Page 1 Operating Instructions INTILION | scalebloc INTILION AG | Wollmarktstr. 115c | D-33098 Paderborn | www.intilion.com | contact@intilion.com...
Page 2 Operating Instructions – INTILION | scalebloc 2.4 AC-coupled lithium-ion battery storage system in an IP55 outdoor enclosure Version: 05.06 Issue: 06.19.2024 Use the following QR codes to download the latest versions of the Operating and Assembly Instruc- tions from the INTILION AG homepage:...
Page 3: Table Of Contents
Contents Introduction........................7 Means of representation....................8 1.1.1 Section-specific warnings..................8 1.1.2 Embedded warnings....................9 1.1.3 Other means of representation................9 Copyright........................10 Warranty and liability....................11 Performance guarantee..................... 12 1.4.1 Determining the state of health................12 Customer service......................13 Safety.......................... 14 Intended use....................... 15 2.1.1 Foreseeable misuse....................
Page 4 Operating Instructions – INTILION | scalebloc 2.4 Overview........................35 3.1.1 Overview of functional elements................35 3.1.2 Overview of safety devices...................37 Nameplate........................38 ControlShield 4.0......................39 3.3.1 The most important controls................40 3.3.2 Power circuit breaker.................... 42 3.3.3 Circuit breakers......................42 3.3.4 Ethernet ports......................44 3.3.5...
Page 5 4.11.3 Application load peak shaving................86 4.12 Settings in grid-forming operation (GFO)..............88 4.13 Running the system test....................89 4.14 Contacting INTILION service..................91 Operation........................92 Turning the system on and off................. 93 5.1.1 Switching on and starting..................93 5.1.2 Stopping and turning off..................93 5.1.3...
Page 6 Operating Instructions – INTILION | scalebloc 2.4 Updating software from remote................106 Malfunction......................107 Communicating via Modbus TCP/IP..............108 Version information....................109 System information (registers 5000–5050)............111 System information (registers 5051–5099)............116 Grid parameters from energy meter............... 121 Setpoint specification (registers 9000–9006)............122 Error messages......................125...
Page 7: Introduction
These operating instructions provide you with all the information you need to operate the battery stor- age system INTILION | scalebloc (hereafter referred to as ‘battery storage’). The operating instructions must be read, understood, and applied by all persons who are entrusted with the commissioning, operation, and maintenance of the battery storage unit.
Page 8: Means Of Representation
Operating Instructions – INTILION | scalebloc 2.4 Means of representation As an indication and direct warning of dangers, text statements in these operating instructions that re- quire special attention are marked as shown in the following subsections. 1.1.1 Section-specific warnings Section-specific warnings apply not only to a specific action, but to all actions within a section.
Page 9: Embedded Warnings
1.1.2 Embedded warnings Embedded warnings are directly integrated into certain actions. Structure SIGNAL WORD: type and source of danger Consequences of non-observance, measures to avoid the danger Action(s) to avoid the danger Action(s) to avoid the danger Hazard levels: Danger / Warning / Caution Note (without warning symbol, "Section-specific warnings") Action(s) to avoid the danger Action(s) to avoid the danger...
Page 10: Copyright
Transfer of the Operating Instructions to third parties, duplication in any type and form – including ex- cerpts – as well as utilisation and/or communication of the contents are not permitted without the written consent of INTILION AG except for internal purposes. Violations oblige to compensation. Further claims remain reserved.
Page 11: Warranty And Liability
Structural changes to the battery storage unit (modifications or other changes to the battery stor- age unit may not be made without the prior written consent of INTILION AG be conducted. In case of infringement, the battery storage device loses its EU conformity)
Page 12: Performance Guarantee
Operating Instructions – INTILION | scalebloc 2.4 Performance guarantee INTILION | scalebloc comes with a performance guarantee which covers a period of 120 months or an energy throughput (1 energy throughput = charge and discharge of 90 % of nominal energy quantity) of 327.500 kWh in total –...
Page 13: Customer Service
For technical information, please contact our customer service: Service contact Phone +49 (0) 5251 69 322 Email INTILION service (service@intilion.com) In addition, our staff are always interested in your experience which may be valuable for the improve- ment of our products. Introduction – Customer service | 13...
Page 14: Safety
Operating Instructions – INTILION | scalebloc 2.4 Safety Failure to observe the following safety instructions can have grave consequences. Danger Danger to persons due to electrical, mechanical, or chemical influences or failure of major assembly functions. Environmental damage due to leaking hazardous substances.
