Sinexcel PWS1-500KTL-EX-1M Installation Manual
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Sinexcel PWS1-500KTL-EX-1M Installation Manual

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PWS1-500K Series Energy Storage PCS

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Summary of Contents for Sinexcel PWS1-500KTL-EX-1M

  • Page 1 Installation Manual PWS1-500K Series Energy Storage PCS...
  • Page 3 Sinexcel PWS1-500KTL-EX-1M/2M/3M/4M/5M/6M/7M/8M PWS1-500KTL-EX-M1/M2/M3/M4/M5/M6/M7/M8 Series Bi-directional Energy Storage PCS Installation Manual Version: V2.1 Shenzhen Sinexcel Electric Co., Ltd. All rights reserved. In case of any content change, it shall be without prior notice. Shenzhen Sinexcel Electric Co., Ltd. Website: http://sinexcel.us/ www.sinexcel.com Add: Building 6, Area 2, Baiwangxin High-tech Industrial Park, No.

  • Page 4: Table Of Contents

    Contents 1 INFORMATION ON THIS DOCUMENT ..........................7 1.1 V .................................... 7 ALIDITY 1.2 T ................................... 7 ARGET ROUP 2 SAFETY PRECAUTIONS..............................9 2.1 I ............................9 MPORTANT AFETY INSTRUCTIONS 2.2 A ..............................12 DDITIONAL NFORMATION 3 INSTALLATION DESIGN ..............................13 3.1 I ...............................
  • Page 5 5.5.1 Container internal layout distance ........................25 5.5.2 Fan installed inside the container .......................... 26 5.5.3 Fan installed outside the container........................27 5.5.4 Air duct design ............................... 29 5.5.5 Installation of Fan module ............................. 30 6 ELECTRICAL INSTALLATION ............................31 6.1 E ..............................
  • Page 6 8.3.1 Touch screen power on ............................56 8.3.2 Log into the control Interface ..........................57 8.3.3 Select Control Mode .............................. 57 8.3.4 General Settings ..............................58 8.3.5 Communication setting ............................58 8.4 M ............................59 ANUAL TARTUP ROCEDURE 8.5 A ............................
  • Page 7 11.5 DC settings ................................70 11.6 S ................................72 YSTEM ETTING 11.6.1 General Setting ..............................72 11.6.2 Power Quality Mode Settings ..........................73 11.6.3 Country Code Settings ............................73 11.6.4 DRM Settings and DRED ............................73 12 WEB MONITORING PORTAL ............................73 13 CONTACT ..................................

  • Page 8: Information On This Document

    1.1 Validity This document is valid for the following device models with or without STS module: • PWS1-500K • PWS1-500KTL • PWS1-500KTL-EX-1M/2M/3M/4M/5M/6M/7M/8M • PWS1-500KTL-EX-M1/M2/M3/M4/M5/M6/M7/M8 Model definition This section introduces product model definition in this user's manual, as shown in Fig. 1-1:...
  • Page 9 • Installation and commissioning of electrical equipment and installations • Understand all applicable standards and directives • Understand and follow this manual and all safety information...

  • Page 10: Safety Precautions

    2 Safety Precautions 2.1 Important Safety instructions This user’s manual is about installation and operation of Sinexcel PWS1-500K series Bi-directional Storage Inverter (PCS). Before installation, please read this user’s manual carefully. The PCS must be commissioned and maintained by the engineers designated by the manufacturer or the authorized service partner.
  • Page 11 IEC 60417-5041 Watch surface ISO 7000-1641 Refer to the operation manual Any contact with copper bar, contactor and terminal inside the device or connected with the loop of utility grid might result in burning or fatal electric shock. Don’t touch any terminal and conductor connected with the loop of utility grid. Pay attention to any instruction and safety documents about power on-grid.
  • Page 12 Large leakage current Before connecting input power supply, please ensure that the grounding is reliable. The device must be grounded complying with the local electric codes. When storage battery is connected to PCS, there may be DC voltage at input port. Please pay attention to it during operation or check the battery system user manual Don’t touch electric parts within 15 minutes after switchin off! There is dangerous energy in capacitance storage.

  • Page 13: Additional Information

    2.2 Additional Information Links to additional information can be found at http://sinexcel.us/ or www.sinexcel.com.

  • Page 14: Installation Design

    3 Installation design 3.1 Installation process Start Preparations Lifting and transporting Mechanical Installation Electrical Installation Installation Check Commissioning startup and operate Fig. 3-1 Installation Process Installation process description Process Explanation Chapter Preparation 4 Storing, lifting and transporting Lifting and transporting Mechanical Installation 5 Mechanical Installation Electrical Installation...

