INTILION scalestac power User manual

ASSEMBLY MANUAL
INTILION AG
Wollmarktstraße 115c
D-33098 Paderborn
Phone [phone]
Email [e-mail]
Internet www.intilion.com
Store for later use!
INTILION | scalestac power
INTILION | scalestac power boost

AC-coupled lithium-ion battery storage system for
indoor installation
Year of construction: 2022
Version 1.3
Edition: January 2023
© INTILION AG
This assembly 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.

INTILION | scalestac I
Contents
1 Introduction ...................................................................................................................................... 3
1.1 Means of representation .......................................................................................................... 3
1.1.1 Section-relevant warnings .......................................................................................... 3
1.1.2 Incorporated warnings ................................................................................................ 5
1.1.3 Other means of representation ................................................................................... 5
1.1.4 Symbols used in this manual ...................................................................................... 5
1.2 Warranty and liability ................................................................................................................ 6
1.3 Guarantee ................................................................................................................................ 7
1.4 Copyright protection ................................................................................................................. 8
1.5 Service/customer service ......................................................................................................... 8
1.6 Installation location requirements ............................................................................................ 9
2 Safety ............................................................................................................................................... 10
2.1 Intended use .......................................................................................................................... 10
2.1.1 Structural changes to the battery storage system .................................................... 11
2.1.2 Foreseeable misuse ................................................................................................. 12
2.2 Personnel requirements ......................................................................................................... 13
2.2.1 Responsibilities ......................................................................................................... 14
2.2.2 Obligations of personnel ........................................................................................... 14
2.2.3 Unauthorised persons .............................................................................................. 14
2.2.4 Training ..................................................................................................................... 15
2.3 Personal protective equipment .............................................................................................. 15
2.4 General safety information ..................................................................................................... 16
2.5 Safety measures for environmental protection ...................................................................... 17
2.6 Special warnings .................................................................................................................... 18
2.6.1 Symbols used on the battery storage system .......................................................... 18
2.6.2 Danger due to electrical energy ................................................................................ 19
2.6.3 Dangers due to lithium-ion batteries ......................................................................... 21
2.6.4 Dangers due to hot surfaces .................................................................................... 22
2.6.5 Dangers due to working at height ............................................................................. 22
2.6.6 Dangers due to noise ............................................................................................... 23
2.6.7 Dangers due to the use of incorrect spare parts ...................................................... 23
2.7 Safety and protective devices ................................................................................................ 24
2.8 Information regarding emergencies ....................................................................................... 24
2.9 Obligations of the operating company ................................................................................... 25
2.10 Obligations of the system manager ....................................................................................... 26
3 Assembly ........................................................................................................................................ 27
3.1 General information ............................................................................................................... 27
3.2 Personal protective equipment (PPE) .................................................................................... 27
3.3 Line list ................................................................................................................................... 28
3.4 Necessary tools ..................................................................................................................... 31
3.5 Assembly work steps ............................................................................................................. 33
3.5.1 Delivery of the cabinets and components ................................................................ 33
3.5.2 Positioning and installing the cabinets at the installation location ............................ 34
3.5.3 Assembling the HMI cover plate ............................................................................... 37

II INTILION AG
3.5.4 Battery cabinets (Narada battery racks) .................................................................. 38
3.5.4.1 Preparing the battery racks ...................................................................... 38
3.5.4.2 Inserting the battery modules and the rack BMS ..................................... 39
3.5.4.3 Installing additional control and safety components in the first battery rack
.................................................................................................................. 40
3.5.4.4 Connecting to INTILION cabinet no. 4 (IBU/DCC) ................................... 40
3.5.5 INTILION cabinets ................................................................................................... 41
3.5.5.1 Communication connection ...................................................................... 41
3.5.5.2 Connecting the busbars............................................................................ 45
3.5.5.3 AC connection .......................................................................................... 50
4 Appendix ........................................................................................................................................ 52
5 Acronyms ....................................................................................................................................... 57

INTILION | scalestac 3
1 Introduction
This assembly manual describes the assembly and installation of the INTILION |
scalestac battery storage system.
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.