Page 15: Intended Use
Intended use The operational safety of the battery storage unit is only guaranteed if it is used as intended. INTILION | scaleblocis an AC-coupled battery storage system and is primarily suitable for ‘behind-the- meter’ applications in grid-parallel operation. The Behind-The-Meter application field has three key features:...
Page 16: Structural Modifications To The Battery Storage
In the case of externally sourced parts, there is no guarantee that they have been designed and manufactured to withstand the stresses and to meet safety requirements. Parts and optional equipment that have not been supplied by INTILION AG are not approved for use on the battery storage unit.
Page 17: Requirements For The Personnel
The respective authorisations of the personnel must be clearly defined. The operating instructions must be observed. The persons involved must have attended an INTILION product training. The operating instructions specify the following qualifications for various areas of activity: Personnel to be trained Personnel to be trained, such as apprentices or a temporary employees, do not know all the dangers that can occur during operation of the battery storage unit.
Page 18: Responsibilities
Operating Instructions – INTILION | scalebloc 2.4 2.2.1 Responsibilities Improper handling can lead to considerable personal injury and damage to property. Therefore, have all work carried out only by qualified personnel. Only persons who can be expected to perform their work reliably are permitted as personnel. No persons are allowed to work on the battery storage unit whose ability to react is impaired by drugs, alcohol, medication or similar.
Page 19: Personal Protective Equipment
Personal protective equipment Caution Always wear personal protective equipment (PPE) when operating the battery storage sys- tem to minimize health hazards, regardless of the workplace hazard assessment. Always wear the necessary protective equipment for the job at hand while working. Do not wear metallic watches, rings, necklaces, or other jewellery.
Page 20 Operating Instructions – INTILION | scalebloc 2.4 Use hearing protection Wear hearing protection to protect against hearing damage. Use harness Wear suitable fall protection (safety rope and safety harness) when working at heights. The personal protective equipment must be provided by the operator and must comply with the applic- able requirements.
Page 21: General Safety Information
In case of malfunctions, immediately put the battery storage out of operation. Have faults rectified by INTILION AG or by appropriately trained specialists. Always keep the operating manual at the place of use of the battery storage unit. It must be en- sured that all persons who conduct activities on the battery storage unit can view the operating manual at all times.
Page 22: Safety Measures For Environmental Protection
Operating Instructions – INTILION | scalebloc 2.4 Safety measures for environmental protection Caution Particularly during installation and maintenance work as well as during decommission- ing, take care to ensure that substances hazardous to groundwater, such as greases, oils, coolants, cleaning fluids containing solvents, etc., do not contaminate the soil or enter the sewage system.
Page 23: Special Hazard Warnings
Special hazard warnings Symbols used on the battery storage Warning of electrical voltage This symbol warns of the danger to life due to dangerous electrical voltage. There is an immediate danger to life in the event of contact with live parts. Warning of electrical voltage in electrical operating rooms This symbol warns of the danger to life from dangerous electrical voltage.
Page 24: Dangers Due To Electrical Energy
Operating Instructions – INTILION | scalebloc 2.4 Follow instructions This symbol requires that the operating instructions and safety instructions be ob- served. 2.6.1 Dangers due to electrical energy Note For the safe execution of electrical work, the operator can transfer his/her obligations to a person(s) responsible for the system (electrician).
Page 25 Work on the electrical equipment may only be conducted by a skilled electrician – e. g. company electrician – with a WLE pass. The electrician in charge must have attended an INTILION product training. Always use insulated tools (up to 1000 V) when working.
Page 26: Dangers From Lithium-Ion Batteries
Operating Instructions – INTILION | scalebloc 2.4 2.6.2 Dangers from lithium-ion batteries Danger Even at battery voltages starting at 60 V, there is a considerable risk to health and life in the event of electric shock. Lithium-ion batteries can deliver a high short-circuit current even when supposedly discharged.
Page 27: Dangers Due To Hot Surfaces
After contact with leaked electrolyte, react as follows: After inhalation, remove the affected persons to fresh air and keep them calm. In case of large quantities and irritation of the respiratory tract, consult a doctor. In case of contact with skin, immediately flush the area with water for at least 15 minutes. Seek medical attention if skin irritation persists.
Page 28: Dangers Due To The Use Of Incorrect Spare Parts
Incorrect or faulty spare parts can lead to damage, malfunction or total failure as well as impair safety. Only use original spare parts. Procure the spare parts via INTILION AG. You will find the necessary information on the spare parts in the enclosed parts lists. In case of doubt, contact "Customer service".
Page 29: Safety And Protective Devices
Safety and protective devices Caution Make sure to close off the work area at the battery storage. Before switching on the battery storage unit, always check that all safety and protec- tive devices are properly fitted and in working order. When partial components are supplied, the protective devices must be fitted by the op- erator in accordance with the regulations.
Page 30: In Case Of An Emergency
Operating Instructions – INTILION | scalebloc 2.4 In case of an emergency Recommendation for the fire department Smoke emission of the battery storage can be caused by fire of the electronics as well as of battery modules. Therefore, it is important to detect the cause.
Page 31: Obligation Of The Operating Company
The operatur must make sure that all work at the battery storage is documented in the service re- port and transmitted to INTILION AG. Safety – Obligation of the operating company | 31...
Page 32: Decription Of The Battery Storage
Energy flow control for these applications is provided by an intelligent energy management system, which sends data to the INTILION Cloud via an integrated LTE modem for monitoring and service sup- port.
Page 33 The air conditioning concept described is designed for the ambient temperatures noted in the "Techni- cal data INTILION | scalebloc". For the validation of the air conditioning concept and its functionality, performance profiles are defined (see "Fig. 2: Power curve with two full cycles per day and 45 kVA load "...
Page 34 Operating Instructions – INTILION | scalebloc 2.4 Considering two full cycles per 24 h, which occur with a time in- terval of min. 4 h offset from each other, the air conditioning ensures that the storage system is oper- ated in a temperature window...
Page 35: Overview
This section gives an overview of all functional elements of the battery storage. 3.1.1 Overview of functional elements View with doors closed Figure 4: INTILION | scalebloc functional elements outside LTE antenna (only master version) Air conditioner (mounted on the left side) Door Outdoor housing IP55 Decription of the battery storage –...
Page 36 Operating Instructions – INTILION | scalebloc 2.4 View with doors open Figure 5: INTILION | scalebloc functional elements inside Fire protection enclosure with battery module Socket Temperature sensor PT1000 Battery Management System (BMS) Inverters ControlShield...
Page 37: Overview Of Safety Devices
For the optional implementation of an external lightning protection, it is possible to attach a lightning rod to the attachment point threads also used for transportation. INTILION recommends the lightning rod of the company DEHN SE (Lightning rod article no.: 103211).
Page 38: Nameplate
Operating Instructions – INTILION | scalebloc 2.4 Nameplate The nameplate (1) is attached to the base on the side of the air conditioner (near the edge to the front for better readability). In ad- dition, another nameplate is at- tached to the inside of the air con- ditioner door.
Page 39: Controlshield 4.0
ControlShield 4.0 The ControlShield is the central control unit of the battery storage. If has a variety of functions, like electrical fuse protection, EMERGENCY STOP contacts, uninterruptible power supply for internal pe- ripherals, lightning protection, optional 24 V supply and various connection points for customer sys- tems.
Page 40: The Most Important Controls
Operating Instructions – INTILION | scalebloc 2.4 3.3.1 The most important controls Figure 9: Controls 5S1, 5SF2, 5SF3 in ControlShield right centre The knob switch 5S1 has the following switching positions: Left The Control Shield’s voltage supply is switched off.
Page 41 Operating status of battery storage Status LED at knob switch 5SF2 Run / Standby Permanent ON Stop / starting 2 s ON and 0.5 s OFF Commissioning / SoH calibration / manual mode Flashing with 0.5 Hz Warning / error Flashing with 1 Hz Critical error / communication error Flashing with 2 Hz...
Page 42: Power Circuit Breaker
Operating Instructions – INTILION | scalebloc 2.4 5SF3 The blue pushbutton 5SF3 resets the system in case of failure (reset button). 3.3.2 Power circuit breaker Normally, the power circuit breaker 1QA1 does not need to be operated. If the transparent plastic flap on the right-hand side is closed, it is in automatic mode.
Page 43 Label Function 3FA1 Lightning protection 1FB1 Residual current-operated circuit breaker with integrated overcurrent protection (RCBO) for socket 2FC1 Fuse protection of air conditioning 5FC2 Primary fuse protection of power supply unit Table 7: Functionality of circuit breakers Decription of the battery storage – ControlShield 4.0 | 43...
Page 44: Ethernet Ports
Operating Instructions – INTILION | scalebloc 2.4 3.3.4 Ethernet ports Figure 12: Ethernet ports XF13, XF-14, XF15 Label Function XF13 External TCP/IP interface (see "Communicating via Modbus TCP/IP"). XF14 Connection of the energy meter (for master system, otherwise connection to preceding INTILION | scalebloc).
Page 45: Fuse Protections
3.3.5 Fuse protections The melting fuses 1FC1 protect the internal components and de- vices of the ControlShield. Figure 13: Melting fuses 1FC1 Figure 14: 16KF1, 16KF3, 16KF4, 16KF5, 16KF7, 5FC1, 5FC3, 16KF2, 16KF6 Label Function 16KF1 Shutdown contactor for inverters and battery management 16KF2 Control of optical and acoustic warning indicator 16KF3...
Page 46 Operating Instructions – INTILION | scalebloc 2.4 Label Function 16KF6 Shutoff relay for UPS 16KF7 Contactor for battery fan 5FC1 Protection of UPS battery 5FC3 Secondary protection of power supply unit Table 9: Functionality of fuse protections...
Page 47: Main Terminal
3.3.6 Main terminal XD11 is the main terminal. The terminals can hold cables up to 70 mm cross-section (in the ver- sion „fine-wire conductor with- out ferrule“). For all other conduc- tors, the maximum cross-section is 50 mm (WAGO POWER CAGE CLAMP 50.00 mm²).
Page 48: Uninterruptible Power Supply (Ups)
Operating Instructions – INTILION | scalebloc 2.4 3.3.7 Uninterruptible Power Supply (UPS) At the back of the cabinet, there is the uninterruptible power supply. The UPS has a 7 Ah battery unit. In case of a power failure, it supplies the ControlShield with 24 V auxiliary voltage for the controls and protection units of the battery storage.
Page 49: Terminal Strips
3.3.8 Terminal strips Also at the back, next to the UPS unit, the terminal strips are mounted vertically (see following illustra- tions, from top to bottom): Figure 18: Terminal strips XD3 + XD13 Label Function 24 V supply XD13 Customer connectivity XD13.1 Auxiliary contact for connection of grid and plant protection (NC contact) XD13.3...
Page 50 Operating Instructions – INTILION | scalebloc 2.4 Figure 19: Terminal strips XD14 + XD15 + XD16 Label Function XD14.1 EMERGENCY STOP contacts XD14.4 XD14.2 EMERGENCY STOP contacts XD14.3 XD14.5 Digital input for islanding XD15 Control line for optionally subsequent INTILION | scaleblocs...
Page 51: Safety Devices
Safety devices INTILION | scalebloc verfügt über eine ganze Reihe von Features, die einen sicheren Betrieb des Batter- iespeichers gewährleisten: "Smoke detector " "Door contact switch " "Warning indicator" "Emergency stop contacts" "Grid and plant protection" "Fire protection housing" "Flue gas duct"...
Page 52: Door Contact Switch
Operating Instructions – INTILION | scalebloc 2.4 3.4.2 Door contact switch The door contact switch monitors the doors of the battery storage. If the doors are opened, air condi- tioning is switched off. If the doors are open for more than 30 minutes, the system will shut down.
Page 53: Emergency Stop Contacts
3.4.4 Emergency stop contacts The ControlShield has terminals where an emergency stop switch or an emergency stop circuit / safe- ty circuit can be connected. If this circuit is interrupted, the battery storage unit is disconnected from the grid via an integrated cir- cuit breaker and set to a fused state.
Page 54: Flue Gas Duct
The battery storage has an internal monitoring of the system parameters. If parameters are outside the specified value range, errors are generated. There are three distinct categories of error messages: If INTILION | scalebloc is in the “Warning” state, then the system continues to be oper- Warning able.
Page 55 If INTILION | scalebloc is in the “Error” state, then charging and discharging power is Error limited. After resolving the problem, the system automatically resumes. If INTILION | scalebloc is in the “Critical” state, then the system has the operating Critical mode “Critical“...
Page 56: 3.4.10 Safety-Related Power Reduction Of The System
Operating Instructions – INTILION | scalebloc 2.4 3.4.10 Safety-related power reduction of the system In addition to the error messages, exceeding or falling below certain limit values of system parameters leads to a reduction of the available power. These dependencies are explained below.
Page 57 Cell voltage Each individual cell voltage is measured. At a minimum cell voltage of less than 3.2 V or a maximum cell voltage greater than 4.155 V, no more power is available. In the ranges from 3.25 V to 3.2 V and 4.15 V to 4.155 V, the maximum available discharge or charge power is reduced linearly to 0 kW.
Page 58: Operating Modes
Operating Instructions – INTILION | scalebloc 2.4 Operating modes The battery storage system can be operated in grid-parallel (normal operation connected to the grid) and grid-forming (stand-alone or islanding operation) mode. Switching between the two operating modes is possible via the Modbus interface or the dry contact (DI) at XD13.5 (see "Fig.
Page 59: Energy Meter
Figure 26: Connection diagram energy meter INTILION AG offers various energy meters as accessories. The energy measurement is neces- sary for the use of the applications from this chapter. For this purpose, please contact "Cus- tomer service".
Page 60: Technical Data Intilion | Scalebloc
System type AC-coupled battery energy storage system (BESS) in air-conditioned IP55 outdoor control cabinet Scalability Up to 4 INTILION | scaleblocs connected in parallel (retrofittable) Operating mode Grid-connected operation (GCO), grid-forming operation (GFO) Applications Setpoint specification, self-consumption optimisation, load peak shav-...
Page 61 B, UNE 217002:2020, UNE 206007-1:2013, UNE 206006:2011 Table 13: Technical data INTILION | scalebloc 1 Parallel connection of five or more INTILION | scaleblocs as well as retrofits on request 2 Grid-forming operation mode only for 1 BESS possible 3 Other grid types on request 4 For dynamic load/generator connection <...
Page 62: Commissioning
Operating Instructions – INTILION | scalebloc 2.4 Commissioning The initial commissioning (trial operation) of the battery storage system is carried out by INTILION AG or by INTILION AG trained personnel in the presence of the person(s) responsible for the system.
Page 63: Preparatory Tasks And Information
Preparatory tasks and information Conduct the following tasks before initial commissioning or recommissioning: Check and make sure that all safety devices are in place and working. Check the battery storage unit for visible damage, rectify any defects found immediately, opera- tion is only permitted in perfect condition.
Page 64: Changing Network Settings In Windows
Operating Instructions – INTILION | scalebloc 2.4 Changing network settings in Windows For many settings while commissioning, it is necessary to change the network address of your com- missioning computer. This description is intended for the Windows 10 operating system.
Page 65 Select the network adapter, in this case ‘Ethernet 3’ and right click on it to see the options: Figure 28: Options for the network adapter For the next step, you need Windows administrator privileges. Click on ‘Properties’ in the context menu and then enter the Windows administrator password in the “User Account Control”...
Page 66 Operating Instructions – INTILION | scalebloc 2.4 The properties of the network adapter are displayed: Figure 29: IP address, default gateway and DNS server settings In the list on the left-hand side, double-click to open the ‘Internet Protocol, Version 4 (TCP/IPv4)’...
Page 67: Commissioning The Energy Meter
Commissioning the energy meter This section describes commissioning of the ‘Carlo Gavazzi EM24DINAV53XE1X’ energy meter. For further information, refer to the current documentation of the manufacturer Carlo Gavazzi. After wiring the energy meter, the display shows CT RATIO. In this display mode, it is possible to enter the current transformer ratio on the device.
Page 68 Operating Instructions – INTILION | scalebloc 2.4 The screenshot shows an overview of the UCS configuration software: Figure 30: Energy meter configuration – Main menu Under MANUAL CONNECTION, click CONNECT and the page with the connection settings is dis- played: Figure 31: Energy meter configuration –...
Page 69 The energy meter is available after a short connection setup: Figure 32: Energy meter configuration – Selecting the energy meter Click on the energy meter you found. An overview page with information about the energy meter is displayed: Figure 33: Energy meter configuration – Device overview 10) Click SETTINGS.
Page 70 Operating Instructions – INTILION | scalebloc 2.4 The page for inputting the current transformer ratio is displayed: Figure 34: UCS configuration software – entering the current transformer ratio The current transformer ratio is to be set under the tab ELECTRICAL SYSTEM at CURRENT TRANS- FORMER RATIO.
Page 71 13) Select the COMMUNICATION tab. Figure 35: Energy meter configuration – Network settings 14) Here, set DHCP to DISABLED (if not already set). 15) Make the following entries for IP ADDRESS, SUBNET MASK and DEFAULT GATEWAY: IP ADDRESS 192.168.55.90 SUBNET MASK 255.255.255.0 DEFAULT GATEWAY 192.168.55.1...
Page 72: Filling In The Commissioning Report
Operating Instructions – INTILION | scalebloc 2.4 Filling in the commissioning report Conduct all commissioning steps according to the INTILION commissioning report and fill in the re- sults. According to DGUV regulation 3 (BGV A3), the system must be commissioned in accordance with VDE 0100-600 when it is first put into operation.
Page 73: First Switch-On Of The Battery Storage
First switch-on of the battery storage At the ControlShield, check the following settings: Is the flap at the power circuit breaker 1QA1 closed (see "Power circuit breaker")? If not, close the flap to switch to automatic mode. Are all circuit breakers (1FB1, 2FC1, 5FC1, 5FC2 and 5FC3) switched on (see "Circuit breakers")? If necessary, switch them on.
Page 74: Logging Into The Web Visualisation
Table 18: Login data for web visualisation Figure 36: Login window of the web visualisation Now, the ‘INTILION web visualisation’ is displayed. At the top right of the interface, the language ver- sions German (DE) and English (EN) can be selected.
Page 75 Service Table 19: Login data for web visualisation The user interface for the commissioning engineer is displayed: Figure 38: INTILION web visualisation – user interface Click the ‘Configuration’ button to open the configuration settings. Commissioning – Logging into the web visualisation | 75...
Page 76: Configuration Settings
Figure 39: INTILION web visualisation – configuration interface In the centre of the configuration screen, there is a table with IP address and subnet mask: Figure 40: INTILION web visualisation – Configuration (detail central area) Here, you can edit the IP address and subnet mask, if necessary.
Page 77 Table 20: Configuration data INTILION | scalebloc Note The only configuration option for slave systems is entering the ‘scalebloc ID’. Here, you specify the slave system (1, 2, or 3). All other information concerning the slave system is configured at the master system.
Page 78 Operating Instructions – INTILION | scalebloc 2.4 Click the ‘Play’ button to apply the settings and automatically write them to the ‘Actual value’ column.
Page 79: Entering Serial Numbers
Entering serial numbers You have to enter the serial numbers of the battery modules of all INTILION | scaleblocs into the black highlighted table of the INTILION web visualisation (see "Fig. 42: INTILION web visualisation – configuring the master system").
Page 80 Operating Instructions – INTILION | scalebloc 2.4 Use the arrows to the left and right of ‘scalebloc 0’ to switch between the individual battery stor- ages. ‘scalebloc 0’ is the master. For ‘n’ scaleblocs, you must enter n x 9 serial numbers.
Page 81: Noting Battery Characteristics
Noting battery characteristics In addition, the serial number table (see "Fig. 42: INTILION web visualisation – configuring the master system") shows the relevant battery values. All values (from ‘SoC’ to ‘minimum module temperature – module’) must be entered in the commissioning report.
Page 82: Configuring The Energy Meter
Configuring the energy meter On the central left of the ‘Configuration’ screen (see "Fig. 39: INTILION web visualisation – configu- ration interface "), you can integrate an energy meter with connection to the INTILION Cloud. This ap- plies exclusively to the master system.
Page 83: Settings In Grid-Connected Operation (Gco)
4.11 Settings in grid-connected operation (GCO) The following screenshot shows a table where you configure the application-specific settings. Figure 45: INTILION web visualisation – application settings Power control value See sections "Application self-consumption optimisation" and "Appli- cation load peak shaving".
Page 84: 4.11.1 Application External Setpoint Specification
In application 0 ‘External setpoints’, no individual settings are necessary since the battery storage is controlled by an external energy management system or a higher-level controller via the Modbus TCP/ IP interface (external setpoints, see "Communicating via Modbus TCP/IP"). Figure 46: INTILION web visualisation – external setpoint specification...
Page 85: 4.11.2 Application Self-Consumption Optimisation
In the table on the lower left (under ‘Application settings’), you can see the “power control value” that is the threshold value for the battery storage at the grid connection point. Figure 47: INTILION web visualisation – self-consumption optimisation Make sure to set the “power control value” to 0 kW (default value).
Page 86: 4.11.3 Application Load Peak Shaving
Operating Instructions – INTILION | scalebloc 2.4 4.11.3 Application load peak shaving By adjusting the power control value (threshold value) at the grid connection point, power balancing is possible, for example, in order not to exceed a certain power consumption from the grid for the load curve shown below.
Page 87 VDE FNN Note ‘Connection and Operation of Storage Units on the Low-Voltage Grid’ of the battery storage unit loses its validity, and the operating regulations of INTILION AG would be violated. It should be noted that this peak shaving is not based on 15-minute average power values, but on in- stantaneous values.
Page 88: Settings In Grid-Forming Operation (Gfo)
(INTILION | scalebloc power) would result in a voltage of 218.5 V or 241.5 V. Additional information on the characteristic curves and operation management can be found in "Operational management in grid-forming operation". Contact INTILION AG for further documen- tation on grid-forming operation.
Page 89: Running The System Test
VDE-AR-N 4110. Contact INTILION AG to learn how to change the grid code. On the start page of the web visualisation (see "Fig. 38: INTILION web visualisation – user inter- face ") click the ‘Commissioning’...
Page 90 Balancing to reach cell voltage difference < 25 mV Table 23: Sequence of commissioning system test Figure 53: INTILION web visualisation – system test states Afterwards, the battery storage is charged up to an SoC of 88.9 %. If the differential voltage between cell minimum and maximum is more than 25 mV, balancing is performed subsequently (this process can take up to two weeks, see also the beginning of this chapter).
Page 91: Contacting Intilion Service
4.14 Contacting INTILION service After completing all commissioning steps, contact "Customer service" and send them the filled-in commissioning report so that they can create a customer account for the INTILION Cloud. Commissioning – Contacting INTILION service | 91...
Page 92: Operation
Operating Instructions – INTILION | scalebloc 2.4 Operation The battery storage unit is operated in the operating modes grid-connected operation (normal opera- tion) and grid-forming operation (stand-alone grid). Always keep the doors of the battery storage unit closed. If the doors are open for more than 30 min- utes during operation, the battery storage unit switches to alarm mode.
Page 93: Turning The System On And Off
Turning the system on and off The following subsections are oriented to grid-connected operation, but also apply analogously to grid- forming operation. If the system is to start up in GFO, this must be selected via Modbus register 9004 or the dry contact.
Page 94: Switching Gco And Gfo
Operating Instructions – INTILION | scalebloc 2.4 Switching GCO and GFO The switchover between grid-connected operation (GCO) and grid-forming operation (GFO), shown in the following graphic, is done either via the Modbus TCP/IP interface (see "Switching via Modbus TCP/IP") or the dry contact (digital input at XD13.5, "Switching via digital input").
Page 95: Ac-Dc Voltage Dependency
Note Star point treatment in grid-forming operation The neutral point is simulated in the GFO by the inverter and must be earthed by the customer. For more information, refer to the application rule VDE-AR-E 2510-2. 5.2.1 AC-DC voltage dependency In the operating modes and when switching between them, the dependence between the maximum AC voltage of the grid and the DC voltage of the battery must be observed.
Page 96: Switching Via Modbus Tcp/Ip
Operating Instructions – INTILION | scalebloc 2.4 5.2.2 Switching via Modbus TCP/IP The Modbus interface XF13 in the ControlShield (see "Fig. 12: Ethernet ports XF13, XF-14, XF15") can be used to switch between grid-connected operation and grid-forming operation. Für detailliertere Informationen, see "Communicating via Modbus TCP/IP".
Page 97: Operational Management In Grid-Forming Operation
Further information on operational management of the grid-forming operation is provided by INTILION AG can provide this information in a separate document on request. 5.3.1 Frequency change (P-f characteristic) In the GFO, the nominal frequency changes as a function of the instantaneous active power according to the P-f characteristic pre-set during commissioning (see "Settings in grid-forming operation (GFO)").
Page 98: Voltage Change (Q-V Characteristic)
Operating Instructions – INTILION | scalebloc 2.4 5.3.2 Voltage change (Q-V characteristic) In the GFO, the nominal voltage changes as a function of the instantaneous reactive power accord- ing to the Q-V characteristic pre-set during commissioning (see "Settings in grid-forming operation (GFO)").
Page 99: Maintenance
Update the displayed State of According to description "Calibrating the SoH" Health Air conditioner According to the specifications "Air conditioning unit" of INTILION AG Smoke detector According to the specifications "Smoke detector" of the supplier Doors According to description "Doors"...
Page 100: Safety Measures During Maintenance Work
Operating Instructions – INTILION | scalebloc 2.4 Safety measures during maintenance work If it becomes necessary to conduct work in the battery storage unit which raises dust (e. g. re- moval of dirt deposits), the smoke detector must be covered with a protective cap before start- ing the work.
