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Summary of Contents for INTILION scalestac power
- Page 1 ASSEMBLY MANUAL INTILION | scalestac power INTILION | scalestac power boost INTILION AG Wollmarktstraße 115c D-33098 Paderborn Phone +49 (0) 5251 69 32 0 Email contact@intilion.com Internet www.intilion.com Store for later use!
- Page 2 Year of construction: 2022 Version 1.3 Edition: January 2023 © INTILION AG This assembly manual and all of the illustrations contained within are copyright-protected. Any use that goes beyond the limits of copyright law without the prior written consent of the publisher is impermissible and punishable by law.
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Page 3: Table Of Contents
Necessary tools ........................31 Assembly work steps ......................33 3.5.1 Delivery of the cabinets and components ..............33 3.5.2 Positioning and installing the cabinets at the installation location ......34 3.5.3 Assembling the HMI cover plate ................37 INTILION | scalestac... - Page 4 3.5.4.2 Inserting the battery modules and the rack BMS ........39 3.5.4.3 Installing additional control and safety components in the first battery rack ........................40 3.5.4.4 Connecting to INTILION cabinet no. 4 (IBU/DCC) ........40 3.5.5 INTILION cabinets ....................41 3.5.5.1 Communication connection ..............
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Page 5: Introduction
Introduction This assembly manual describes the assembly and installation of the INTILION | scalestac battery storage system. Means of representation Text that should be paid particular attention to and that constitutes instructions or a direct warning against hazards is indicated as follows in this operating manual: 1.1.1... - Page 6 Hazard with a low level of risk that, if not avoided, can lead to material damage. This assembly manual is only valid in connection with the operating manual. All persons involved in the assembly of the battery storage system must be familiar with, and act in accordance with, the operating manual. INTILION AG...
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Page 7: Incorporated Warnings
Unauthorized access prohibited This symbol prohibits access to the indicated areas by unauthorised persons. Hazards cannot be recognised by unauthorised persons. Observe manual This symbol stipulates the observance of the operating manual and the safety instructions. INTILION | scalestac... -
Page 8: Warranty And Liability
Structural modifications to the battery storage system (conversions or other changes – to the battery storage system must not be made without the prior written approval of INTILION AG. The battery storage system will lose its EU conformity in the event of any infringements) Incorrectly performed repairs –... -
Page 9: Guarantee
Guarantee INTILION AG provides a five-year product guarantee for all components of the battery storage system, with the exception of the lithium-ion battery cells. INTILION AG also provides a ten-year performance guarantee for the capacity of the lithium-ion battery cells. With the conclusion of this contract, INTILION AG guarantees that the remaining useful battery capacity does not fall below a relative minimum value for the specified battery capacity. -
Page 10: Copyright Protection
Infringements will lead to liability for damages. The right to make any further claims remains reserved. Customer service INTILION AG is part of the HOPPECKE Group. Our customer service team is available to provide you with any technical information you may require: HOPPECKE Service Competence Center... -
Page 11: Installation Location Requirements
Installation location requirements Observe the installation location requirements for the battery storage system, as specified in the document “Empfehlung_Aufstellort_scalestac_3.1.pdf” INTILION | scalestac... -
Page 12: Safety
The operational safety of the battery storage system is only guaranteed if it is used as intended. INTILION | scalestac is an AC-coupled battery storage system and in grid-building operation, it is primarily suitable for the “behind-the-meter” application. There are three important features that are worth mentioning for the behind-the-meter field of application: The system interacts with the energy meter at the operating company’s mains... -
Page 13: Structural Changes To The Battery Storage System
Parts and special equipment that have not been approved by INTILION AG must not be used. -
Page 14: Foreseeable Misuse
Avoid short circuits. – Do not operate the battery storage system in a potentially explosive – environment. Only operate the battery storage system in intended networks. – INTILION AG... -
Page 15: Personnel Requirements
These persons must have completed an INTILION | scalestac product training session and must be familiar with and act in accordance with the operating manual. -
Page 16: Responsibilities
Keep unauthorised persons away from the working area. – If in doubt, approach persons in the working area and escort them out if necessary. – Stop work if there are unauthorised persons in the working area. – INTILION AG... -
Page 17: Training
Wear insulating (1000 V) protective gloves in accordance with EN 60903 or VDE 0682 Part 311 to protect the hands from dangerous electric shock when touching live parts. INTILION | scalestac... -
Page 18: General Safety Information
Keep the ventilation slots on the battery storage system open. Do not place any – materials in front of the ventilation slots either from the inside or the outside. Do not exceed the technical performance data (see technical data sheet). – INTILION AG... -
Page 19: Safety Measures For Environmental Protection
Take the battery storage system out of operation immediately in the event of – malfunctions. Have the malfunctions rectified by appropriately trained specialists or by INTILION AG or the HOPPECKE Service team. Always store the operating manual in the location where the battery storage system is –... -
Page 20: Special Warnings
This symbol prohibits fire, open flame and smoking in the area of the battery storage system. Observe manual This symbol stipulates the observance of the operating manual and the safety instructions. Keep all safety instructions and warnings on the battery storage system in a legible condition. Replace the warnings as necessary. INTILION AG... -
Page 21: Danger Due To Electrical Energy
The individual battery modules cannot be de-energised. There is always dangerous electrical voltage at the power connections on the battery modules and at the input + and input - connections on the control box. INTILION | scalestac... - Page 22 Work on the electrical equipment must only be performed by a responsible specialised – electrician (e. g. industrial electrician) with WLE certification. The responsible specialist electrician must have completed an INTILION | scalestac – product training session. Always used insulated tools (up to 1000 V) when working.
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Page 23: Dangers Due To Lithium-Ion Batteries
Wherever possible, store damaged battery modules outside of buildings and in a shock-proof and fire-proof outer packaging. Use warning signs to mark and secure the storage location. Have used battery modules disposed of by a certified specialist company or by INTILION AG. INTILION | scalestac... -
Page 24: Dangers Due To Hot Surfaces
A person must not be left suspended in a harness for more than 15 minutes, as otherwise they could go into shock, with potentially fatal consequences. Qualification for working at heights must be demonstrated. INTILION AG... -
Page 25: Dangers Due To Noise
Incorrect or faulty spare parts can lead to damage, malfunctions or total failure, and can also impair safety. Only use original spare parts. Procure spare parts from INTILION AG. The necessary information regarding spare parts can be found in the enclosed parts lists or in Section 1.5 “Service/customer service”. -
Page 26: Safety And Protective Devices
In the event of personal injury, inform the first-aid officer and an emergency doctor or – the emergency services immediately. Clear the access routes for rescue vehicles. If necessary, assign somebody with the – task of briefing the emergency services. INTILION AG... -
Page 27: Obligations Of The Operating Company
The operating company must have all safety devices checked for correct functioning – and completeness on a regular basis. The operating company must perform regular checks to establish that all of the safety – instructions and warnings attached to the battery storage system are legible and permanently affixed. INTILION | scalestac... -
Page 28: Obligations Of The System Manager
The system manager is responsible for the safe performance of electrical work. The transfer of responsibility is performed in writing by the operating company. The system manager must have read and understand the operating manual. He or she must consult the HOPPECKE Service Competence Center in the event of misunderstandings. INTILION AG... -
Page 29: Assembly
Assembly The assembly work for the INTILION | scalestac is split into the following steps: – Preparatory measures – Positioning and assembling the pre-assembled individual parts – NARADA cabinets – Inserting the battery modules Inserting the Control Box Connecting the battery modules (power and communication cables) -
Page 30: Line List
X8:4 X3:8 X8:5 (PE) X3:9 (PE) Feedback, supply X3:1 X3:1 voltage and X3:2 X3:2 feedback, MSS X3:3 X3:3 inverter 1-8 X3:4 X3:4 =BS+IPCS1-WD3.1 (YSLY-JZ 12x0.75 =ScS+ICU =BS+IPCS1 X3:5 X3:5 mm²) X3:6 X3:6 X3:7 X3:7 X3:8 X3:8 X3:9 X3:9 INTILION AG... - Page 31 =BS+ICU X2:12 =BS+IPCS2 X1:N (YSLY-JZ 3x2.5 mm²) of WR X2:15 X1:PE 24V DC supply of X3.7:1 X3.7:1 the IBU in the DC =BS+ICU-WD6.6 X3.7:2 X3.7:2 =BS+ICU =BS+IBU connection field (YSLY-JZ 3x2.5 mm²) X3.7:3 X3.7:3 (PE) (PE) INTILION | scalestac...
- Page 32 Output + (NSSHÖU 1x70 mm²) positive, rack 2 =BS+DCC-WB1.5 Battery rack Power connection =BS+DCC -Q1.1:4 Output - (NSSHÖU 1x70 mm²) negative, rack 1 =BS+DCC-WB1.6 Battery rack Power connection =BS+DCC -Q1.1:4 Output - (NSSHÖU 1x70 mm²) negative, rack 2 INTILION AG...
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Page 33: Necessary Tools
Electric tool Rack screws Insulated torque wrench Installing high-current cables For the installation of high- Insulated socket current cables (use 17- and 19-mm connector) Insulated extension Installing high-current cables Cutter Unpacking Transport cabinets and Forklift truck modules INTILION | scalestac... - Page 34 High-lift truck Transporting and assembling battery modules (recommended) Inclinometer/level Assembling the rack frame INTILION AG...
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Page 35: Assembly Work Steps
Assembly work steps 3.5.1 Delivery of the cabinets and components Check for completeness based on the parts list/delivery note Unpack the components Check the delivery for damage Illustration 1: Cabinet delivery on a pallet INTILION | scalestac... -
Page 36: Positioning And Installing The Cabinets At The Installation Location
Nevertheless, INTILION AG recommends using a lift truck and forklift truck or similar for this step, as the control cabinets are difficult to move by hand due to their weight. - Page 37 With fields 1 to 4, a minimum distance of 200 mm from the back of the cabinet to the wall must be maintained for the air supply, as shown in the following figure. Illustration 4: Distance to the wall (200 mm) INTILION | scalestac...
- Page 38 The battery cabinets (field 4) do not need to be a minimum distance from the wall, and are installed flush with the wall. The empty, unequipped battery racks can also be brought into the room horizontally if this is required due to the height of the room opening. INTILION AG...
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Page 39: Assembling The Hmi Cover Plate
4. The plate must now be fixed onto the door by means of the K discs on the top two screws. The bottom two screws are fixed in place with the washers. The earthing resistance of the HMI cover plate must now be checked in accordance with the specifications. INTILION | scalestac... -
Page 40: Battery Cabinets (Narada Battery Racks)
Connect the equipotential bonding of rack 1 in cabinet no.4 +IBU. Establish an equipotential bonding connection between the following racks and the previous rack using an equipotential bonding strap. Disconnect the protective conductor (PE) from the doors and unhinge the doors. INTILION AG... -
Page 41: Inserting The Battery Modules And The Rack Bms
Screw the cover back on again immediately after completion. Remove the cover for the modules being connected. Screw on the busbars (torque 9 Nm) firstly at the top and then at the bottom INTILION | scalestac... -
Page 42: Installing Additional Control And Safety Components In The First Battery Rack
Establish the cable connections according to the cable list in Table 1. 3.5.4.4 Connecting to INTILION cabinet no. 4 (IBU/DCC) Connect the DC lines to output+ and output- on the rack BMS (30 Nm) of the installed racks, and connect the lines to DC+ and DC- on the DC cabinet (-Q1.1) with a torque of 30 Nm. -
Page 43: Intilion Cabinets
INTILION cabinets For further information, please also refer to the enclosed wiring diagram and the connection list for the INTILION cabinets. Cabinets no. 1 (ICU), 2 (IPSC1) and 4 (IBU/DCC) must then be connected to one another via control lines, communication lines and busbar connectors. - Page 44 Illustration 11: Cabinet cable feed-through Illustration 12: Cable harness (cabinet no. 3) The lines are then guided into cabinet no. 1 from below through the base plate and positioned on the terminal strips. INTILION AG...
- Page 45 Illustration 13: Laid wires in cabinet no. 1 INTILION | scalestac...
- Page 46 Illustration 14: Overview of terminal blocks and network connections (cabinet no. 1) INTILION AG...
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Page 47: Connecting The Busbars
Connect the conductors L1, L2, L3, N and PE between cabinets no. 1 and no. 2. The position of the busbars is indicated in the following figure. Illustration 15: Busbars L1, L2, and L3 (top) and N and PE (bottom) INTILION | scalestac... - Page 48 It is important to be aware that the lugs on the connectors must be on top of each other in the case of 10 mm busbars and next to each other in the case of 5 mm busbars. Illustration 17: Busbar connectors N ant PE (left) and L1, L2 and L3 (right) INTILION AG...
- Page 49 Illustration 19: Touch protection for L1, L2 and L3 Connect the conductors DC+, DC- and PE between cabinet no. 2 or 3 (depending on system scaling) and cabinet no. 4. The PE busbar is screwed onto an angled copper busbar (torque 25 Nm). INTILION | scalestac...
- Page 50 Conductors DC+ and DC- must be connected using straight busbar connectors. One half shell of the connector is connected at the back of the busbar, and one at the front. The half shells are then clamped together using the screws (torque 20 Nm). INTILION AG...
- Page 51 Illustration 22: DC+ and DC- busbar in cabinet no. 3 Illustration 23: Connecting and tightening busbars The touch protection (plexiglas) then needs to be re-attached. INTILION | scalestac...
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Page 52: Ac Connection
L1, L2 and L3 must be connected from left to right (torque 40 Nm). Illustration 24: Touch protection for AC connections L1, L2 and L3 The AC cable is also inserted into cabinet no. 1 via the base plate. INTILION AG... - Page 53 Illustration 25: AC connections L1, L2 and L3 in cabinet no. 1 Wires N and PE are screwed in at the right-hand side of housing no. 1 (torque 40 Nm). Illustration 26: AC connectors N and PE in cabinet no. 1 INTILION | scalestac...
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Page 54: Appendix
Appendix Illustration 27: Example NARADA Rack INTILION AG... - Page 55 Illustration 28: Example installation Illustration 29: Example rack connection INTILION | scalestac...
- Page 56 Illustration 30: Position of the temperature sensor INTILION AG...
- Page 57 Illustration 31: Position of the temperature sensor 2 INTILION | scalestac...
- Page 58 Illustration 32: Example cable routing with 2-4 racks INTILION AG...
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Page 59: Acronyms
Battery protection unit CCCV Constant current constant voltage Direct current Digital input Domain name system Energy management system Human machine interface INTILION Battery Unit INTILION Control Unit Ingress protection Industrial PC Long-term evolution Network building operation Network parallel operation NS protection...