Installation & Operation Manual

Energy Storage System (ESS)

Storion-T50/T100 (Off-grid, Indoor)

V01
 IMPRINT Your Smart Energy

IMPRINT

Alpha ESS Co., Ltd.

+86 (0) 513-80606891

[email protected]

www.alpha-ess.cn

Jiu Hua Road 888, Nantong High-Tech Industrial Development Zone, Nantong City, China,
226300

Alpha ESS Europe GmbH

+49 (0) 6103 / 459 160-1

[email protected]

www.alpha-ess.de

Paul-Ehrlich-Strasse 1a, 63225 Langen, Germany

Alpha ESS Italy S.r.l.

+39 (0) 599 239 50

[email protected]

www.alpha-ess.it

Via Loda, 17-41013 Castelfranco Emilia (MO), Italy

Alpha ESS Australia PTY. Ltd.

+61 1300 968 933 (Technical Support)

[email protected]

www.alpha-ess.com

Suite 1, Level 1, 530 Botany Road, Alexandria, NSW, 2015, Australia

Dec. 25th, 2018

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Your Smart Energy Copyright Statement

Copyright Statement

This manual is under the copyright of Alpha ESS Co., Ltd, with all rights reserved. Please
keep the manual properly and operate in strict accordance with all safety and operating
instructions in this manual. Please do not operate the system before reading through the
manual.

Version Information

Version Date Content

V01 Dec. 25th, 2018 First edition, off-grid version, indoor

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 Content Your Smart Energy

Content

IMPRINT .......................................................................................................... 1
Copyright Statement ...................................................................................... 2
Version Information ....................................................................................... 2
Content ........................................................................................................... 3
1. Introduction.............................................................................................. 5
Brief Introduction............................................................................... 5
Explanation of Terms ........................................................................ 5
2. Safety Instructions .................................................................................. 7
Manual Keeping ................................................................................. 7
Operator Requirements ..................................................................... 7
Protection of Warning Sign............................................................... 7
Setting of Warning Sign for Safety ................................................... 7
Live Line Measurement ..................................................................... 7
Measuring Equipment ....................................................................... 8
Electrostatic Prevention.................................................................... 8
Moisture Prevention .......................................................................... 8
Operation After Power Failure .......................................................... 8
Minimum Personal Protective Equipment ..................................... 8
3. Product Description .............................................................................. 10
Appearance of the Product ............................................................. 10
Product Characteristics .................................................................. 11
Parameters of Components ............................................................ 11
PCS ........................................................................................................... 11
Battery System .......................................................................................... 14

4. Installation.............................................................................................. 21
Installation Precautions .................................................................. 21
Parts List .......................................................................................... 21
Installation ........................................................................................ 23
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Your Smart Energy Content

PCS Installation ........................................................................................ 23

Battery System Installation ....................................................................... 25

Wiring ............................................................................................... 30
Battery Side Wiring ................................................................................... 30
Inverter Side-Wiring .................................................................................. 34
Dry Contact Description ............................................................................ 36

5. Operation................................................................................................ 37
Switch on.......................................................................................... 37
Check Before Operation ........................................................................... 37
Power-on Procedures ............................................................................... 37

EMS Setting ...................................................................................... 39

Diesel Generator Control .......................................................................... 40

Switch off ......................................................................................... 43

Power-off Procedures ............................................................................... 44

Online Monitoring ............................................................................ 44

Register ..................................................................................................... 44
Registering License .................................................................................. 46
Generator Control Setting On Server ....................................................... 47

Emergency Stop .............................................................................. 47

6. Routine Maintenance............................................................................. 48
Maintenance Plan ............................................................................ 48
Routine Inspection .................................................................................... 48
Routine Maintenance ................................................................................ 50

Notes................................................................................................. 53
7. Troubleshooting .................................................................................... 55
Battery and BMS Troubleshooting ................................................. 55
Error Type ................................................................................................. 55
Emergency Handling Plan ........................................................................ 56

EMS Troubleshooting ...................................................................... 56

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 Introduction Your Smart Energy

1. Introduction

Brief Introduction
This manual applies for Storion-T50/T100 Li-ion battery energy storage system, mainly
includes:

(1) Safety introduction

Introduces the product use, operating notes and qualification of operators of T50/T100 Li-ion
battery energy storage system.

(2) Product description

Describes product appearance, product characteristics, system composition and major

functions of T50/T100 Li-ion battery energy storage system.

(3) System installation

Introduces the installation of T50/T100, including cautions.

(4) Operation

Introduces the operation of T50/T100 system.

(5) Routine maintenance

Introduces items in maintenance of T50/T100 kWh Li-ion battery energy storage system,
including attentions.

(6) Trouble-shooting

Introduces the faults of T50/T100 Li-ion battery energy storage system, causes to faults, and
processing method.

Explanation of Terms
(1) Lithium iron phosphate cell (LiFePO4)

Basic unit constituted by electric poles and electrolytes; Each cell is independent and closed.

Notes: Paralleled cell cannot be regarded as an independent cell, even repacked as

one whole battery pack.

(2) Lithium iron phosphate pack

Combination made up of battery monitoring circuit, battery equalization circuit, electrical

connectors, communication interfaces, thermal management devices and multiple Lithium iron
phosphate cells.

Notes: For packs from same company, all the details such as physical size,

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Your Smart Energy Introduction

working performance and interface specification should be consistent so that all the
packs are compatible and interchangeable.

(3) Battery management system

Electronic equipment collection for monitoring the operating information of cells, packs and
system units (such as voltage, current, temperature, protective parameter of batteries),
evaluating the state of charge (SOC), the state of health (SOH) and cumulative processed
energy and protecting batteries for safety, etc.

(4) Battery system unit

A combination of batteries through series parallel combination inside and a battery

management system (BMS) in which accesses to DC side of a bidirectional converter.

(5) Storage unit

A combination of a bidirectional converter and a battery system unit, which can be used as an
independent load or be controlled directly by monitoring system.

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 Safety Instructions Your Smart Energy

2. Safety Instructions

Manual Keeping
This manual contains important information about operating the system. Before operating,
please read it very carefully.

The PCS should be operated in strict accordance with the description in the manual, in case
that it causes damage or loss to equipment, personnel and property.

This manual should be kept carefully for maintenance and reparation.

Operator Requirements
The operators should get a professional qualification, or trained.