Page 101: Preparatory Measures
Preparatory measures Danger There is a risk of electric shock when touching energised parts. As batteries are present in the system and cannot be de-energised, a life-threatening DC voltage is always present in parts of the system. The battery storage system can only be de-energised on the mains side up to the battery management system (connections P+ and P–).
Page 102: Maintenance - Annual
Operating Instructions – INTILION | scalebloc 2.4 Maintenance – annual The following maintenance work must be carried out annually. 6.3.1 Battery storage Perform visual inspection Perform a visual inspection and check the battery storage for mechanical damage dirt deposits unfamiliar sounds Remove dirt deposits Cover the smoke detector with a protective cap.
Page 103: Calibrating The Soh
mechanical damage corrosion markings on plus and minus pole Report any damage to the operator immediately. 6.3.3 Calibrating the SoH Like the system test during initial commissioning, the SoH calibration can be started by clicking the ‘Commissioning’ button in the web visualisation (see "Running the system test"). If commissioning followed by the system test has already been completed once, the system “remembers”...
Page 104: Air Conditioning Unit
Operating Instructions – INTILION | scalebloc 2.4 6.3.4 Air conditioning unit To maintain the performance of the air conditioning unit, clean the air filter regularly (at least every three months). The intake air filter is located behind the front cover. To access the filter, first loosen the screw of the lower grille insert.
Page 105: Special Maintenance Intervals
Special maintenance intervals Air conditioning unit Clean the air filter of the air conditioner at least every 3 months. Inverter It is recommended to replace the cooling fan after six years of operation. This can be done by the cus- tomer or by the manufacturer.
Page 106: Updating Software From Remote
Operating Instructions – INTILION | scalebloc 2.4 Updating software from remote In case of a software update the person responsible for the plant will be contacted by INTILION AG. A predefined period will be defined during which the software update will be installed.
Page 107: Malfunction
Malfunction In case of malfunctions, please get in touch with "Customer service" or your contact person at INTILION AG (INTILION contact email). Malfunction – | 107...
Page 108: Communicating Via Modbus Tcp/Ip
Operating Instructions – INTILION | scalebloc 2.4 Communicating via Modbus TCP/IP INTILION | scalebloc supports communication via Modbus TCP/IP. The physical interface being the XF13 port of the “first” or “master” scalebloc (see "Ethernet ports"). If connected to an external EMS (Energy Management System), the battery storage system works like a “slave“...
Page 109: Version Information
Version information Function code 0x04 (read input registers) Register Typ Beschreibung 4900 ASCII Manufacturer #1 and #2 letter: 'IN' 4901 ASCII Manufacturer #3 and #4 letter: 'TI' 4902 ASCII Manufacturer #5 and #6 letter: 'LI' 4093 ASCII Manufacturer #7 and #8 letter: 'ON' 4904 ASCII Spare...
Page 110 Operating Instructions – INTILION | scalebloc 2.4 Register Typ Beschreibung 4929 ASCII Software version #7 and #8 digit 4930 ASCII Software version #9 and #10 digit 4931 ASCII Software version #11 and #12 digit 4932 ASCII Software version #13 and #14 digit...
Page 111: System Information (Registers 5000-5050)
Error code 5012 UINT Error code 5013 UINT Battery fan at SB#16 to SB#01 5014 UINT No. of INTILION | scaleblocs in the system 5015 UINT No. of verfügbaren INTILION | scaleblocs 5016 UINT System mode 5017 UINT Internal power target...
Page 112 Operating Instructions – INTILION | scalebloc 2.4 Resolu- Register Type Unit Description tion 5028 UINT Maximum discharging power 5029 UINT Remaining runtime with current active power 5030 UINT Charging power over 5 min 5031 UINT Charging power over 10 min...
Page 113 Sum of all battery currents. Here, a negative current corresponds to a charging current. System SoC (5002) The state of charge (SoC) of all INTILION | scaleblocs corresponds to the state of charge of the batter- ies. The value ranges from 0 % (battery discharged) to 100 % (battery fully charged).
Page 114 Operating Instructions – INTILION | scalebloc 2.4 Battery fans (5013) The individual bits indicate in which INTILION | scalebloc the battery fans are active. If bit 0 is ‘true’, the the fans are active. Number of INTILION | scaleblocs in the system (5014) The total number of INTILION | scaleblocs in the system.
Page 115 Maximum charging and discharging power (5027–5028) