Delta PCS100 Installation Manual
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Delta PCS100 Installation Manual

Power conditioning system
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Delta Power Conditioning System
(PCS100)
Installation Manual
Version: 1.0.3

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Summary of Contents for Delta PCS100

  • Page 1 Delta Power Conditioning System (PCS100) Installation Manual Version: 1.0.3...

  • Page 2: Table Of Contents

    ABLE OF ONTENTS About this Manual .................. 1 Version Control ................1 Purpose ..................2 Scope ..................2 Audience ..................2 Organization ................2 Safety Symbols and Terminology Definitions ....... 3 Introduction .................... 5 Overview ..................5 Features ..................6 Applications .................
  • Page 3 Warranty ....................58 Appendix ....................59 Specifications ................59 Glossary ..................61 Screw Torque Table ..............63 Installation Manual...
  • Page 4 Delta may modify or update the Manual from time to time without any notice. Delta will do its best efforts to keep the Manual updated and maintain the accuracy of the Manual. Delta disclaims any kinds or forms of warranty, guarantee or undertaking, either expressly or implicitly, including but not limited to the completeness, accuracy, non-infringement, merchantability or fitness for particular purpose or usage.

  • Page 5: About This Manual

    About this Manual About this Manual Version Control Table 1: Version Control Rev. Change Description Date 1. Add opening the door space. 2. Add parallel installation. 1.0.0 3. Add detail description about terminal resistor switch and terminals on new 31Dec2020 J board.

  • Page 6: Purpose

    PCS, and information about configuration of the unit. It does not provide details of batteries. Audience The manual is intended for anyone who needs to install Delta PCS100. Installers should be certificated technicians or electricians. Organization This manual is organized into the following chapters: Chapter 1: “About the Manual”...

  • Page 7: Safety Symbols And Terminology Definitions

    About this Manual Important Safety Instructions Save these Instructions General Safety Instructions (EN) This manual contains important instructions for PCS that should be followed during installation and maintenance. PCS is designed and tested to meet all applicable International safety standards. However, like all electrical and electronic equipment, safety precautions must be observed and followed during installation and operation of PCS to reduce the risk of personal injury and to ensure a safe installation.
  • Page 8  The PCS section does not contain user-serviceable parts. For all service and maintenance, a Delta repair technician or authorized service partner is required for onsite maintenance services.  Read all of these instructions, cautions, and warnings for the PCS and associated PCS documentation.

  • Page 9: Introduction

    It supports demand charge management by peak shaving, enables load shifting for time-of-use savings, and provides real power and reactive power compensation to improve power quality. With Delta’s PCS solution you can realize the fullest value of an energy storage system. Figure 1. Typical PCS Application System Architecture...

  • Page 10: Features

    Introduction Features  High conversion efficiency with latest technologies  High efficiency: peak 97.9%  High power density in outdoor application: 146 W/l, 322 W/kg  Low standby power loss: < 25W @sleep mode  Integrated AC and DC switches for easy installation ...

  • Page 11: Installation

    Installation Installation This chapter describes how to mount and install the PCS, including the information about recommended tools, groundwork preparation, location and ventilation considerations, unpacking, moving and mounting. Read this chapter and plan your PCS layout and installation accordingly. Before You Begin Recommended Tools The following tools are recommended for a successful installation: ...

  • Page 12: Foundation

    Installation Foundation The PCS cabinet is recommended to be mounted on concrete floor. Follow the illustration below to prepare the groundwork. Before installing a PCS cabinet, it is recommended to have a solid foundation established. The following information is provided to serve as a guide for the setup of a recommended foundation. The footprint boundary area of the PCS is 600 x 800 mm (23.62 x 31.49 in.), and there are two ways for mounting: 1.

  • Page 13: Location And Ventilation Requirements

    600 mm (23.6 in) 800 mm (31.5 in) (1.73 in) 855 mm (33.66 in) Figure 5. Front and Side Views of a Delta PCS100 Location Considerations To fully experience the benefits and reliability of the PCS design, follow the provided guidelines: ...
  • Page 14 Installation  Under certain operating conditions, the PCS emits an audible noise. It is advisable to install away from living accommodations to protect against noise levels.  The PCS should not be installed in an area that is excessively dusty, as this may decrease the performance of the air cooling system.
  • Page 15 Installation Maintenance distance requirements A minimum distance of 800 mm behind the PCS is required for maintenance from rear side, a minimum distance of 800mm in front of the PCS is required for maintenance from front side and a minimum distance of 100mm on top of the PCS is required for lifting the PCS if needed as shown in Figure 7.
  • Page 16 Installation Installation Manual...

