MSA ENERGY STORAGE ES-650 Series User manual

Limited Liability Company
«NPK MORSVYAZAVTOMATICA»
26E, Kibalchicha str., 192174,
St. Petersburg, Russia
[email protected]m
www.unicont.com
Phone.: [phone]
Fax: [phone]
ENERGY STORAGE
ES-650-ХХХ, ES-750-ХХХ,
ES-850-ХХХ, ES-950-ХХХ TYPES
Operating manual

Version 0.1 2
Energy storage
ES-650-ххх, ES-750-ххх, ES-850-ххх, ES-950-ххх types
TABLE OF CONTENTS
TERMS AND ABBREVIATIONS............................................................................................................ 3
INTRODUCTION ...................................................................................................................................... 4
1DESCRIPTION AND OPERATION OF THE SYSTEM.................................................................... 5
1.1 Description............................................................................................................................................ 5
1.2 Technical specifications........................................................................................................................ 5
1.3 The Product composition...................................................................................................................... 8
1.4 Structure and operation of the Product.................................................................................................. 8
1.5 Measurement tools, instruments and appliances................................................................................. 13
1.6 Marking and sealing............................................................................................................................ 14
1.7 Packaging............................................................................................................................................ 14
2INTENDED USE.................................................................................................................................... 15
2.1 Operation limitations........................................................................................................................... 15
2.2 Pre-starting procedures ....................................................................................................................... 15
2.3 Usage of the System............................................................................................................................ 16
3TECHNICAL SERVICE....................................................................................................................... 18
3.1 General description............................................................................................................................. 18
3.2 Safety features..................................................................................................................................... 18
3.3 Maintenance routine............................................................................................................................ 18
3.4 Preservation......................................................................................................................................... 19
4CURRENT REPAIR OF THE SYSTEM ............................................................................................ 20
5.1 General description............................................................................................................................. 20
5.2 Safety features..................................................................................................................................... 20
5.3 Current repair...................................................................................................................................... 20
5STORAGE.............................................................................................................................................. 21
6TRANSPORTATION............................................................................................................................ 22
7DISPOSAL.............................................................................................................................................. 23
8WARRANTY.......................................................................................................................................... 24
ANNEX A OVERALL AND INSTALLATION DIMENSIONS....................................................... 25

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Operating Manual
TERMS AND ABBREVIATIONS
CH
Charger
SPTA
Spare parts, tools and accessories
LFGS
Large fine porous granulated silica gel
BP
Battery pack
CM
Control module
ES
Energy storage
PC
Personal computer
OM
Operating manual
LED
Light-emitting diode
CL
Check list
ТS
Technical service
SB
Storage battery
AU
Alarm unit
Battery management system (BMS) –an electronic system that controls SB
voltage, current, temperature, state of charge (SOC) and SB status to ensure its safe and
reliable operation.
Cycle –regularly repeated sequence of actions that may consist of discharge after
charge or charge after discharge under some specific conditions. The sequence may also
include rest time.
State of Charge (SOC) –percentage value expressed in percentage points that
means the level of charge of an electric battery relative to its capacity.

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Energy storage
ES-650-ххх, ES-750-ххх, ES-850-ххх, ES-950-ххх types
INTRODUCTION
This operating manual (hereinafter –OM) describes composition, structure and
specifications of Energy storage units ES-650-ххх, ES-750-ххх, ES-850-ххх, ES-950-ххх
types (hereinafter –the Product, the ES) and their components, instructions for the correct
and safe operation of the Product (operation, technical service, intended use, current repair,
etc.), and disposal information on the Product components.
In addition to the instructions given in this document, the safetyregulations and rules
applicable in the field shall be observed.
Only those who have read and understood this document and those who have had
special training shall be permitted to operate the Product according to the applicable
regulations.