  • Page 15: Storing, Lifting And Transporting

    Certificate of quality 1 copy The electronic document can be downloaded from Sinexcel’s website or provided by Sinexcel’s staff. 4.2 Safety during Transport If the lifted or suspended load falls over, falls or sways, there is a risk of crushing Vibration or careless or hasty lifting and transport can cause the product to tip over or fall.

  • Page 16: Transporting The Pcs

    Damaged frame structure of the PCS due to uneven support surface Placing the PCS on an uneven surface can cause bending, which causes the PCS door to no longer close properly. This can cause moisture and dust to seep into the PCS. Do not place the PCS on an unstable, uneven surface, even for short periods of time.

  • Page 17: Unpacking The Pcs

    Fig. 4-1 Moving PCS Before the rack is moved, please ensure that the module is fixed stably. 4.3 Unpacking the PCS Please take care to protect the PCS inside the package when unpacking. PCS can’t be inverted and the vertical tilt angle should not exceed 30 degree. 5 Mechanical Installation 5.1 Safety during Installation Risk of electric shock caused by live voltage:...
  • Page 18 Do not touch any live components. Observe all warning messages in products and documents. Obey all safety information from the battery manufacturer. Electric shock hazard caused by DC cable: The DC cable connected to the battery is live. Contact with live cables can cause electrocution, death or serious injury and shock.

  • Page 19: Installation Requirements

    Be sure to always tighten the live bolt connection using the correct torque specified in this document. Use only the right tools when working on the device. Avoid repeatedly tightening the live bolt connection as this may result in unacceptably high torque. 5.2 Installation requirements 5.2.1 Environment requirements It is installed indoor.

  • Page 20: Operation Space

    At the rear of the rack, heat dissipation should be guaranteed and ventilation equipment needs to be installed so as to ensure that the heat emitted from the storage inverter can be discharged outside the machine room. 5.2.4 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.
  • Page 21 B rear ≥200mm when there are cooling fan near the rear door. The distance between PCS side steel plate and container wall is no less than 50mm to ensure that the PCS can be installed inside the container. Fig. 5-2 Side installation space of storage inverter...

  • Page 22: Other Requirements

    2) Rat-proofing After wiring, fireproofing mud should be used to seal inlet and outlet holes so as to meet the rat-proofing requirement. Fireproofing mud is not provided by Sinexcel. 5.3 Mounting preparation Drilling mounting holes is required in the foundation. The overall dimension of the PCS is shown in figure below.

  • Page 23: Rack Installation

    The PWS1-500KTL cabinet, width: 1100mm, height: 2,160mm (without lifting rings); depth: 800mm. The height of the lintel is 60mm and it can be taken down if there is no sufficient height into the room. The PWS1-500KTL series Bi-directional Storage Inverter is without lifting rings and can’t be lifted. Fig.
  • Page 24 When the rack is fixed to the concrete floor, make holes on the floor and fix the rack to the concrete floor with expansion screws. Module fastening bolts Fig. 5-7 Module fastening bolt position in the back side of each module After confirming the above items and finished and tested, open the back door of the PCS and remove the module fastening bolts.
  • Page 25 before moving the converter into the container. Can contact the manufacturer to confirm.

  • Page 26: Installation In Container

    5.5 Installation in container 5.5.1 Container internal layout distance Internal layout can be customized design according to customer’s requirements. Please contact the manufacture to know the internal layout for specific project. The distance between PCS side steel plate and container wall is no less than 50mm to ensure that the PCS can be installed inside the container.

  • Page 27: Fan Installed Inside The Container

    5.5.2 Fan installed inside the container When the fan is installed inside the container, its on the inner side of container door near the ventilation thermal outlet of the PCS. The Dimension of the Fan and installation position below is just an examples. Please contact manufacturer to confirm the Fan position for particular project.

  • Page 28: Fan Installed Outside The Container

    5.5.3 Fan installed outside the container The standard external fan module is recommended and easy to install. When the fan is installed outside the container, its on the outward side of container door near the ventilation thermal outlet of the PCS. Fig.
  • Page 29 Fig. 5-11 Components of Container external fan Fig. 5-12 Three external fan on the outward side of the door...

  • Page 30: Air Duct Design

    Fig. 5-13 PWS1-500K series Fan and its corresponding Module; Relative position of Fan and back door 5.5.4 Air duct design Air duct can be customized design according to customer’s requirements. Please contact the manufacturer for information on air duct design for specific projects. Model System air Ventilation air volume...