The operators should be familiar with the whole storage system, including compositions and
working principles of the system.

The operators should be familiar with the Product Instruction.

While carrying out maintenance work it has to be at least two operators in the filed all the time.
They can not operate on any equipment until they are all powered off and fully discharged.

It is strictly prohibited for any maintenance to be carried out when equipments are on or charged.

Protection of Warning Sign

The warning sign contains important information for the system to operate safely and it is strictly
prohibited to torn or damage the sign.

Ensure that the warning sign is always clear.

The signs should be replaced immediately if damaged.

Setting of Warning Sign for Safety

While instructing, maintaining and repairing, to prevent unrelated personnel nearby to cause
incorrect operation or accident, the suggestions below should be followed:

Obvious signs should be set at front switch and rear-level switch in case of accidents caused
by false switching.

Warning signs or tapes should be set near the operation areas.

Keys of the system must be pulled out after maintenance or operation.

Live Line Measurement

High voltage in the container which may cause vital electric shock when touched by accident.

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Your Smart Energy Safety Instructions

Equipment protection must be taken in live line measurements (e.g.: insulation gloves).

The measuring equipment should be connected and used correctly to ensure personnel safety.
When measuring, at least two workers are needed.

Measuring Equipment
To ensure the electrical parameters to match requirements, related measuring equipment are
required when the system is being connected or tested.

Ensure that the connection and use matches specification in case of electric arc or shock.

Electrostatic Prevention
Contact or improper operation of the printed circuit board or other ESD sensitive components
may result in damage to the device. Unnecessary contact should be avoided.

Moisture Prevention
It is very likely that moisture may cause damages to the system.

Do not open the container door if the humidity is larger than 95%.

Repair or maintaining activities in wet conditions should be avoided or limited.

Operation After Power Failure

The battery system belongs to energy storage system, which maintains fatal high voltage even
when the DC side is disconnected. Therefore, touching of the battery output is strictly prohibited.

The PCS maintains fatal voltage even when both the DC or AC side are disconnected, so it
must be tested by the multimeter for safety before operation.

Minimum Personal Protective Equipment

For the safety of operators to the system, personal protective equipments are required. During
the operation, following protective equipments are required:

No. Item Notes

1 Work clothes
2 Protective shoes
3 Protective glasses

When doing maintenance works such as checking cables or wires, measuring voltage,
replacing small electrical parts or cleaning modules and brackets, as minimum the following
protective equipments are required:

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 Safety Instructions Your Smart Energy

No. Item Notes

1 Work clothes
2 Protective shoes
3 Protective glasses
4 Insulated gloves For touching live parts

Note: All metal tools during maintenance should be insulated.

When replacing modules, the following protective equipments are required:

No. Item Notes

1 Work clothes
2 Protective shoes
3 Protective glasses
4 Insulated gloves For touching live parts

Note: When replacing modules, the stacking machine should be used carefully in
case that the modules may fall down. All workmen are suggested to wear high-safety
and high strength protective shoes to protect their feet.

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Your Smart Energy Product Description

3. Product Description
The AlphaESS Storion-T50/T100 energy storage system is an off-grid system. The excessive
energy generated by the PV will be stored in the batteries. The stored energy can be used when
the PV is not generating enough energy. When connected with a generator, if there is neither
enough PV supply nor enough stored energy, the loads will be automatically powered by
generator through STS (Smart Transform Switch).The overall system connection diagram is as
follows:

Figure 3.1 Applications of the system

Appearance of the Product

Figure 3.2 shows the appearance of the system.

6
1

5
2

3 4

Figure 3.2 T50/T100 without container

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 Product Description Your Smart Energy

Table 1 T50/100 System composition

Item Components
1 Storion-T50/100-INV
2 M48112-S
3 Junction Box
4 HV900112 Box
5 Battery Rack
6 TOP BMU Box

Product Characteristics
LiFePO4 batteries produced by AlphaESS have longer lifespan and higher reliability, which is
able to satisfy the application of energy storage systems.

The system is highly modular designed, and it is easier to assemble, transport and maintain.

The system has a three-level BMS and is allowed for system expansion.

The system adopts all time balancing technology so that the consistency of batteries and
modules can be well ensured.

The system is designed as a removable container which is compact in structure, flexible,

convenient for installation and testing, suitable for the working environment and is able to satisfy
different kinds of applications.

The system has current balance technology between strings in case of circulating current or
unbalanced power.

The system has relatively developed thermal management technology so that the consistency
of the system environment can be ensured.

The system has both remote monitor function and local control function.

The system realizes flexible scheduling of electric power system through communication
among BMS, PCS and monitoring system.

The system realizes emergency fire protection by using the automatic alarming and fire
extinguishing system

Parameters of Components

PCS

3.3.1.1 Product Instruction

Storion-T50/T100-INV is a hybrid inverter. It has DC/DC and DC/AC modules. It can transform
the DC electricity from PV panels into three-phase AC electricity to supply loads. The DC/DC

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Your Smart Energy Product Description

module can charge batteries by using the electricity generated by PV panels. The DC/AC
module is bidirectional so that the battery can also be charged by the grid through the inverter.

3.3.1.2 Appearance Instruction

Figure 3.3 Appearance of the PCS

Table 2 Composition of the PCS

No. Description No. Description

1 Power indicator 7 PCS module
2 Normal indicator 8 STS module
3 Fault indicator 9 PV DC switch
4 Scram button 10 Battery switch
5 Display screen 11 Load switch
6 Handle 12 Diesel switch

3.3.1.3 Technical Parameters

Table 3 Technical parameters of the PCS

No. Item Storion-T50-INV Storion-T100-INV

AC Side Data (off-grid)
1 AC Nominal Output Power 50 kW 100 kW
2 AC Max. Power 55 kW 110 kW
3 AC Output Voltage 400 Vac (± 10% configurable)
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 Product Description Your Smart Energy

4 Voltage Range 400 V ± 10 %

5 AC Output Current 72 A (max. 79 A) 144 A (max. 159 A)
6 AC Connection 3-phase and 4-wire system (including
transformer)
7 AC Frequency 50 Hz / 60 Hz
8 Output THDu <2%
Listed: 0.8~1 leading or lagging
(Load-depend)
9 AC PF
Actual: 0.1~1 leading or lagging
(Load-depend)