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Operating Manual
1DESCRIPTION AND OPERATION OF THE SYSTEM
1.1 DESCRIPTION
Energy storage units ES-650-ххх, ES-750-ххх, ES-850-ххх, ES-950-ххх types
with same-type rechargeable battery packs BP-125 and BP-160 types are designed to
power shipborne electric and communication equipment, alarm system and automation on
sea- and river-going vessels.
Sample code of energy storage:
«Energy storage ES–YYY–ХХХ »,
where «ХХХ» − capacity А·h;
«YYY» − rated voltage.
Sample code of battery pack:
«Battery pack BP-160-ххх»,
where «ххх» –rated input voltage.
1.2 TECHNICAL SPECIFICATIONS
1.2.1 The Product ensures:
electric energy storage for following power supply of load;
disconnection of load once end voltage is reached (see Table 1);
short circuit protection in load circuit;
control over voltage, charge current, temperature on each battery pack.
Control module (hereinafter –CM) ensures:
LED light indication of ES status and operation mode;
Connection with charger (transmission of data on SB status);
Connection with external cooling system.
1.2.2 Table 1 describes main technical specifications of the Product. Table 2
describes technical specifications of integrated BP.

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Table 1 –Main technical specifications
Parameter
ES-650-160
ES -650-125
ES-750-160
ES-750-125
ES-850-160
ES-850-125
ES-950-160
ES-950-125
Value
Integrated battery
pack
BP-160
BP-125
BP-160
BP-125
BP-160
BP-125
BP-160
BP-125
Max. charge
voltage, V
759.2
876
992.8
999
Max. output
voltage range, VDC
520…760
600…876
680…993
760…999
ES discharge end
voltage, V
603.2
696
788.8
881.6
Capacity, А*h
160
125
160
125
160
125
160
125
Energy, kW*h
104
80.6
120
93
136
105.4
152
117.8
Overall dimensions,
mm
1700 х 840 х 741
1910 х 840 х 741
2120 х 840 х 741
2330 х 780 х 710
Weight, kg
1156
1123
1311
1273
1466
1423
1621
1572
Type of BP
installation
pull-out
Quantity of BPs
13
15
17
19
Fuse rating and
quantity, A
2 х 400
IP rating
IP 44
Charge
temperature, °С
0…+45
Discharge
temperature, °С
–15…+55
Limiting
temperature, °С
–20…+55
Terminal block to
connect external
cable
+
Material
metal
Base
+
Transportation with
SB
+

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Table 2 –Technical specifications of BP-160 and BP-125
Parameter
Value
BP-160-51.2
BP-160-25.6
BP-160-12.8
BP-125-51.2
BP-125-25.6
BP-125-12.8
Rated output voltage, V DC
51.2
25.6
12.8
51.2
25.6
12.8
Max. output voltage, V DC
58.4
29.2
14.6
58.4
29.2
14.6
Energy, kW·h
8
6.2
Capacity, А·h
160
320
640
125
250
500
Specific energy, Wh/kg
122
94
Min. state of charge, V
46.4
23.2
11.6
46.4
23.2
11.6
Nominal mode
Charge
0.5С (80 А)
0.5С (80 А)
0.5С (80 А)
0.5С (80 А)
0.5С (80 А)
0.5С (80 А)
Discharge
1С (160 А)
1С (160 А)
1С (160 А)
1С (160 А)
1С (160 А)
1С (160 А)
Max.
continuous
mode
Charge
2С (320 А)
2С (320 А)
2С (320 А)
2С (320 А)
2С (320 А)
2С (320 А)
Discharge
2С (320 А)
2С (320 А)
2С (320 А)
2С (320 А)
2С (320 А)
2С (320 А)
Quantity of discharge –
charge cycles –current 1С,
at t + 22 °С, 80 % DOD
5000
5000
Charge time of one BP with
1Сcurrent up to 95 %,
hours
max. 1
max. 1
Number of terminals to
connect load or BP, pcs.
1
1
Weight, kg
72.4
69.8
Overall dimensions, mm
417 х 208 х 652.5
417 х 208 х 652.5
Optimal temperature, °С
+19…+22
Charge temperature, °С
0…+45
Discharge temperature, °С
–15…+55
Limiting temperature, °С
–25…+55
Mounting
Into cabinet
Alarm (light)
–exceedance of preset charge current and voltage limits in BP circuit;
–no BP connection;
–BP discharge
Service life (for operation
according to preset
technical; conditions), min.
7 years
Type of storage element
Li-Ion

