration 72: Disassembling the panels for the ControlShield and the installation areas ................ 108
Illustration 73: Removing the floor plates............................................................................................ 108
Illustration 74: Disassembling the panels for the BMS and the inverter.............................................. 109
Illustration 75: Disassembling the panels for the fire protection housings .......................................... 109
Illustration 76: Battery module - removing the safety caps ................................................................. 110
Illustration 77: Battery module - disassembly from the fire protection housing................................... 111
Illustration 78: Disassembling the earthing system for rack rails ........................................................ 112
Illustration 79: Disassembling the foundation earthing system........................................................... 112
Illustration 80: Securing the front panel............................................................................................... 113
Illustration 81: Overview of the attachment points .............................................................................. 115
Illustration 82: Removing the covers over the attachment points ....................................................... 115

Tables
VI INTILION GmbH
Tables
Tab. 1: Training......................................................................................................................................18
Tab. 2: Technical specifications –INTILION scalebloc battery storage system ...................................40
Tab. 3: Technical specifications - battery modules ...............................................................................41
Tab. 4: Transformer based on power output.........................................................................................70
Tab. 5: Connecting the control cables...................................................................................................74
Tab. 6: Maintenance intervals .............................................................................................................100

INTILION scalebloc 7
1 Introduction
Thank you for choosing an INTILION GmbH product. As part of the HOPPECKE Group,
INTILION GmbH As part of the HOPPECKE Group, INTILION GmbH stands for high-
quality storage solutions.
This operating manual provides all of the information needed for the smooth operation of
the INTILION scalebloc battery storage system (hereinafter referred to as the “battery
storage system”).
The operating manual must be read, understood and applied by all persons tasked with
the assembly, commissioning, operation, maintenance, decommissioning and
disassembly of the battery storage system. This applies in particular to the specified
safety instructions.
After reading the operating manual, you will be able to
–Commission the battery storage system
–Operate the battery storage system in compliance with the safety standards
–Properly maintain the battery storage system
–Decommission and disassemble the battery storage system
The generally applicable, statutory and other mandatory regulations relating to accident
prevention and environmental protection valid in the country of use must also be
observed in addition to the operating manual.
The operating manual must be kept at the location where the battery storage system is
installed at all times.

1 Introduction
1.1 Means of representation
8INTILION GmbH
1.1 Means of representation
Text that should be paid particular attention to and that constitutes instructions or a direct
warning against hazards is indicated as follows in this operating manual:
1.1.1 Section-relevant warnings
Section-relevant warnings apply not only to a certain action, but to all actions within a
section.
Structure
SIGNAL WORD
Symbol
providing
more
details on
a hazard
Hazard type and source
Possible consequence(s) of non-observation
–Measure(s) for risk prevention
Hazard levels
DANGER
Hazard with a high level of risk that, if not avoided, can lead to death or
serious bodily injury.
WARNING
Hazard with a medium level of risk that, if not avoided, can lead to death or
serious bodily injury.
CAUTION
Hazard with a low level of risk that, if not avoided, can lead to minor or
moderate bodily injury.
NOTE
Hazard with a low level of risk that, if not avoided, can lead to material
damage.