105%~115% 10min;
10 Overload Capability 115%~125% 1min;
125%~150% 200ms
DC Data (Battery Side)
11 DC Voltage Range 250 – 520 V
12 One-Way Maximum Input
150 A 300 A
Current
13 Max. DC Power 50 kW 100 kW
PV Side Data
14 PV Voltage Range 520 – 900 V (MPPT: 520~800 V)
15 PV DC Max. Current (in case
192 A 384 A
of completely consumption)
17 Max. PV Power 100 kW 200 kW
General Data
18 Max Efficiency 95.5%
19 Dimensions (W x H x L) 800 x 2160 x 800 mm
20 Weight 520 kg 750 kg
21 Altitude 3000 m
22 Ingress Protection IP20
23 Noise 70 dB

24 Operation Temperature -25 ℃ ~ +50 ℃ (De-rating over 45°C）

25 Cooling Concept Forced Air

26 Humidity 0~95% (Non-Condensing)
27 Communication Interfaces Ethernet‚ RS-485‚ CAN

3.3.1.4 Emergence Stop Switch

The converter stops working immediately after pushing the button.

If you want to restart the converter, please proceed in the following order:

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Your Smart Energy Product Description

a) Conduct counter clockwise rotation on the emergency stop switch and then loosen the
locking status.
b) Push the AC breaker into “OFF” position, pull up the emergence button and then turn
the AC breaker “ON”.
c) Launch the machine and operate it as required

Battery System

Table 4 Battery system parameters

Item Description Parameter Remark

1 Nominal discharge power 50 kW / 100 kW
2 Energy storage capacity According to the project Ambient temperature
situation
is 30℃, measured at

DC side
3 Continuous discharge current 1C (continuous)
4 Direct voltage 250 ~ 520 V
5 Communication interface RS485, CAN2.0

3.3.2.1 M48112-S

Figure 3.4 Battery appearance

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 Product Description Your Smart Energy

Figure 3.5 Battery front cover

Table 5 Battery interface definition:

No. Description No. Description

1 Battery negative pole 5 Dip switch
2 Battery positive pole 6 COM port (CAN) x 2
3 Earthing point x 4 7 Information label
4 LED light 8 Earthing point (reserved)

The dip switch of M48112-s defines the serial number. Please see the detailed description in
the following table.

Table 6 Dip switch definition of M48112-S

Serial Serial Serial

Dip Switch Dip Switch Dip Switch
Number Number Number

1 6 11

2 7 12

3 8 13

4 9 14

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Your Smart Energy Product Description

5 10 15

Table 7 Battery technical parameters:

No. Item Technical parameter Remarks

1 Battery model M48112-S
2 Assembly method 16S2P
3 Nominal voltage 51.2 V

4 Voltage range 48～58 V

Max. charge / discharge

5 Nominal capacity 112 Ah
current 1C
6 Nominal stored energy 5.734 kWh
7 Work power consumption 0.4752 W
8 Dormant power consumption 1.52 mW Battery dormant state
9 Max. charge/discharge current 112 A Constant current mode

10 DC internal resistance ＜20 mΩ Factory default

Transportation/storage
11 -20 ～ 45 ℃
temperature range
Charging work temperature
12 0～50 ℃
range
Discharging work temperature
13 -10～50 ℃
range
14 Communication mode CAN
15 Weight 70 ± 2.0 kg
494.6 x 615.3 x 162.6
16 Size (W x D x H)
(±5) mm

17 Humidity 15%～85%

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 Product Description Your Smart Energy

3.3.2.2 HV900112

Figure 3.6 HV900112 front cover

Table 8 HV900112 interface definition:

No. Description No. Description

1 DCin+ 7 DCout-
2 DCin- 8 AC input (auxiliary power)
3 Earthing point x 4 9 AC Air switch (auxiliary power)
4 Moulded case circuit breaker 10 BMU COM port (CAN) x 2
5 Information label 11 LMU COM port (CAN)
6 DCout+ 12 LED light
13 Earthing point (reserved)

HV900112 technical parameters:

No. Item Technical parameter Remarks

1 High-voltage control box HV900112
2 Working voltage range 200 ~ 900 V
3 Modules Connection 5~9 M48112-S in series for T50/100,
with only 5 batteries,
the batteries will not
be fully discharged
4 Rated current 112 A
5 Dimensions (W x D x H) 494.6 x 552.6 x 162 ± 5mm

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Your Smart Energy Product Description

6 Weight 20 kg
7 Power consumption <10 W

3.3.2.3 Top BMU Box (with EMS)

Functions such as remote monitoring, remote upgrade, etc. can be realized through the
TOP BMU Box with EMS.

Figure 3.7 Front cover of TOP BMU box with EMS

Table 9 Top BMU box with EMS interface definition:

No. Description No. Description

1 BMU COM port 17 DIP switch
2 BMU COM port 18 Meter COM port (reserved for RS485)
3 Ethernet 19 Air conditioner COM port( (reserved for RS485)
4 Reserve power supply 20 INV PCS COM port (reserved for RS485)
5 Dry contact COM port 21 PV junction COM port (reserved for RS485)
6 Meter COM port 22 Dry contact COM port (reserved for RS485)
7 EMS COM port (reserved) 23 Meter RS485A port
8 Air conditioner COM port 24 Meter RS485B port
9 PCS COM port 25 Air conditioner RS485A port
10 PV junction COM port 26 Air conditioner RS485B port
11 Dry contact port 27 PCS RS485A port
12 EMS display screen 28 PCS RS485B port
13 DB9 COM 29 PV Junction RS485A port

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 Product Description Your Smart Energy

14 Storage card 30 PV Junction RS485B port

15 Burning port 31 Dry contact +24V
16 COM pin board 32 Dry contact earthing point
33 Earthing point x 4

NOTE: TOP BMU box (with EMS) can communicate with outside device, such as PCS,
Air conditioner, PV junction box, etc.
If the communication type is CAN, you can connect from the COM port (from Port 1 to
10) in TOP BMU box to the device by using regular net cables.
If the communication type is RS485, please connect to the RS485A and RS485B port in
TOP BMU box. Besides, the two corresponding COM ports in TOP BMU box should be
connected with each other.

Table 10 Technical parameters:

No. Item Technical parameter

1 Dimensions(W x D x H) 490.6 x 323 x 161 ± 5 mm
2 COM RS-485×4; Ethernet 10/100/1000Mbps×1
3 Internal storage CD card, 16 GB
4 Events diary Recent one-month happenings
5 Work voltage 24 V
6 Power consumption <10 W

3.3.2.4 Junction box

1 3 1 2 4 2
5 5

Figure 3.8 Inside of the junction box

Table 11 Wiring definition of the junction box:

No. Description No. Description

1 2 x DC IN INV- 4 7 x DC OUT+

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Your Smart Energy Product Description

2 2 x DC IN INV+ 5 Handle
3 7 x DC OUT-

Table 12 Technical parameters:

No. Description Technical parameter

1 Dimensions (W*D*H) 490.5 x 205 x 162 mm
2 Weight 7 kg

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 Installation Your Smart Energy

4. Installation

Installation Precautions
The following sites are not allowed for installation:

- Sites which are salty and where humid air can penetrate.
- Flooded areas.
- Earthquake areas –additional security measures are required here.
- Sites that are higher than 3000 meters above the sea level.
- Sites that are in an explosive or potentially explosive atmosphere.
- Sites with extreme changes of ambient temperature.
- Sites with highly flammable materials or gases.

Parts List
Table 13 Parts List

M48112-S

1 X Power Cable 1 X Communication Cable 4 X M6

4 X M6*16
130 mm, Black-Red, BAT-BAT 280 mm, BAT-BAT Gouding Serrated Washer

Hv900112

1 X Communication Cable 1 X Communication Cable 4 X M6

4 X M6*16
300 mm, BAT-HV Box 680 mm, HV Box - HV Box Gouding Serrated Washer

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Your Smart Energy Installation

1 X Power Cable 1 X Power Cable

AC Auxiliary Power Cable 1 X Terminal Resistance
2500 mm, Black-Black, BAT-HV 130 mm, Red-Red, BAT-HV

TOP BMU Box

1 X Communication Cable 4 x M6
1 X Terminal Resistance 4 x M6*16
2500 mm, TOP BMU-HV BOX Gouding Serrated Washer

Junction Box (if required)

1 X 4500 mm Power Cable 1 X 4500 mm Power Cable 4 x M6

4 x M6*16
Black-Black, Junction Box-INV Red-Red, Junction Box-INV Gouding Serrated Washer

Rack

1 x 4500 mm Power Cable, 1 x 4500 mm Power Cable,

Black-Black, For HV Box - Red-Red,For HV Box – Junction,

1 x Communication Cable
Junction Box (If Junction Box (If Junction Box Required); Or 1 x M6 Nut
7500 mm EMS-INV
Required); Or For HV Box - INV For HV Box – INV,(If Junction

(If Junction Box Not Required) Box Not Required)

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 Installation Your Smart Energy

4 X M12 Hex Nut 4 X M12*25 Hex Screw

Installation

PCS Installation

4.3.1.1 Removal
When removing the T50/T100-INV, a forklift can be used to remove the whole case. Users can
lift the device bottom with a forklift or remove the inverter cabinet through the lifting hole on its
top with a crane. It can be transported alone.

Figure 4.1 Moving method for inverter

Don’t insert the module into the cabinet and move them together! Before the cabinet is
moved, pull out the module and move the cabinet alone.

4.3.1.2 Operation Space

The installation space of the PCS should have a proper distance from its peripheral walls
so as to ensure that the machine door can be opened and closed conveniently and there
will be sufficient space for module insertion and extraction, normal heat dissipation and
user’s operation.

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Figure 4.2 Installation space

A≥1,000mm, make sure that the front door of the cabinet can be fully opened and there is
sufficient space for cold air to enter. Users can conveniently insert and extract the module and
operate the breaker.

B≥1,000mm, make sure that the rear door of the cabinet can be fully opened. Ventilation and
heat dissipation should be ensured. Users can also have sufficient space for product
maintenance.

4.3.1.3 Cabinet Installation

After the cabinet is removed to the installation position with a forklift or a tool. The cabinet
should be adjusted and removed to the designed position. Then open the internal door of
cabinet, and fix the cabinet with M13 screws, as shown in Figure 4.3.

Figure 4.3 Diagram of the cabinet base

When the cabinet needs to be fixed on the steel channel, Φ14 holes can be made in the steel
channel. Fix the cabinet to the steel channel with screws, as shown in Figure 4.4.

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 Installation Your Smart Energy

Figure 4.4 Fix the cabinet to the steel Figure 4.5 Fix the cabinet to the
channel concrete floor

When the cabinet is fixed to the concrete floor, make holes on the floor and fix the cabinet to
the concrete floor with expansion screws, as shown in Figure 4.5.

4.3.1.4 Inverter Grounding

The modules in the Bi-directional Hybrid Storage Inverter can realize grounding connection with
the cabinet through hangers.

As for cabinet grounding, the cabinet bottom is installed with grounded cooper bars. During
wiring, refer to the following table for cable diameter. The grounding resistance should be less
than 4Ω.

Rated power PE line section recommendation

50 kW ≥16 mm²
100 kW ≥25 mm²

Battery System Installation

4.3.2.1 Battery Rack Installation

a. Open the battery rack package(s).

The tray is for the battery, the holder 1 is for HV900112 and the holder 2 is for junction box or
TOP BMU box as the below figures show. The locations of them can be exchanged.

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L Holder

Tray Holder 1 Holder 2

Note: the location of L holder on holder 2 is flexible. The front location is for the
junction box and the rear location is for TOP BMU box.

b. If there are only one or two clusters, the junction box is not required, and the same is true of
cluster racks. Just place the rack(s) in the suitable place(s) by using a crane or forklift.

If there are more than three racks, place the first rack beside the PCS, which is different from
others as Figure 4.6 shows.

different from others

Figure 4.6 First rack appearance

c. Place other racks as Figure 4.7 shows.

d. Fix the rack foundation(s) with hex screws and nuts if the fixing is required, which you can
find in the rack parts list. The customer shall prepaid for some materials, such as a cable to
connect your own grounding cooper bar to the grounding screws of the rack bottom by using
the grounding nut M6 from the rack parts list.

Grounding screw

e. Fix the back fixing spot by using a ladder to prevent incline.

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Figure 4.7 PCS and racks installation

4.3.2.2 Control Box Installation

Open the HV900112 package(s) and the TOP BMU box package (if TOP BMU is required).