  • Page 31: Installation Of Fan Module

    5.5.5 Installation of Fan module Fan module (including fans and fan covers) need to be disassembled before container commissioning and transportation. The steps for disassembling and waterproofing the corresponding fan and hood are as follows: Step 1. Fasten the fan assembly with the screw to the container. Step 2.

  • Page 32: Electrical Installation

    6 Electrical Installation 6.1 Electrical Connections 6.1.1 Input requirement DC voltage of the PCS should be within the input voltage range, or the PCS will be unable to operate. When configuring the quantity of batteries in each string, the maximum charging voltage and minimum discharging voltage should be fully considered.
  • Page 33 Fig. 6-1 Design of the connection with one one-hole terminal lug Position Nut M12 Spring washer Fender washer Connection BUS bar Tin-plated one-hole terminal lug Screw M12...
  • Page 34 Open the dam-board of back door and then can see the wiring copper bar as shown below. Back View 3D View Fig. 6-3 PWS1-500K-XM series with 1 branch DC input cabinet wiring copper bars designation...
  • Page 35 Table 6-3 PWS1-500K-XM series with 1 branch DC input cabinet wiring copper bars description Position Designation Description Battery + Battery input positive pole Battery - Battery input negative pole Phase A, dimension is shown as below. Phase B Phase C Fig.
  • Page 37 Front View 3D View Fig. 6-6 PWS1-500K series with 4 branch DC input cabinet wiring copper bars designation...
  • Page 38 Table 6-4 PWS1-500K-M4 series with 4 branch DC input cabinet wiring copper bars description Position Designation Description Battery + Battery positive port Battery + Battery positive port Battery - Battery negative port Battery - Battery negative port Battery + Battery positive port Battery + Battery positive port Battery -...
  • Page 39 Front View 3D View Fig. 6-7 PWS1-500K series with 8 branch DC input cabinet wiring copper bars designation...
  • Page 40 Table 6-5 PWS1-500K-M8 series with 8 branch DC input cabinet wiring copper bars description Position Designation Description Battery + Battery positive port Battery + Battery positive port Battery - Battery negative port Battery - Battery negative port Battery + Battery positive port Battery + Battery positive port Battery -...

  • Page 41: System Grounding

    Fig. 6-8 PWS1-500K series with 8 branch DC input DC wiring copper bar dimension Fig. 6-9 PWS1-500K series AC wiring copper bars dimension 6.1.4 System grounding The modules in the PCS realize grounding connection with the rack through hangers.

  • Page 42: Dc Port Wiring

    As for rack grounding, the rack 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. Notice that the AC output neutral is not bonded to ground. Table 6-5 Grounding PE cable description Rated power Copper PE line section recommendation (mm²)

  • Page 43: Ac Port Wiring

    Disconnect DC distribution switch and ensure that there is no dangerous voltage in the system during wiring. The positive and negative poles of batteries cannot be connected inversely. Before wiring, a multi-meter needs to be used for measurement. 6.1.6 AC port wiring 1) Use a phase-sequence meter to ensure that the phase sequence is positive (R-W-B).

  • Page 44: Wiring Of Terminal Strips

    All wires are connected to the wiring terminals externally from the wiring holes at the bottom of PCS. After wiring, fireproofing compound should be used to seal the wiring holes. 6.1.7 Wiring of terminal strips Except power cable connection in the whole PCS, there are also auxiliary power connection, input and output of some node signals.
  • Page 45 Fig. 6-9 Definition of terminal strip ports BMS Faults Signal External EPO Normal Close Reserved From external CAN From external RS485 From external AUX Power From external AUX Power To Container Fan To 500KVA Transformer Fan To 500KVA Transformer Temperature Control Switch Fig.
  • Page 46 External EPO Normal Open Fig. 6-11 Definition of additional terminal strip ports for 1 branch DC Input Switch BMS Faults Signal 1 BMS Faults Signal 2 BMS Faults Signal 3 BMS Faults Signal 4 BMS Faults Signal 5 BMS Faults Signal 6 BMS Faults Signal 7 BMS Faults Signal 8 External EPO Normal Open...

  • Page 47: Communication Interface

    Fig. 6-13 Definition of touch screen communication ports The LAN (Ethernet) port is used for communication. The USB port is used for system update or the logs export. The other communication ports in the back of touch screen have been wired to the wiring terminal strip ports.

  • Page 48: Connecting The Ems Over Rs485 Or Ethernet

    6.2.1 Connecting the EMS over RS485 or Ethernet Sinexcel’s PCS has several different communication interfaces: Ethernet, RS-485 and CAN. When connecting to the Sinexcel or other brand EMS, the communication port is default as RS 485 as shown below. The Ethernet communication port can also used to connecting EMS according to the requirements for certain project.