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NOTE
Hazard with a low level of risk that, if not avoided, can lead to material
damage.
This assembly manual is only valid in connection with the operating manual. All
persons involved in the assembly of the battery storage system must be familiar
with, and act in accordance with, the operating manual.

INTILION | scalestac 5
1.1.2 Embedded warnings
Incorporated warnings are directly integrated into certain actions.
Structure
SIGNAL WORD Hazard type and source
Possible consequences of non-observance, measures for preventing the hazard
Hazard levels
– DANGER/WARNING/CAUTION
– NOTE (without warning triangle, see Section 1.1.1 “Section-relevant warnings”)
1.1.3 Other means of representation
The information symbol provides useful information.
– These markings are followed by lists.

These markings are followed by text describing activities that need to be
performed in the order in which they are listed.
“ “ Text in quotation marks constitutes references to other chapters or sections.
1.1.4 Symbols used in this manual
Particular hazards are indicated as follows in the form of warnings:
Warning of electrical voltage
This symbol warns of the risk to life due to dangerous electrical voltage.
Warning of the danger due to lithium-ion batteries
This symbol warns of potential hazards due to the use of lithium-ion
batteries.
Unauthorized access prohibited
This symbol prohibits access to the indicated areas by unauthorised
persons.
Hazards cannot be recognised by unauthorised persons.
Observe manual
This symbol stipulates the observance of the operating manual and the
safety instructions.

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1.2 Warranty and liability
The obligations agreed upon in the delivery contract apply, along with the general terms
and conditions and the delivery conditions of the battery storage system and the statutory
regulations valid at the time the contract was concluded.
All information and specifications in this operating manual have been compiled taking into
account the applicable standards and regulations, the current state of technology and our
many years of knowledge and experience.
Warranty and liability claims for personal injury or material damage are excluded if they are
due to one or several of the following causes:
– Improper use of the battery storage system or use other than the intended use
– Improper installation, commissioning, operation and maintenance of the battery
storage system
– Operation of the battery storage system with faulty safety devices or with improperly
fitted or non-functioning safety and protective equipment
– Failure to observe the operating manual and the instructions in the operating manual
with regard to the installation, commissioning, operation and maintenance of the
battery storage system
– Use of non-qualified or untrained personnel
– Structural modifications to the battery storage system (conversions or other changes
to the battery storage system must not be made without the prior written approval of
INTILION AG. The battery storage system will lose its EU conformity in the event of
any infringements)
– Incorrectly performed repairs
– The use of non-approved spare parts or the use of spare parts that do not meet the
technically define requirements.
– Disaster situations, the infiltration of foreign bodies and force majeure
The time between the installation and commissioning of the battery storage system must
not exceed three months.
We reserve the right to make technical changes as part of improvements to the usage
properties and further development.

INTILION | scalestac 7
1.3 Guarantee
INTILION AG provides a five-year product guarantee for all components of the battery
storage system, with the exception of the lithium-ion battery cells.
INTILION AG also provides a ten-year performance guarantee for the capacity of the
lithium-ion battery cells. With the conclusion of this contract, INTILION AG guarantees
that the remaining useful battery capacity does not fall below a relative minimum value for
the specified battery capacity. The State of Health (SoH) (a classifying factor for the
remaining useful capacity of a battery) is an indication of the ageing condition of the
battery storage system.
Additional information and the conditions of the guarantee can be found in the
separately provided document entitled “Guarantee conditions for the INTILION |
scalestac storage system”.

8 INTILION AG
1.4 Copyright protection
This operating manual is copyright-protected.
The release of the operating manual to third parties, reproductions of any type or form –
including of extracts – and the processing and/or communication of the content of the
manual is not permitted for purposes other than external purposes without the written
approval of INTILION AG.
Infringements will lead to liability for damages. The right to make any further claims remains
reserved.
1.5 Customer service
INTILION AG is part of the HOPPECKE Group. Our customer service team is
available to provide you with any technical information you may require:
HOPPECKE Service Competence Center
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Our employees are also always interested in any information or feedback on your
experiences with actual use that may be useful for us in improving our products.