 If the junction box is required

a. Put the TOP BMU box on the top of the second rack as Figure 4.8 shows.

Figure 4.8 TOP BMU box installation

b. Put all the HV900112 boxes in the right places as Figure 4.9 shows.

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Figure 4.9 HV900112 boxes installation

 If the junction box is not required, just put the HV900112(s) in the bottom of the rack(s).

Figure 4.10 One cluster with HV900112

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4.3.2.3 Battery Installation

Step 1: Open all the battery packages. Step 2: Check the Battery No. and cluster No. on the
battery cover.

BAT 1-01
BAT 1-02
BAT 1-03
BAT 1-04
BAT 1-05
BAT 1-06
BAT 1-07
BAT 1-08
BAT 1-09

Step 3: Put the same cluster of batteries on the same rack with the serial number of 01 to 09
from top to bottom as the above figure shows. The dip switch defines the serial number, see
Table 6.

NOTE: All the cluster battery group No. shall be the same.
In one cluster the dip switch of each battery should be different from ohers.
When you are installing the battery, pleasecto avoid scratches because of the heavy
battery.

Step 4: After completing one rack, please check whether the installed batteries have the same
cluster No. and the same battery group No.

Step 5: If there are more than one rack, please repeat step 3 and 4 to install the other battery
racks as Figure 4.11 shows.

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Figure 4.11 All batteries installation

Wiring

Battery Side Wiring

4.4.1.1 Communication Cables Connection

a. Please refer to the following figure, b. Take the terminal resistance in the
connect the communication cables among HV900112 parts list and insert it into the top
batteries of each cluster. These cables are battery COM port of each battery cluster. You
in each battery parts list. can see the detailed information Figure 4.13.

Figure 4.13 Terminal resistance in the top

Figure 4.12 Communication cables
battery of each cluster
connection in one cluster

c. Connect the bottom battery of each cluster to V900112 (LMU Port) by using the
communication cables from HV900112 parts list.

d Connect HV900112 (COM Port) in the nearest cluster from TOP BMU and TOP BMU box
(COM Port, Port 1 or 2) by using the communication cable from TOP BMU part list. Then
connect HV900112 (COM port) one by one by using cable from HV900112 parts list, please
see Figure 4.14.
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Figure 4.14 Battery side communication cables connection

e To connect the PCS and EMS please open the PCS cabinet front door and remove the shield
of the right side. You can see the communication interface at the right bottom. Then please
connect TOP BMU box (Port 27 -485A and Port 28 - 485B) to the PCS (Port 9 - 485A and Port
10 - 485B) by using the RS485 cable from the rack parts list as Figure 4.15 shows.

Shield

TOP BMU

PCS

Figure 4.15 Conection between EMS and PCS

The terminal strip ports of PCS are defined as in Table 14 shown.

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Table 14 Definition of terminal strip ports of PCS

Item Terminal Notes

Input Signal Loop
1 IN1
BMS Fault Signal
2 IN1 GND
3 IN4
On/Off-grid Switch Node 1
4 IN4 GND
5 IN5
On/Off-grid Switch Node 2
6 IN5 GND
External Communication Loop
7 CAN H
From External BMS
8 CAN L
9 485 A
To External RS485
10 485 B
External Aux Power Input
11 L
From External AUX Power
12 N

f. Connect the COM port 9 and COM port 20 of TOP BMU box with a regular net cable.

g. The last COM port of HV900112, which has no cable to connect, should be inserted with the
terminal residence from HV900112 parts list. You can see the detailed information Figure 4.16.

Figure 4.16 Terminal resistance in one of the HV900112

4.4.1.2 Power Cables Connection

 If there are only one or two clusters, you don’t need the junction box. The battery DC
positive and negative port of HV900112 can be directly connected to the BAT+ and BAT- of
PCS as Figure 4.17 shows.

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Figure 4.17 Battery side-power cables connection without junction box

 If you use the junction box, place the relevant power cables to junction box at the first, as
shown in Figure 4.18. Then put the junction box in to the rack as shown in Figure 4.19.

The cover of the junction box should be taken off for wiring. The cables should be
connected vertically with the copper bars in the junction box.

Figure 4.18 Battery side-power cables connection with junction box

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After wiring the junction box, please fix it on

the rack by using the screws and grounding
serrated washers in junction box parts list

Figure 4.19 Placing junction box

After wiring the battery side, please fix each

Earthing Point box with the four screws and four grounding
serrated washers to the racks. These screws
and grounding serrated washers are
shipped in the corresponding batteries,
HV900112, Top BMU box, junction box
packages.

Inverter Side-Wiring
The connection positions are in the bottom down position of the inverter cabinet. The cables
shall be passed through the hole on the base of cabinet into the cable trench. Open the front
door and remove the inner door, you can see the wiring copper bar. In view of the requirements
of connecting cables, single or multiple cables with suitable diameter shall be selected.

For T50 the 35 mm²cable with copper core is suggested for each phase.

For T100 the 50 mm²cable with copper core is suggested for each phase.

Figure 4.20 Inverter wiring diagram

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Position Description Position Description

1 PV DC input positive pole 7 Load output phase L2
2 PV DC input negative pole 8 Load output phase L3
3 Battery input positive pole 9 Grid/GEN input phase L1
4 Battery input negative pole 10 Grid/GEN input phase L2
5 Ground connect 11 Grid/GEN input phase L3
6 Load output phase L1 12 Neutral connect

Please connect the AC side – the loads and the diesel generator as Figure 4.21 shows.

Notes: For the diesel generator selection, the rated power of the generator should
be more than the inverter rated power.

Figure 4.21 AC-Side wiring diagram

4.4.2.1 AC Auxiliary Power Cable Connection

Please connect the AC auxiliary power inputs of each HV900112 with the Grid/GEN L phase
(anyone of L1, L2 and L3 phase) and N pole of PCS by using the AC auxiliary power cable in
HV900112 parts list as the following figure shows.

Figure 4.22 AC Auxiliary Power Cable Connection

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Notes: The auxiliary power cable bond must be placed above the AC power cable
bond. After this please tighten the screw.

Dry Contact Description

1. Connect DO_2 to the dry contact of the diesel generator, port 2 and 3 (normally closed contact),
1 and 2 (normally open), you can connect the diesel dry contact to control the 1 and 2.
2. Connect DI_2 to the fire fighting dry contact, port 14 and 15 are respectively corresponding to
the composite fire alarm of connecting fire fighting. (if required)
3. Please connect the diesel control dry contact as the below picture shows:

Notes: normally open/closed contact which connects the Genset according to the
genset controller.