  • Page 49: Connecting A Bms Over Can

    If the BMS use Ethernet communication port, a Ethernet-CAN protocol converter is needed. That Ethernet-CAN protocol converter should be bought by the user and its beyond Sinexcel’s scope of supply. The PCS communicates with battery management unit (BMS) to monitor battery state information, give an alarm and provide fault protection for battery according to the battery state and improve the safety of storage battery.

  • Page 50: Rcds

    6.3 RCDs The following values of RCDs should be used with the AC connection: Minimum RCD Value 10kW to 30kW Type B 100mA >30kW to 70kW Type B 200mA >70kW to 125kW Type B 300mA >125kW to 250kW Type B 500mA >250kW to 500kW Type B 900mA 6.4 Check after installation...

  • Page 51: Installation Checklist

    6.5 Installation checklist After finishing the installation, check the list below: Mechanical installation √ There is sufficient free space in front and at the back of the unit. □ The module fastening bolts are removed □ The ambient operating conditions are within the range in specification. □...

  • Page 52: Batteries

    All of the doors and door locks are in place. □ Insulation withstand test □ The grounding resistance should be less than 4Ω. □ 6.6 Batteries The PCS is designed to operate with a DC voltage of 600V to 900V. If the DC voltage is lsess than 600V then the output voltage may be low and the PCS may not operate within specifications.

  • Page 53: Functional Description

    7 Functional Description 7.1 Operating Status 7.1.1 Overview of the Operating Status Powered Off status Power On procedure Power Off procedure Powered up status Stop status Setting and startup Shut down procedure procedure Or Faults occurred Operation status Including: Off-grid Operation On-grid Operation Fig.
  • Page 54 The device does not alarm, on-grid mode is RUN green light in front door is always on, On-grid set, and the device receives startup command. and the module green light is always on. The device does not alarm, off-grid mode is RUN green light in front door is always on, Off-grid set, and the device receives startup command.

  • Page 55: Operating States Without Sts

    7.1.2 Operating States without STS After external wiring of the storage inverter is completed, and wiring is fully checked, close the breaker in AC port. The storage inverter can be switched in different modes under the conditions below. Without STS Module Powered up Stop running when switching between On-grid and off-grid...

  • Page 56: Operation

    8 Operation 8.1 Safety during Operation DC side operation is disturbed due to incorrect parameter settings When setting the mode of the AC side, please make sure that the control parameters are consistent with the grid requirements. 8.2 Power On Procedure Power on for the first time: 1): Confirm the DC and AC cable firmly connected according to the check list in the Installation Manual.

  • Page 57: Setting Procedure Before Startup

    Check Step 4 Step 4 Step 1 Step 1 Fig. 8-1 Power on sequence 8 Branch DC Input 1 Branch DC Input Powered Off Step 1.Closing AUX Power supply switch Step 2. Closing SPD switch Step 3. Closing AC breaker (Grid) Step 4.Closing battery switch Powered up...

  • Page 58: Log Into The Control Interface

    will appear. It shows that “The system is booting, please wait ……”. After system booting, the interface will disappear. Fig. 8-4 Main Interface Sample Detailed Menu information can be seen in Appendix. “11.1 Touch Screen Startup” 8.3.2 Log into the control Interface 1.

  • Page 59: General Settings

    8.3.4 General Settings Fig. 8-5 Setting Interface Sample There are General Setting and Advanced Setting, the commonly used setting is in the “General” Users should set the “DC Configuration” according to the voltage and current requirement of BMS. The detailed advanced setting can be seen in Appendix1 12.4 Parameter Setting. 8.3.5 Communication setting Procedure: 1.

  • Page 60: Manual Startup Procedure

    8.4 Manual Startup Procedure Check before startup 1. Select “User”, Log into the control interface on touch screen with password. 2. Select “Ctrl Mode” > “Manual Operate” 3. Select “Operation”, the detailed menu explanation can be seen in Appendix. 4. Select “Operation” >“System Startup” The detailed menu explanation can be seen in Appendix1 12.7 Manual Startup.

  • Page 61: System Power Off

    8.8 System Power Off When PCS is in “Stop” mode, can cut off the DC and AC power and power off the system 1): Manually or remote control the system stop. 2): Disconnect the AC switch. 3): Disconnect the Battery DC switch. 8.9 Emergency shutdown For any abnormal or dangerous situation, press the emergency shutdown button “EPO”...