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1.3 THE PRODUCT COMPOSITION
The Product includes a metal cabinet (see position 1, Figure 1) where same-type с
Li-Ion BPs BP-160 or BP-125 types are installed (see position 2, Figure 1). Control the
cabinet using an integrated control module (CM) (see position 3, Figure 1).
Figure 1 Layout of the Product components
1.4 STRUCTURE AND OPERATION OF THE PRODUCT
1.4.1 Operation of the Product
Figure 2 describes structural diagram. For the description of diagram elements see
Table 3.

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Figure 2 –Structural diagram of the Product

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Table 3 –Description of structural diagram elements
Element
Description
Control module (CM)
BMS-3
Control module (to control the Product and connection to external storage units)
DC/DC
DC/DC converter 24 V to power CM
AC/DC
AC/DC voltage converter, frequency 50 Hz 220 V to power CM
LED
LED indicators to display operation mode
LCD*
Touch LCD to display current operation mode
Air cooling system
RS-422/485
Digital interface for remote control and data output to PC
Ethernet*
Interface for remote control over BPs and data output to PC according to standard
IEEE 802.3
Alarm
Dry contacts opening in case of alarm
Remote switch-on
Remote button to switch on/off CM
Power button
To switch on/off CM
Battery pack (BP-1…BP-n)
BMS-2.1… BMS-
2.n
Control module (to control BP and connection to BPs)
LED
LED indicators to display operation mode of BP
Air cooling system of BP
Battery cell 1…n
Li-Ion battery cell
BMS-1.1…BMS-
1.n
Unit to control battery cell and connection to battery cells
External connections of storage unit
Load
To connect shipborne equipment
Charger
To connect charger for battery packs
ES-2…ES-n
Serial connection of storage units to power bus in case of operation within energy
storage system
Other
Balance
Special line to balance state of charge of external storage units and BPs
Data
Transmission of data on voltage, charge current, temperature on ES, BP and battery
cell
Sense
To measure voltage, charge current and battery cell temperature
*At option.
Note –All electric wiring of the Product including detachable connections is
integrated and hidden due to safety features and in order to prevent a user from touching
conductive parts.

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1.4.2 Description of battery packs BP-160 and BP-125 types
BP consists of several Li-Ion battery cells connected in series. Each battery cell has
a control unit BMS-1.n (hereinafter –BMS, controller) that maintains battery operation
during its all life. BMS-1.n has integrated sensors that measure charge voltage and current,
and control temperature on each battery cell.
Battery controllers transmit all measured data to battery pack control unit BMS-2.n.
It collects all received data and using data transmission line sends the data to CM of energy
system. In addition, CM controls connection to other battery packs integrated in ES.
Each BP has three LED indicators (hereinafter –LED) that display current mode of
operation according to data on voltage, charge and temperature received from battery cells’
controllers. Figure 3 and Table 4 represent layout and description of LEDs.
Figure 3 –BP’s LEDs
Table 4 –Description of BP’s LEDs
Light-emitting diode (LED)
Description
«NORMAL» (green)
Normal operation status –the Product is switched on, ready for
operation, characteristics are within normal range.
«ALARM» (yellow)
Abnormal operation mode (emergency).
«FAILURE» (red)
Indication during charge.
Rear panel of BP is equipped with a connector for BPs, battery cells cooling fan, and
a vent to connect a channel of emergency gas vent system. Gases are automatically released
through valves located at the top part of battery cells to avoid emergencies due to excess
internal pressure. Gas vent shall be carried out to the atmosphere beyond the ship and
separate from the main cooling and ventilation system. Inside BP, emergency gas vent is
released to a special chamber separated from the main ventilated part, thus preventing
electrolyte vapors from penetrating the room (Figure 4).

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Figure 4 –Appearance of S1-WM controls and LEDs
1.4.3 Description of control module operation (CM)
CM collects data on BP status and then outputs operation mode data using LEDs on
the front panel or integrated touch display (at option).
Figure 5 describes layout of LEDs. Table 5 represents description of LEDs.
Figure 5 –Appearance of S1-WM controls and LEDs
Table 5 –Description of CM LEDs
Light-emitting diode (LED)
Description
«NORMAL» (green)
Normal operation status –the Product is switched on, ready for
operation, characteristics are within normal range.
«FAILURE»(red)
Indication of operation failure.
In case of emergency, ES circuit breaker integrated in CM disconnects the load. In
addition to that, CM ensures data exchange and connection to other systems (charger,
ventilation system) and energy storage units (if the Product is a part of energy storage
system).

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1.4.4 Balancing system
Balancing system is in charge of balancing state of charge on each battery cell.
Balancing system is electrically connected to BP and integrated CM byspecial lines.
CM averages and equates output voltage of all BPs.
1.4.5 Alarms and warnings
The Product actuates alarm signaling in case of abnormal operation (exceedance of
preset charge current or voltage limits in BP circuit, no BP connection, discharge or
overheating of battery cell) using:
1)light alarm - LEDs on front panels of BP and CM (red «Alarm» LED lighting up),
see 1.4.2 and 1.4.3;
2)relay contacts and signal output to external devices connected using serial
interface RS-422 or Ethernet (at option).
CM actuates one of the abovementioned signaling types automatically in case of
emergency.
1.4.6 ES deep discharge protection
The Product has a function of deep discharge protection.
Operation principle: once the min. state of charge of battery is reached, the Product
disconnects a load (according to Table 1).
1.5 MEASUREMENT TOOLS,INSTRUMENTS AND APPLIANCES
Technical service of the Product is carried out using tools and consumables
represented in Table 6.
Table 6 –Amount of consumables required for the TS
Name and identifier of
consumables
Amount of
consumables
Note
Cleaning cloth
0.10 kg
1) To clean surfaces and parts of the system –use clean cloth.
2) To clean severe contamination –use alcohol-soaked cloth.
Rectified hydrolytic
technical ethyl alcohol
0.01 l
To soak cloth while removing contamination
Varnish
0.005 kg
To cover surfaces of the unit in case of paint coating damage
Abrasive cloth
0.06 х 0.06 m
To polish surfaces of the unit in case of paint coating damage

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ES-650-ххх, ES-750-ххх, ES-850-ххх, ES-950-ххх types
1.6 MARKING AND SEALING
The Product has nameplates on each BP and CM displaying their serial number,
weight, IP rating, power supply voltage and power consumption. Sealing of the Product is
not provided.
1.7 PACKAGING
While delivered, the Product is placed on flat wooden pallet; corrugated cardboard
is placed on the external elements, then the Product is wrapped with stretch film, ensuring
its transportation and storage at the warehouse.
Transport packaging is also used as a returnable packaging for transportation of the
Product to the repair location and back. Sealing of the packaging is not provided.

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2INTENDED USE
2.1 OPERATION LIMITATIONS
Select an installation place in compliance with operational limitations (operating
temperature and IP rating) and according to the rules of Register.
ATTENTION!
Distance between the installation site and magnetic compass shall not be less than 1 m!
To ensure long-term and correct operation of battery cells, carry out full charge-
discharge cycle of each BP at least every half of year. Use information in 2.3.2 to fulfil this
requirement.
Foremergency gas venting,providea separate gas vent channel(see 1.4.2),andconnect
it according to the drawing in Appendix B.
2.2 PRE-STARTING PROCEDURES
2.2.1 Safety features
While preparing the Product for operation, check it visually and make sure there is no
mechanical damage.
Connect the Product to power supply network considering input voltage requirements.
Before connection, the Product shall be switched off and grounded.
While using the Product the staff shall follow «The technical rules for operation of
electric installation»and «Safety rules for operation of electric installation»while testing
electrical circuits and insulation resistance.
2.2.2 Visual check procedure
Before switching the SC on, the installer shall:
–observe visually the cable integrity and initial position of the controls on the SC
front panels;
–clean the SC from dust and dirt by clean soft cloth, if necessary;
–check fail-safe cable connections to the SC and their proper grounding.
2.2.3 Instructions on powering the Product
While connecting the Product and preparing it for operation follow the steps below:
–before first use (switch-on), check the Product’s state of charge (using integrated
display on CM or connected PC); if state of charge is less than 10% from capacity, charge
the Product;
–transfer circuit breakers of main power switchboard to «ON» position;

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Energy storage
ES-650-ххх, ES-750-ххх, ES-850-ххх, ES-950-ххх types
–switch on the charger;
–transfer a piano type switch on the Product to «On» position and control BP charge
on the CM display or using PC;
–transfer a piano type switch «On/Off» to «Off» position;
–transfer circuit breakers of main power switchboard to «OFF position»;
–connect the load;
–transfer circuit breakers of main power switchboard to «ON» position;
–transfer a piano type switch on the Product to «On» position.
Switch the Product off in the reversed order
2.3 USAGE OF THE SYSTEM
2.3.1 Start of operation
Start of operation has several options (Figure 6).
The first option requires primary network availability (CM is powered from external
power). In this case the Product may be switched on immediately after external power supply.
In the second case power is supplied from own accumulators. To switch the Product
on, press on/off button on the CM. State of charge shall be more than 10%. The Product is
ready for operation after voltage balancing on each BP.
Figure 6 Connection diagram of charger and load to the Product

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2.3.2 Instructions on charge
BP charger shall be capable to ensure the following charge mode: current stabilization
mode during main phase of charge with switching to voltage stabilization in the end phase of
charge. Figure 7 describes charge current and voltage curves in the graph. Voltage and current
valuerequiredfor ESchargeatthemomentiscalculatedbyBMSautomaticallyand transmitted
via RS-485 interface during charge.
Figure 7 Charge current and voltage curves
2.3.3 ES cascading
Other storage units may be connected to the Product in parallel creating storage
system (Figure 2).
ATTENTION!
Storage units that are connected in parallel shall have the same number of BPs!
Energy storage units are connected to bus bar automatically (in load connection
mode) starting from the unit with the highest state of charge; state of charge of other units
is balanced, and then they are connected to power bus. Available capacity is calculated
considering quantity of ES and their types (quantity of integrated BPs).
If several storage units are applied as a system, interconnect balancing systems of
each Product along with other wiring. In addition, next storage unit is connected to a CM
that controls all the system.

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ES-650-ххх, ES-750-ххх, ES-850-ххх, ES-950-ххх types
3TECHNICAL SERVICE
3.1 GENERAL DESCRIPTION
Before performing the TS the staff shall familiarize with the Product structure and
operation features.
In order to provide safe and reliable operation of the Product, the staff shall maintain
technical service № 1 (hereinafter – ТS-1) –semi-annual TS.
ТS-1 is carried out on the equipment in operation.
3.2 SAFETY FEATURES
While maintaining TS, observe 4.2 of this OM.
3.3 MAINTENANCE ROUTINE
The list of works for all types of TS is given in Table 7. Maintenance routine
procedure is given in CL, represented in Tables 810. Amount of consumables required for
TS is shown in Table 6.
Table 7 –List of works for the System SC
CL №
Work
1
Visual check of the Product
2
Operation test
3
Charge-discharge cycle
Table 8 –CL № 1. Visual check of the SC
To be done
Routine
Man-hours
per 1 SC
Examine the
Product
1) check completeness and appearance of the Product; mechanical
damage, paint defects must be absent; marking plates shall be present;
legends shall be read easily;
2) clean up the Product surfaces with clean cloth;
3) remove severe contamination, parts of corrosion, oil spots from the
metal surfaces –using ethyl alcohol, avoiding its penetration inside the
Product; all surfaces clean dry by clean cloth and dry up;
4) If varnish paint coating is damaged, polish it with sand paper, then
clean with alcohol-soaked cloth, cover with varnish АК-113 and dry up.
1 person
5 minutes
Check reliability
of cable and bus
connection to the
Product
1) check that connectors and attaching screws are tightened; provide
further tightening if necessary.
2) check the cable intactness (no mechanical damage) within visibility.
1 person
5 minutes

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Table 9 –CL № 2. Check of the SC operation
To be done
Routine
Man-hours
per 1 SC
Test operation of the
Product
1) switch the power on;
2) make sure that green LED «NORMAL» is lighting up on
the front panel.
1 person
5 minutes
Table 10 –CL № 3. Check operation of command transmission, general alarm and
entertainment broadcasting
To be done
Routine
Man-hours
per 1 SC
Carry out full charge-
discharge cycle of the
Product
1) connect a load to the Product;
2) switch the Product on;
3) discharge BP to 10% threshold voltage;
4) switch the Product off, disconnect the load;
5) connect a charger to the Product;
6) switch the Product on;
7) charge BP to 95%–100% max. voltage;
8) switch the Product off;
9) disconnect the charger
1 person
5 minutes
3.4 PRESERVATION
The Product and set of operational documents are stored in preserved condition in
Manufacturer’s packaging boxes.
Re-preservation time –6 months since the date of packaging at the Manufacturer’s
plant.
The preservation is done in full terms, for 2 years, applying protection and
packaging according to the applicable standards.
The Product shall be stored at 45%–50% state of charge of battery cells; every half
of year the Product shall be de-preserved in order to carry out full charge-discharge cycle of
each BP to 45%–50 % state of charge according to 2.3.2.
The re-preservation is done in heated rooms in the same order as the preservation.
The Product after re-preservation and documents are placed in packaging.

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4CURRENT REPAIR OF THE SYSTEM
5.1 GENERAL DESCRIPTION
Control operation of the Product by power LED lighting on the front panel, and
displayed picture on the screen.
To provide diagnostics of the problems, see Table 11.
If a problem cannot be diagnosed or trouble shooting cannot be provided, contact
the Manufacturer’s service center.
5.2 SAFETY FEATURES
Only qualified personnel, examined in occupational safety may perform repair
works.
Installation, commissioning and repair works are PROHIBITED in the room, where
less than 2 people present.
The Product must be grounded before repair works. Check the grounding of the
Product.
Replacing defected parts, cards and modules when power of device under repair is
ON is STRICTLY PROHIBITED.
It is PROHIBITED to put a poster «DO NOT switch on! Under Operation!», when
power supply switch is in OFF position.
5.3 CURRENT REPAIR
The service personnel can provide repair works as described in Table 11.
Repair of other defects/malfunctions shall be carried out only by specialists or
authorized representatives of the Manufacturer.
Table 11 –Possible problems/defects and troubleshooting
Malfunction
Potential reasons
To be done
«NORMAL» LED on BP
is not lighting up;
«FAILURE» LED is
lighting up.
BP malfunction
Replace the unit from SPTA.
Disconnect the Product from power network.
Unscrew mounting screws, pull out BP from
the battery compartment, disconnect BP
cables. Replace BP