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5. Operation

Switch on

Check Before Operation

Before operation, please check the equipment according to following procedures:

If no sign of damage is inspected visually outside the inverter module and all the battery switch,
PV switch and load switch, diesel engine switch are in the "OFF" position, you will

a. check whether the DC input wiring of the energy storage system and the AC output wiring
are normal and whether the earthing is good;

b. check whether the wire connection polarity is normal;

Power-on Procedures
The system shall be turned on in the correct sequence to avoid any damage.

A. Turn on the moulded case circuit breakers of HV900112 in each cluster respectively.

From left to right: OFF- triggered position-ON

Figure 5.1 Moulded case circuit breaker in switch-off status

B. Turn on the AC air switch of HV900112 in each cluster respectively. If there is an AC main
switch, turn it on.

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Figure 5.2 AC switch in switch-on status

C. After the power is on, the LED on the batteries and HV900112 starts flashing.

D. Two minutes later, turn on the battery and PV switches of the inverter by pushing up the
switch handles. The green indicator of the inverter starts flashing. After 10 seconds, the red
indicator is on.

Figure 5.3 PV switch and battery switch in switch-off satus

E. Turn on the load switch by pushing up switch handles. If a diesel generator is connected,
turn on the generator switch.

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Figure 5.4 Load switch and diesel switch in switch-off satus

G. Normal system operation

After the system is powered on, it will be switched on automatically if there are no errors and
warnings.

EMS Setting
Step 1: Enter into EMS menu and get into Step 2: Enter the password (the initial
Setting. password for installers is 1111).

Step 3: Get into the Function menu. Choose Step 4: Get into the PCS menu. Choose
PCS. AC_Tied.

Step 5: If you connect a diesel generator in Step 5: Make sure in the PCS menu the Minv
the off-grid system, please get into the is the system model, such as T50.

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AC_Tied menu. Choose Type as

AC_Generator.

Diesel Generator Control

This section will introduce the diesel generator control setting in EMS. The setting parameters
of diesel generator control are as the following table.

Table 15 Setting parameter for diesel generator control

No. Parameter Description

1 GeneratorEN Yes-Diesel generator enabled
No-Diesel generator disabled
2 GeneratorMode Fix SOC mode: SOC mode, TOU mode, manual
3 GCSOCStart Lower limit of the configured SOC range
4 GCSOCEnd Upper limit of the configured SOC range
5 GCTimeStart Start time of generator running
6 GCTimeEnd Start time of generator running
7 GCOutputMode Optional 8, 9 mode
8 GCChargePower Battery charging power
9 GCRatedPower Diesel generator output rated power

When the diesel generator is enabled, it will supply the load first.

1. SOC mode: When the SOC drops below the lower limit of the configured SOC range, the
diesel generator will start; when it raises beyond the upper limit, the diesel generator will then
be turned off.

2. TOU mode: the generator will run during the configured GCTime (from GCTimeStart to
GCTimeEnd).

3. Charging power mode

If the mode 8 - battery charging power mode is selected, the diesel generator will charge the
batteries with configured power.

4. Diesel generator rated power mode

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If the mode 9 – diesel generator output rated power mode is selected, the diesel generator will
charge batteries with the rest of the power under the condition of satisfying load.

The rest power is Prest = Poutput – Pload.

You can also set the control mode on the website, see 5.4.3

For diesel generator control setting, please operate according to following steps:

Step 1: Please get into setting menu, then the Step 2: Please get into GeneratorEN and
function menu, after that get into generator select Enable as YES.
menu.

Step 3: Please get into GeneratorMode Step 4.1: If you choose SOC control mode,
menu. please select the mode as SOC Mode.

Step 4.1.1: Get into GCSOCStart menu. Step 4.1.2: Set the lower limit of the
configured SOC range.

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Step 4.1.3: Get into GCSOCEnd menu. Step 4.1.4: Set the upper limit of the
configured SOC range

Step 4.2: If you choose time control mode, Step 4.2.1: Get into GCTimeStart menu.
please select the mode as TOU Mode.

Step 4.2.2: Set the diesel generator start time Step 4.2.3: Get into GCTimeEnd menu.

Step 4.2.4: Set the diesel generator end time Step 5: Get into the GCOutputMode menu

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Step 5.1: If you choose fixed charging power, Step 5.1.1: Get into the GCChargePower
please select the output mode as GCCharge. menu.

Step 5.1.2: Set the fixed charging power. Step 5.2: If you choose rated power mode,
please select the output mode as GCRated.

Step 5.2.1: Get into the GCRatedPower Step 5.2.2: Set the generator rated power.
menu.

Switch off
Step 1: Enter into EMS menu and get into Step 2: Enter the password (the initial
Setting. password for installers is 1111).

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Your Smart Energy Operation

Step 3: Enter into function menu and get into Step 4: Choose ModeOff as yes
INVcmd

The system shall then be powered off.

Power-off Procedures
The system shall be powered off according to following steps:

A. turn off all of the loads.

B. turn off two DC breakers of the inverter.

C. turn off two AC switches of the inverter.

D. turn off the AC air switch of HV900112 in each cluster.

E. turn off the moulded case circuit breaker of HV900112 in each cluster.

Note: the system will be switched on automatically if it is still powered on after 5

min.

Online Monitoring

Register
You have to create a new account on our webserver for the normal monitoring.

So please use the following steps:

Open the portal: www.alphaess.com.

Enter the username and password, then click “Login” to jump to the home page. There will be
a prompt after a failed login.

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Figure 5.5 Monitoring login interface

Users who haven't yet registered need to click “Register” to visit the registration page: (as
shown below)

Boxes followed by a “*” mark must be filled,

and the contents you fill must consist with
the facts. Registered users come in 2
types: end users and installers. Please
choose between them according to the
actual situation. Then you can check
whether you need auto upgrade or not
according to your own situation. Then Click
“SIGN UP NOW” to go to the login page.

More detailed information can be obtained

in Online Monitoring Webserver installation
Manual.

Figure 5.6 Register interface

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Your Smart Energy Operation

Registering License

Click Install new system to

register the license No.