  • Page 17: Unpacking The Unit

    Installation Unpacking the Unit Use a forklift to move and place the crate containing the PCS100 and the wooden pallet on a designated location. Make sure the location is clean and prepared prior to moving the crate. WARNING! The PCS100 and crate have a combined weight of approximately 418 kg/921 lbs. DO NOT attempt to lift and/or move the package/unit by hand.
  • Page 18 7. Remove the front and rear walls. Figure 12. Removing Front and Rear Walls Upon unpacking the page, inspect the unit for signs of damages that may have been caused during shipping. If damage is found, immediately contact Delta and the shipping company.. Installation Manual...

  • Page 19: Installing The Pcs Onsite

    Installation Installing the PCS Onsite The PCS Series must be located in weather-proof enclosure or enclosed-area. The PCS is not intended or designed for exposure to water or excessive dust. The PCS system is designed to support the requirements of various environments. ...
  • Page 20 The dimensions and weights specified must be taken into consideration when mounting the PCS100. All lifting equipment and lifting components (hooks, bolts, lifts, slings, chains, etc.) must be properly sized and rated to safely lift and hold the weight of the PCS100 during the mounting process.
  • Page 21 Installation 1. Unpack the PCS100, see “Unpacking the Unit” on page 12. 2. Remove the hexagonal nuts and washers securing the PCS100 to the shipping pallet. Figure 13. Detaching PCS from a Pallet CAUTION! AKE SURE THE SWITCH IS OFF...
  • Page 22 Installation 3. Use the provided key to unlock the front panel. 4. Rotate the door handle to open the front panel and pull the door open. Figure 14. Opening a Front Panel Make sure the door limiter at the bottom of the panel engages in the track to keep the front panel from closing accidentally.
  • Page 23 Installation 5. Repeat for the rear panel. Figure 16. Opening a Rear Panel Make sure the door limiter at the bottom of the panel engages in the track to keep the rear panel from closing accidentally. Figure 17. Locking a Rear Panel in a Cabinet The rear panel locks in place when it is fully extended.
  • Page 24 Installation Figure 18. Removing the Top Cover To close the front panel, the interlocking mechanism holding the door and cabinet in place must be first released. 8. Locate the interlocking mechanism at the base of the door. See the following image. 9.
  • Page 25 Installation Figure 20. Closing a Front Panel Note: Make sure there is no gap between the front panel and the cabinet. An improperly closed front panel may damage the locking mechanism on the cabinet, the cabinet or cause injury. 12. Repeat for the rear panel. Figure 21.
  • Page 26 ANY LIFTING DEVICE MUST BE RATED TO WITHSTAND THE MAXIMUM REQUIRED WEIGHT CAUTION! HE UNIT SHOULD NOT BE INSTALLED WITH THE CABINET DOORS OPEN 13. Locate the eye bolts on each corner of the PCS100. 14. Check the eye bolts are properly tightened to frame. Eye Bolts for Positioning with Hoist Figure 22.
  • Page 27 Installation 15. Connect the hoist to the eye bolts on the cabinet. Make sure the load is secured before making any attempt to move it. The recommended diagonal length of the sling is 2 to 2.5 m (6.56 to 8.2 ft.).
  • Page 28 ENCLOSURE FRONT TO BACK AND SIDE TO SIDE DURING LIFTING BECAUSE THE CENTER OF GRAVITY OF THE ENCLOSURE IS NOT THE CENTER OF THE ENCLOSURE 1. Unpack the PCS100, see “Unpacking the Unit” on page 12. 2. Using the forklift to move the PCS100.
  • Page 29 Installation Figure 25. Removing Left and Right Base Covers Installation Manual...
  • Page 30 Installation d. Align the forklift with the bottom channels on the cabinet, see the following image. e. Once aligned, insert the forks into the channels until they are completely through the opposite side of the insertion channels. WARNING! Take care the unit is balanced and no risk to prevent it fell. Carefully lift the cabinet.
  • Page 31 Installation b. Remove the screws securing the front/rear base covers. c. Remove the front and rear side panels. Figure 28. Removing Front/Rear Base Covers d. Align the forklift with the bottom channels on the cabinet, see the following image. e. Once aligned, insert the forks into the channels until they are completely through the opposite side of the insertion channels.
  • Page 32 Installation 3. Once the cabinet is secured to the location, install the top cover, see “Securing a Cabinet in a Final Location” on page 30. Installation Manual...