INTILION | scalestac 9
1.6 Installation location requirements
Observe the installation location requirements for the battery storage system, as specified
in the document “Empfehlung_Aufstellort_scalestac_3.1.pdf”

10 INTILION AG
2 Safety
DANGER
Failing to observe the following safety instructions can have serious consequences:
– Environmental damage due to escaping hazardous substances
– Failure of important assembly functions
– Danger to persons due to electrical, mechanical or chemical influences
Read the safety instructions and warnings in this section carefully before
putting the battery storage system into operation.
In addition to the instructions in this operating manual, make sure to also
observe the general safety and accident-prevention regulations.
In addition to the instructions in this operating manual, the operator must
also observe any existing national working, operating and safety
regulations. Any existing internal site regulations must also be observed.
2.1 Intended use
The operational safety of the battery storage system is only guaranteed if it is used as
intended.
INTILION | scalestac is an AC-coupled battery storage system and in grid-building
operation, it is primarily suitable for the “behind-the-meter” application.
There are three important features that are worth mentioning for the behind-the-meter field
of application:
- The system interacts with the energy meter at the operating company’s mains
connection*
- The system optimises the load and energy flows within the operating company’s
infrastructure*
- The system does not provide any energy to the public power grid (in Germany: UCTE
network) 1
The battery storage system is not intended for any use other than that specified in this
document.
1 additional hardware required, please contact. INTILION AG

INTILION | scalestac 11
NOTE
The battery storage system is designed for indoor use.
INTILION AG offers alternative product solutions for outdoor use.
Intended use also includes
– Observation of all instructions in the operating manual
– Compliance with the inspection and maintenance intervals
– Use of consumables in accordance with the applicable safety regulations
– Compliance with the operating conditions
The technical specifications set out in the technical data must be complied with without
exception.
Only ever use the battery storage system as intended in order to guarantee safe
operation.
The operating company using the battery storage system and not the
manufacturer is responsible for all personal injury and property damage arising
from improper use.
2.1.1 Structural changes to the battery storage system
The design and the manufacturer acceptance are performed based on the German Product
Safety Act (ProdSG). No modifications, additions or conversions may be made to the
battery storage system without the prior written approval of INTILION AG.
The product will lose its EU conformity in the event of non-compliance. The manufacturer
of the battery storage system is outside of the warranty and any warranty claims.
Components not in perfect condition must be reported to the HOPPECKE Service team
immediately (see section 1.5). Continued use of the system is not permitted.
Only use original spare parts/wear parts/accessories. These parts have been specially
designed for the battery storage system. If parts that are manufactured by third parties are
used, it cannot be guaranteed that they have been designed and produced such that they
can bear sufficient loads and comply with safety standards.
Parts and special equipment that have not been approved by INTILION AG must not be
used.

12 INTILION AG
2.1.2 Foreseeable misuse
DANGER
Any use that differs from or goes beyond the intended use of the battery
storage system can lead to serious injury.
– Only use the battery storage system as per the intended use.
– Do not charge or discharge the battery modules outside of the
temperature range specified in section 2.6.3.
– Do not operate the battery modules outside of the operating conditions
defined in the data sheet.
– Do not expose the lithium-ion cells of the battery storage system to
ambient temperatures of above 40 °C or below 0° C. Compliance with
the temperature specifications must be ensured during operation by a
room air-conditioning system.
– Avoid short circuits.
– Do not operate the battery storage system in a potentially explosive
environment.
– Only operate the battery storage system in intended networks.