Figure 5.7 Menu for installer

Figure 5.8 System registering interface

Input S/N, Check Code, License No., Date, Name, and Contact No. to complete the
registering process.

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Generator Control Setting On Server

You can set according to the actual conditions by customers.

There are two options, SOC control or time control.

At the first, please click Generator to enable it.

 Choose SOC control to set SOC range. If the SOC drops below the lower limit of the
configured SOC range, the diesel generator will start; when it raises beyond the upper limit,
the diesel generator will then be turned off.
 If you set the battery charge power, it will charge the batteries with the configured battery
charge power.
 If you set the Generator output power, it will charge the batteries with the rest of the
power under the condition of satisfying load. The rest of the power is P=Poutput – Pload.
 Choose time control, the diesel generator will start during the configured working time.

Emergency Stop
When the energy storage system is abnormal, you can press the emergency stop button "EPO"
on the cabinet door, follow the step A to D in 0 to power it off.

In order to prevent personal casualty, if you want to repair or open the machine after power-off,
please measure the voltage at the input port with the multimeter first. Before any relevant
operation, please confirm that there is no grid electric supply!

The upper cover plate cannot be opened until the DC-link capacitance inside the module
discharges completely about 15 minutes (see warning label on the surface of module for details).

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 Your Smart Energy Routine Maintenance

6. Routine Maintenance

Maintenance Plan
 check if wire connection loose
 check if cables aged/damaged
 check if cable insulating ribbon drop
 check if cable terminal screw loose, any overheat sign
 check if ground connection is well

Routine Inspection
Minimum PPE
Training/qualificat (Personal
Item Details Frequency Notes
ion requirements protection
equipment)
Check the
Once Work cloth;
Foundation foundation for tilt No tilt or sink
6 months Protective shoes
or sink
Check the
earthing bar of Once Work cloth;
Footing No rusting
the container for 6 months Protective shoes
rusting.
Check the
Lighting lighting supply;
Once All the lights should Work cloth;
power all the lights
6 months work normally Protective shoes
supply should work
normally
Check the
All emergency
emergency
lights should work
Emergency lighting Once Work cloth;
normally after
lighting equipments; all 6 months Protective shoes
power supply is
the lights should
down
work normally
Check the
Bracket Once 6 No rusting or Work cloth;
brackets for rust
surface month damage Protective shoes
or damage
Check the fixing All bolts are tight Work cloth;
of brackets Protective shoes;
Bracket between Once 6 Wrenches
fixing brackets and months
ground of the
container
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Check the No rusting or Work cloth;

Module Once 6
modules for rust damage Protective shoes
surface months
or damage
Check the fixing All bolts on module Work cloth;
of modules are tight Protective shoes;
Module Once 6
between Wrenches;
fixing months
modules and Insulated gloves
brackets
Check the All bolts of copper Work cloth;
Module module serial Once 6 bars and cables are Protective shoes;
connection and parallel months tight Wrenches;
connection Insulated gloves
The bolts on Work cloth;
module surface Protective shoes;
should be Wrenches;
Check the
electrically Insulated gloves
Module module for Once 6
connected to the
grounding correct months
bracket surface and
grounding
grounding
bars(tested by a
multimeter)
Check the All red and black Work cloth;
terminals of covers should be Protective shoes;
Module Once 6
modules for complete Wrenches;
terminal months
insulation Insulated gloves
protection
Check the on-off The circuit breaker Work cloth;
function and function should be Protective shoes;
Circuit Once 6
tripping function OK; When breaker Wrenches;
breaker months
of circuit is off , no voltage is Insulated gloves
breakers allowed
All data on PCS Work cloth;
PCS Check the PCS Once 6 including voltage, Protective shoes;
display screen months power and current
is OK
Check inside No alarming events Work cloth;
temperature of on PCS Protective shoes;
PCS inside PCS, including
Once 6
temperatur module
months
e temperature and
cabinet
temperature
PCS cable Check the Once 6 No overheating Work cloth;

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terminals of months marks or burning Protective shoes;

PCS cables for marks
overheat marks
Check the PCS No rusting or Work cloth;
PCS Once 6
for correct damage Protective shoes;
grounding months
grounding
All fixing bolts Work cloth;
Check the
Once 6 should be tight Protective shoes;
PCS fixing fixings of PCS
months Wrenches;
with container
Insulated gloves

Routine Maintenance
Maintenance Training/qualification
Item Equipment
cycle requirements
Work clothes;
Protective
Painting on
shoes; 6 months Corresponding color number
brackets
Anticorrosive
paint
Work clothes;
Fixing on Protective Fixing between brackets and
6 months
brackets shoes; container ground
Wrench
Work clothes;
Grounding Protective
3 months Use multimeter to test grounding.
of brackets shoes;
Screwdriver
Battery Work clothes;
Battery
system Protective The brackets and modules should
system 6 months
shoes; be clean
cleaning
Cloth
Work clothes;
Protective
Painting on
shoes; 6 months Corresponding color number
modules
Insulating
paint
Work clothes;
Fixing on Protective Fixing between modules and
3 months
modules shoes; brackets
Wrench
Connecting Work clothes;
3 months Serial copper bars
cooper bar Protective

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fixing shoes;
Wrench
Work clothes;
Insulation Protective
3 months Protecting cover on module poles
protection shoes;

Work clothes;
Module
Protective
tamper 3 months Tamper proof labels
shoes;
proof labels

Work clothes;
Module Protective
3 months Use multimeter to test grounding.
grounding shoes;
Wrench
Battery Work clothes;
Whole discharge-charge-
capacity Protective 6 months
discharge cycle
calibration shoes;
Work clothes;
Battery data Analyze BMS data recorded (by
Protective 6 months
analyze Alpha staff)
shoes;
Junction Work clothes;
Junction box cable Protective
6 months All bolts are tight
box terminal shoes;
fixing Wrench
Check whether the converter is
damaged or deformed or not.
Listen whether abnormal sound is
available during the operation of
converter.
Check all varieties during the
operation of converter.
Operating Check whether the major parts are
Work clothes;
status and Ok or not.
Protective
PCS environmen 6 months Check the heating of converter`s
shoes;
t of the case and use thermal imager to
system monitor the heating situation of the
system.
View whether the air inlet/outlet is
normal or not.
Check the humidity and dust
around the converter and ensure
the filters in air inlet are OK.
Attention! Check the ventilation in

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the air inlet hole. If the module

cannot be effectively cooled down,
it may be damaged due to
overheating.
Clean circuit board and
components.
Work clothes;
Check the temperature and dust of
System Protective 6 months or
the radiator. If necessary, use the
clean shoes; 12 months
compressed air from the fan to
clean the module.
Change the air strainer.
Check whether the power cable is
losse and fasten it with the torque.
Check whether there are damages
The Work clothes; on power cable and control cable,
connection Protective especially the cable skin contacts
6 months
of power shoes; with the metal surface.
circuit Check whether the insulated
ribbon is stripped from the electric
cable’s wiring terminal.

Check whether the screw in

control terminal is loose. If yes,
Connection use the screw driver to fasten.
Work clothes;
of terminal Check whether the main-circuit’s
Protective
and winding 6 months terminal is loose or overheating on
shoes;
displaceme bolt.
nt Visually check the connection of
converter and the winding
displacement.
Check whether some cracks
appear on the fan’s blade.
Maintenanc
Work clothes; Listen whether there are some
e and
Protective abnormal vibration sounds during
alteration of 12 months
shoes; the operation of fan.
cooling fan
Please change the fan
immediately if some faults
occurred on the fan.
Work clothes; Conduct routine inspection on the
Breaker
Protective 6 months or 12 corrosion of metal components.
maintenanc
shoes; months (once half a year)
e
Yearly inspection on the contactor

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(auxiliary switch or micro-switch)

and ensure it good mechanical
running.
Check the operation parameters
(especially voltage and insulation).
Check the emergency stop switch
and LCD
Work clothes; Simulate power off and check
Safety Protective 6 months or 12 whether communication signals
function shoes; months are available during power off.
Check the warning label. If
necessary, please change it in
time.

Notes
After all of the equipments are out of operation, the following notes should be paid attention to
while maintaining:

 Related safety standards and specifications should be followed in operation and

maintenance.
 Disconnect all the electrical connections so that the equipment would not be powered on.
 Wait at least 15 minutes after disconnection in case that the residual voltage of
capacitors down to safe voltage. Use a multimeter to ensure the equipment is completely
uncharged.
 The amount of maintenance staff should be not less than two while maintaining.
 The equipment should be repaired by professional staff and it is strictly forbidden for
maintenance staff to open equipments on their own.
 Appropriate protective measures should be taken while maintaining, such as insulated
gloves, shoes, and anti-noise ear plugs.
 Usually the location of the storage system is far away from urban areas. Related
emergency rescue measures should be prepared in order to be implemented when
necessary.
 Life is priceless. Make sure no one would get hurt first.
 When a fire happened in the container, just make sure the fire system is on (should be
on), then leave the container as soon as possible. After running out, make sure all doors are
closed. The fire extinguishing system would automatically work. Do not try to put the fire out
manually.
 When a fire happened in the PCS container, just close the door and press the
emergency button manually.
 When the fire is outside the containers, please make sure all doors are closed in case of
smoke. Smoke may cause warnings of sensor, but it will not trigger fire system. If the fire
spreads into the container, the temperature sensor would work and the whole system would

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start.
 For single cell, it is better to be sank into water to block burning.
 The batteries need to be charged to 30%~50%SOC rate when the whole system is static
(that is, the batteries has not been charged for two weeks or longer) for a long time, in case of
over discharge.
 Please contact us in time if there are any conditions that could not be explained in the
manual.

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 Troubleshooting Your Smart Energy

7. Troubleshooting

Battery and BMS Troubleshooting

Error Type
Alarm Displayed in EMS Processing method
Cell temperature different fault Cell-Temp-Diff Contact with Alpha service
Balancer fault Balancer Err Contact with Alpha service
Module charge over current
Chrg-Ov-Curr Contact with Alpha service
fault
Module discharge over current
Disch-Ov-Curr Contact with Alpha service
fault
Pole over temperature fault Pole-Ov-Temp Contact with Alpha service
Cell over volt fault Cell-Ov-Volt Contact with Alpha service
cell volt different fault Cell-Volt-Diff Contact with Alpha service
cell discharge under
Disch-Low-Temp Contact with Alpha service
temperature fault
Cell under volt fault Cell-Low-Volt Contact with Alpha service
Cut off BMS at the first, then operate
Insulation resistan fault IR_Fail in power sequence when power the
system
Check communication connection
between batteries (LMU and LMU),
LMU Communication fault Commu_fail_LMU
battery and HV900112 (LMU and
BMU)
Cell over temperature fault Cell-Ov-Temp Contact with Alpha service
Check communication cable between
HV90012s (BMU and BMU), also
BMU Communication fault Commu_fail_BMU
HV900112 and TOP BMU Box (BMU
and TOP BMU)
Cell charge under temperature
Chrg-Low-Temp Contact with Alpha service
fault
Wire beam fault Wire-Harness-Err Contact with Alpha service
Relay fault relay Err Cut off BMS
Temperature sensor fault Temp-Sen-Err Contact with Alpha service

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Emergency Handling Plan

In order to prevent accidents such as electric shock, fire or explosion, the emergency switch
should be pressed immediately to stop the equipments when abnormal sound, smell or sparks
is found.

 Disconnect the AC breaker.

 Check the control power supply. If it is OK, return the power supply to find out the reason.

Please record every detail related to the fault, so we can analyze and solve the fault better. Any
operation of equipments is strictly forbidden, please contact us as soon as possible.

When the batteries are on fire, do not try to put the fire out manually. That is dangerous because
the special chemical property of lithium-ion batteries (though LiFePO4 is safer, there is
possibility of danger). Water or other liquid is not recommended. Novec 1230, FM-200, or
dioxide extinguisher are recommended. ABC extinguishers are not effective when the battery
pack is on fire.

As battery cell contains little Oxygen inside and all cells have got explosion-proof valve,
explosion hardly happens.

EMS Troubleshooting
Alarm Displayed in EMS Processing method
Check communication connection
Inverter Disconnect INV Lost
between EMS and inverter
Check communication connection
Grid Meter Disconnect Meter Lost
between EMS and grid meter
Check communication connection
Battery Disconnect BMS Lost
between EMS and battery system
Check communication connection
PV Meter Disconnect PV-Meter Lost
between EMS and grid meter
SD not inserted or SD writing
SD lost Replug SD card
error
Network card error NetCard Err Contact with Alpha

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