  • Page 33: Securing A Cabinet In A Final Location

    Installation Securing a Cabinet in a Final Location 1. Make sure the installation sites has been prepared, see “Before You Begin” on page 7. CAUTION! AKE SURE THE SWITCH IS OFF POWERED OFF BEFORE OPENING THE FRONT PANEL 2. Use the following guidelines to secure the cabinet if installed using a chain hoist: a.
  • Page 34 Figure 33. Locking a Rear Panel in a Cabinet The rear panel locks in place when it is fully extended. d. Install the top cover and secure the top cover to the PCS100 with screws. Installation Manual...
  • Page 35 Installation Figure 34. Installing the Top Cover e. Push the mechanism upwards to unlock it from the rail. Push the front panel in completely. Make sure the door limiter on the top and bottom of the cabinet are engaged with the front panel. g.
  • Page 36 Installation Figure 35. Closing a Front Panel Note: Make sure there is no gap between the front panel and the cabinet. An improperly closed front panel may damage the locking mechanism on the cabinet, the cabinet or cause injury. 3. Repeat for the rear panel. Figure 36.
  • Page 37 Installation Note: The hole diameter on the cement base of the expansion tube is 20 mm (0.79"). 4. First insert a washer in the anchoring bolt followed by a nut. 5. Turn the nut until it is lowered in the bolt. Do not tighten at this time. All nuts must be inserted in their respective anchoring bolts.

  • Page 38: Wiring Instructions

    This label is installed on the outside of the door and should remain clearly visible. Ensure all sources are OFF or disconnected before servicing. The Delta PCS100 contains electrical components carrying potentially lethal voltages and currents. Extreme caution should be exercised around the system, especially when the cabinet door is open once it's installed.
  • Page 39 Wiring Instructions AC, DC Disconnect Position The following figures show the status of AC and DC disconnects.  ON: Vertical, turn counterclockwise to horizontal position to OFF state.  OFF: Horizontal, turn clockwise to vertical position to ON state. Switch on for PCS Switch off for PCS STA NDBY RUN STA NDBY RUN...
  • Page 40 Wiring Instructions Opening a Front Panel The AC and DC disconnects have an interlock mechanism to prevent the front door from being opened when not in the OFF position. After turning the disconnects to the OFF (horizontal) position, wait at least five minutes before opening the front door.
  • Page 41 Wiring Instructions Figure 41. Opening a Front Panel Make sure the door limiter at the bottom of the panel engages in the track to keep the front panel from closing accidentally. Figure 42. Engaging the Front Panel Limiter The front panel locks in place when it is fully extended. Installation Manual...

  • Page 42: Wire Sizing And Ratings

    Wiring Instructions Wire Sizing and Ratings AC Wire Sizing and Ratings Prepare all the AC power cables meeting the following wiring specifications: Table 2: AC Wire Sizing and Ratings Cable Type Solid Copper Conductor Voltage Rating 600 Volts or greater Temperature 70°...

  • Page 43: Preparation Of Cables

    Wiring Instructions Table 4: Grounding Wire Sizing and Ratings (Continued) Cable Type Solid Copper Conductor Quantity Communication and I/O Wire Sizing and Ratings Here are the requirements for the communication and I/O wires: Table 5: Communication and I/O Wire Sizing and Ratings Cable Type Solid Copper Conductor Voltage Rating...
  • Page 44 Wiring Instructions Preparing AC/DC Cables The following guidelines describe how to prepare the AC/DC cables for a grid connection. When crimping cable, a hexagonal crimping method is recommended. 1. Strip the head of the insulator of the AC and DC power cables. Insert the exposed part of the power cable into the junction hole of the corresponding cable lug, which is available from the accessary kit.