INTILION | scalestac 13
2.2 Personnel requirements
DANGER
Unauthorised persons are prohibited from working on the battery
storage system. The operating manual must be observed.
The battery storage system must only be installed, commissioned,
operated, maintained, repaired, decommissioned and/or disassembled by
persons who are qualified and/or trained in the performance of this work.
These persons must have completed an INTILION | scalestac product
training session and must be familiar with and act in accordance with the
operating manual. The relevant authorisations of the various personnel
must be clearly defined.
The following qualifications are specified in the operating manual for different activity areas.
Personnel in training
Personnel in training, such as apprentices or temporary employees, are not familiar with all
of the hazards that can occur when operating the battery storage system. Work must only
be performed on the battery storage system under the supervision of trained or qualified
personnel.
Trained personnel
Trained personnel have been instructed by the operating company or by qualified
personnel on the tasks assigned to them and the potential hazards involved with improper
conduct as part of a training session.
Qualified personnel
Qualified personnel are those who because of their training, knowledge and experience,
coupled with knowledge of the applicable regulations, are in a position to perform the work
assigned to them and to independently recognise and prevent potential hazards.
Specialised electricians
Specialised electricians are individuals who, because of their specialist training, knowledge
and experience, coupled with knowledge of the applicable regulations, are in a position to
perform work on electrical equipment and to independently recognise and prevent potential
hazards.
Specialised electricians are specifically trained for the working environment in which they
are employed, and they are also familiar with the relevant standards and regulations.
Specialised electrician with WLE certification
Only a specially trained specialised electrician is permitted to carry out work on live
equipment (WLE work). Certification must be performed based on DGUV Rule 103-
011/3.2.4 and VDE 0105-100 Section 6.3.2.

14 INTILION AG
2.2.1 Responsibilities
Incorrect use can result in serious personal injury and material damage.
Therefore, have all tasks performed by qualified personnel only.
– People are only permitted to be approved as personnel if they can be expected to
perform their work reliably. No persons may work on the battery storage system if their
response capability is impaired as a result of substances such as drugs, alcohol or
medication.
– All persons who work on battery storage system must read the operating manual and
provide their signature to confirm that they have understood the content.
– Personnel in training must initially only work on the battery storage system under the
supervision of qualified personnel. Successfully completed training must be confirmed
in writing.
The operating company is responsible for personnel training.
2.2.2 Obligations of personnel
All persons assigned with work on the battery storage system are obligated to do the
following prior to starting work:
– Observe the basic requirements regarding occupational safety and accident prevention
– Read the safety instructions and warnings in this operating manual and to sign to
confirm having understood them
2.2.3 Unauthorised persons
Unauthorised persons who do not meet the qualification requirements for personnel will not
be familiar with the hazards in the working area.
– Keep unauthorised persons away from the working area.
– If in doubt, approach persons in the working area and escort them out if necessary.
– Stop work if there are unauthorised persons in the working area.

INTILION | scalestac 15
2.2.4 Training
Personnel must receive regular training from the operating company (e. g. every six
months). A log must be created after the completion of training (see Table 1 as an
example).
Tab. 1: Training
Date Name Type of
instruction
Training
performed by Signature
2.3 Personal protective equipment
Observe the signs affixed in the working area regarding personal protective equipment.
Irrespective of the workplace risk assessment, personal protective equipment must be worn
when operating the battery storage system in order to keep health risks to a minimum.
– Always wear the necessary protective equipment when performing work.
– Do not wear any metallic watches, rings, chains or other jewellery.
The symbols have the following meanings:
Wear protective clothing (insulating protective clothing)
Protective work clothing is closely fitting work clothing with a low tear-
resistance, with narrow sleeves and no protruding parts. It is primarily
intended for protection against being caught by moving product parts.
Insulating protective clothing is non-
conductive and prevents the passage of
electrical current when the wearer comes into contact with a live part.
Wear foot protection (insulating safety boots)
Wear non-slip safety boots to protect against heavy falling parts or slipping
on smooth surfaces.
Specialised electricians require insulat
ing shoes for carrying out work on live
parts. When worn in combination with insulating protective clothing, these
shoes are designed to protect the wearer from electric shock while also
preventing current from flowi
ng through the body and into the ground via the
feet.
Wear hand protection (1000-V protective gloves)
Wear protective gloves to protect the hands from friction, abrasions,
punctures or deep wounds, aggressive chemicals and from contact with hot
surfaces or chemical substances.
Wear insulating (1000 V) protective gloves in accordance with EN 60903 or
VDE 0682 Part 311 to protect the hands from dangerous electric shock
when touching live parts.

16
INTILION AG
Wear head protection (electrician’s safety helmet)
Wear a safety helmet to protect against falling or flying parts.
Wear an electrician’s safety helmet marked with 1000 V to protect against
thermal impacts such as arcs and to protect against dangerous electric
shock when touching live parts in accordance with DIN EN 50365.
Wear face protection (electrician’s face protection)
Wear face protection to protect the eyes and face.
Wear electrician’s face protection suitable for working on live equipment
(WLE) to protect against potential electric arcs.
Wear ear protection
Wear hearing protection to protect against hearing damage.
Wear a harness
Use suitable fall protection (safety cable and harness) when working at
heights.
Personal protective equipment must be provided by the operating company and must
comply with the applicable requirements.
The national regulations and specifications from the workplace risk assessment must also
be observed, along with any internal instructions from the operating company.
2.4 General safety information
–
The battery storage system must only be commissioned, maintained, decommissioned
and/or disassembled once this operating manual has been read.
–
Only use the battery storage system as per the intended use
(see Section 0)
–
Do not put the battery storage system into operation if there are other people in the
danger zone.
–
When operating the battery storage system, avoid any operation that might impair the
safety of persons or the battery storage system.
–
Never operate the battery storage system without the associated protective and safety
devices. Never take the installed safety devices out of operation.
–
If an alarm is triggered, maintain the maximum possible distance from the battery
storage system and do not open the battery storage system.
With indoor battery storage systems, leave the room and/or building immediately and
warn any other persons in the room.
–
Always keep the working area of the battery storage system clean and tidy in order to
prevent hazards as a result of dirt or parts that have been left lying around.
–
Keep the ventilation slots on the battery storage system open. Do not place any
materials in front of the ventilation slots either from the inside or the outside.
–
Do not exceed the technical performance data (see technical data sheet).

INTILION | scalestac 17
– Keep all safety instructions and warnings on the product in a legible condition and
replace them if necessary.
– Operation of and work on the battery storage system must only be performed by trained
and qualified personnel (see Section 2.2).
– Remote updates must only be performed under the supervision of a qualified person on
site. The qualified person on site may act immediately in the event of an error (e. g. by
carrying out a reboot or importing the old, runnable version).
– Take the battery storage system out of operation immediately in the event of
malfunctions. Have the malfunctions rectified by appropriately trained specialists or by
INTILION AG or the HOPPECKE Service team.
– Always store the operating manual in the location where the battery storage system is
used. It must be ensured that all persons carrying out work on the battery storage
system can access the operating manual at any time.
2.5 Safety measures for environmental protection
For all work, make sure to comply with regulations on waste avoidance and proper waste
recycling or disposal.
During installation and maintenance work in particular, as well as during decommissioning,
it must be ensured that substances that are harmful to groundwater, such as grease, oils,
coolants, cleaning fluids containing solvents etc. do not infiltrate the ground or get into the
sewer system. These substances must be collected, stored and transported in suitable
containers, and disposed of in accordance with national legal provisions.

18 INTILION AG
2.6 Special warnings
2.6.1 Symbols used on the battery storage system
Warning of electrical voltage
This symbol warns of the risk to life due to dangerous electrical voltage.
There is an immediate risk to life in the event of contact with live parts.
Warning of the danger due to lithium-ion batteries
This symbol warns of potential hazards due to the use of lithium-ion
batteries.
Unauthorized access prohibited
This symbol prohibits access to the indicated areas by unauthorised
persons. Hazards cannot be recognised by unauthorised persons.
No access for persons with pacemakers or defibrillator implants
This symbol prohibits the presence of persons with medical implants in the
area of the battery storage system, as the electromagnetic fields risk
causing devices such as pacemakers to malfunction.
No open flames; fire, open ignition sources and smoking are
prohibited
This symbol prohibits fire, open flame and smoking in the area of the battery
storage system.
Observe manual
This symbol stipulates the observance of the operating manual and the
safety instructions.
Keep all safety instructions and warnings on the battery storage system in a
legible condition. Replace the warnings as necessary.