  • Page 62: Troubleshooting

    9 Troubleshooting 9.1 Safety during Troubleshooting Danger of electric shock due to high voltage on the product There may be high voltages on the product under fault conditions. Touching real-time components can lead to danger or death Serious injury due to electric shock. Observe all safety information when operating the product.
  • Page 63 Alarm Clearance method: Auto: After the cause of the alarm disappears, the alarm is automatically cleared. Manual: After the cause of the alarm disappears, you need to manually send an alarm clear command. Power Off: After the causes of the alarm disappear, you need to power off and restart. Alarm Classification + Clearance Method (abbreviate to A.C.

  • Page 64: Earth Fault Detection

    Only for the models with STS, the grid frequency is lower than Grid under frequency Fault + Auto the under frequency protection setting DC input over voltage Fault + Auto PCS DC voltage is higher than the upper voltage limit DC input under PCS DC voltage is lower than the lower voltage limit or DC Fault + Auto...

  • Page 65: Maintenance

    10 Maintenance 10.1 Safety during Maintenance There is high voltage in the live components of the product. Touching field components can result in death or seriousness electric shock injury. Wear appropriate personal protective equipment for all work on the product. Do not touch any live components.

  • Page 66: Maintenance Schedule And Consumables

    The product is only allowed to wiring or assembly and disassembly operate when the product is turned off. Connect the external power supply only after finishing installing the product. If the installation or commissioning process is interrupted, install all dam panels, close and lock the rack. The product must always be closed for storage.

  • Page 67: Clearing And Cleaning

    It may need to be more frequent, depending on the conditions at the installation site. If the DC power distribution parts are affected by adverse environmental conditions, it is recommended to shorten maintenance interval. Sinexcel recommends a visual inspection in regular intervals periods to determine maintenance requirements. Consumables and maintenance materials Consumables, tools and maintenance equipment are usually not included in the standard equipment list.
  • Page 68 Cleaning air ducts and ventilation ducts Check internal Check the bolt connection of the power cord. Check label Check latches, door stops and hinges. Check the SPD (Surge Protecting Device)

  • Page 69: Common Settings

    11 Common Settings 11.1 Language Selection Procedure: 1. Select “User”> Input password> “OK”>“Login”. ( Log into the PCS user interface) 2. Select “Ctrl mode”> “Manual Operate”. 3. Select “Setting”> “Advanced”> ”HMI” > ”Language” >”English” or “简体中文”. 4. Then a window will pop up to remind you that system will restart，click “Yes” or “OK”. 11.2 Date and Time Selecting Procedure: 1.

  • Page 70: Ac Settings

    11.4 AC settings Procedure: 1. Select “User”> Input password> “OK”>“Login”. ( Log into the PCS user interface) 2. Select “Ctrl mode”> “Manual Operate”. 3. Select “Setting”> “Advanced”>”AC Info” “PF setting” : set to regulate the PF of the entire storage system “Active power setting”: Set to regulate the power of the storage system “Reactive power setting”: Set to regulate the reactive power of the storage system “Grid recovery delay”: please keep the default configuration.

  • Page 71: Dc Settings

    11.4.1 The following settings are built into the EMS to comply with AS4777 and local grid codes. These settings are automatically programmed when the Country code is chosen. Setting from the Inverter LCD panel is disabled.  FVRT: frequency/voltage ride-through ...
  • Page 72 manufacturer’s recommendation. Set 2V lead batteries according to 0.02C~0.05C in case of manufacturer’s data cannot be obtained. Other connection types can be set as 1A. “End-of-charge current”: keep the default value. “Maximum charge current”: Set 500K as 500A. “Maximum discharge current”: Set 500K as 500A. “DC control mode”: please set it as factory setting between “Const I and Const P”.

  • Page 73: System Setting

    11.6 System Setting Procedure: 1. Select “User”> Input password> “OK”>“Login”. ( Log into the PCS user interface) 2. Select “Ctrl mode”> “Manual Operate”. 3. Select “Settings” > “System” “Start up mode”: default set “Manual”. “Energy dispatching mode”: please set it as “AC dispatching”. If “DC dispatching” is set according to the actual demand, set “charging and discharging current”...

  • Page 74: Power Quality Mode Settings

    The Inverter can be remotely monitored by logging on to the Monitoring Portal. This is done by the EMS and is set up when the EMS is set up. The default log in is given below: http://52.25.126.4:3000/ Username : sinexcel password : Sinexcel1234 A sample output is shown below:...

  • Page 75: Contact

    • Battery type and number • Communication type • Firmware version • Error number and error message Shenzhen Sinexcel Electric Co., Ltd. Website: http://sinexcel.us/ www.sinexcel.com Add: Building 6, Area 2, Baiwangxin High-tech Industrial Park, No. 1002, Songbai Road, Nanshan District,...

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