  • Page 45: Communication And I/O Wiring And Terminal Resistor Setting

    Wiring Instructions Communication and I/O Wiring and Terminal Resistor Setting Lead the wires with 15-pin, 6-pin and 3-pin connectors prepared for communication and I/O connection through the front square hole of the unit base and through the wire glands in front of the DC cable glands.
  • Page 46 Wiring Instructions I/O Connector (CNJ3) The CNJ3 connector is for digital I/O connection. Take out the green 15-pin connector (CNJ3) from the accessory kit, and connect eight prepared 1.32 mm (0.0508 inch) wires to pin 1~4 and pin 7~10 of this connector as shown in the following figure.
  • Page 47 Wiring Instructions BMS Communication Connector (CNJ13) The CNJ13 connector is for communication between PCS and BMS. Communication with BMS is handled in two ways, RS485/Modbus or CAN bus. RS485 requires three prepared AWG 16 wires connected to pins 1 to 3 on the 6-pin connector from the accessory kit. For CAN bus, connect two prepared AWG 16 wires to pins 5 and 6.
  • Page 48 The CNJ5 connector is used for alternative auxiliary power input with 24Vdc 0.5A. Connect two AWG 16-22 wires to the 2 pins connector as the pin assignment table below. Customer can run PCS100 in black start mode via this terminal.
  • Page 49 Wiring Instructions Figure 50. CNJ5 Pin Assignment Black Start To black start the system, use the following guidelines: Connect the communication cable between the BMS and the PCS, making sure to set the correct batter manufacturer settings. Turn on the BMS power. The BMS establishes a communication connection with the PCS, and the battery outputs to the HV DC.
  • Page 50 Wiring Instructions Ethernet Communication Connector (CNJ16) The CNJ16 connector is used for Ethernet communication. Use a common Ethernet cable to connect to a site controller or cloud server or remote server. Figure 51 Communication connection diagram Table 12: CNJ16 Pin Assignment Item Pin Assignment Notes...
  • Page 51 Wiring Instructions Communication wiring The PCS125 supports two methods for communication: Ethernet and RS485. Ethernet can be used for a site controller or cloud server or remote server. And RS485 can be used for a site controller.  Ethernet and RS485 can’t be connected at the same time. ...
  • Page 52 Wiring Instructions Connected by RS485 When a single PCS#1 is used, make sure the connector CNJ12 not connected. PCS#1 PCS#2 PCS#N CNJ16 CNJ16 CNJ16 CNJ12 CNJ12 CNJ12 CNJ11 CNJ11 CNJ11 SJ1 SJ2 SJ1 SJ2 SJ1 SJ2 RS485 CNJ7 CNJ7 CNJ7 Figure 54.
  • Page 53 Wiring Instructions Terminal resistors setting The terminal resistor switches SJ1 and SJ2 must be set according to Table 13-16. Table 13: Terminal resistor switches setting of single PCS for Ethernet communication Table 14: Terminal resistors switches setting of parallel PCS for Ethernet communication Table 15: Terminal resistors switches setting of single PCS for RS485 communication Table 16: Terminal resistors switches setting of parallel PCS for RS485 communication Switches...

  • Page 54: Wiring

    Wiring Instructions Wiring General Introduction For wiring convenience, you can lead the cables and wires from the left, right, front or rear bottom side of the unit into the cabinet. The following sections will be described in the case of wiring from the front bottom side of the unit as an example.
  • Page 55 Wiring Instructions Above the cable glands, several labels marked DC+, DC-, L1, L2, and L3 along with the protective covers and relevant terminals are illustrated. See the following figure. DC Terminals with AC Terminals with Protective Cover Protective Cover (3 for +, 3 for -) (L1, L2, L3) Figure 57.
  • Page 56 Wiring Instructions DC Wiring 1. Prepare DC cables: Prepare several 1/0 size, 1000V cables for DC wiring. The PCS supports up to 3 sets of battery connection, and each set of battery connection requires two cables (one for positive, the other for negative). Connect the DC cables to the two-hole lugs which are available in the accessory kit, and use heat shrinkable tubing on the junction between the cables and lugs to prevent the exposure of the conductive part.
  • Page 57 Wiring Instructions 3. Connect DC cables to DC terminals: Loose the hex socket screws of the DC terminals, then lead the DC cables with two-hole lugs through the DC cable glands into the PCS. Connect and secure these cables to the relevant “DC+” and “DC-” terminals. Figure 60.
  • Page 58 Wiring Instructions AC Wiring 1. Prepare AC cables: Prepare six 53.49 ~ 33.62 mm (0.3249 ~ 0.2576 inch) 600V cables for AC wiring. The PCS supports 3-phase/3-wire connection type AC wiring with L1, L2 and L3 phase terminals, and each phase terminal requires two cables to connect. Attach the AC cables to the two-hole lugs in the accessory kit, and use thermal casing to prevent the exposure of the naked part.
  • Page 59 Wiring Instructions 3. Connect AC cables to AC terminals: Loose the hex socket screws of the AC terminals by Allen wrench, then lead the AC cables with two-hole lugs through the AC cable glands into the PCS, connect and secure these cables to the relevant “L1”, “L2” and “L3” terminals. Figure 64.
  • Page 60 Wiring Instructions Grounding First attach the two 600 V, 1/0 size cables prepared for grounding to the 2-hole lugs in the accessory kit. Then lead these grounding cables through the front square hole of the unit base and through the grounding cable glands into the PCS cabinet.
  • Page 61 Wiring Instructions Wiring N Cable According to the demand to decide wiring the N cable or not. 1. Prepare the 1/0 600V wire. 2. Remove the nuts securing the plexiglass cover then remove the plexiglass cover. Figure 67. Removing the Plexiglass Cover 3.
  • Page 62 Wiring Instructions 5. Install the plexiglass cover and secure the nuts. Figure 69. Installing the Plexiglass Cover After finishing all the wiring works, reinstall the protective cover, close and lock the front door. Note: Make sure all wirings are secured. After wiring, the protective cover must be installed and can not be energized without protective covers.

  • Page 63: Warranty

    3. operated in unusual circumstances such as strikes, riots, wars or nuclear disasters; 4. repaired, modified, moved or installed by any party without Delta's prior written authorization; 5. damage due to accidents such as fire, inundation, unusual electric shock, power failure or shipping;...

  • Page 64: Appendix

    Appendix Appendix Specifications Table 17: Technical Specifications of the Delta PCS100 Item Description Grid-tied Operation Rated Grid Voltage 400 Vac, 3 phase Grid Voltage Range 312 to 459 Vac Rated Grid Frequency 50 Hz (60 Hz optional) Frequency Range 45 to 55 Hz, adjustable...
  • Page 65 Appendix Table 17: Technical Specifications of Delta PCS100 (Continued) Item Description Crest Factor 2.0 @ rated power Environment Max Altitude 3,000 m ≤ 2000 m: -25 ~ 60º C, derating > 50º C (3%/º C), Operating Temperature -25 ~ 40º C, > 2000 m Storage Temperature -25 ~ 70º...

  • Page 66: Glossary

    Appendix Glossary  Abbreviation for “Alternating Current”.  Abbreviation for “Authority Having Jurisdiction” (electrical inspector).  American Wire Gauge.  Basic Insulation Insulation to provide basic protection against electric shock.  Battery management system.  Abbreviation for “Direct Current”.  The Electro-Magnetic Compatibility (EMC) concerns the technical of the mutual influencing of electrical devices through electromagnetic fields caused by them.
  • Page 67 Appendix  Power Conditioning System, an electrical device which converts DC direct voltage into AC voltage and/or direct current into alternating current.  Power dissipation Power dissipation is designated as the difference between absorbed power and power of a device or process yielded. Power dissipation is released mainly as heat. ...

  • Page 68: Screw Torque Table

    Appendix Screw Torque Table 1. The torque level for M3~M5 screws is 4.8, refer to the following torque standard table to make sure the washers are in close contact with the screws. Table 18: Screw Torque Table for M3~M5 Screws Screw Assembly Torque Standard Unit: N·...

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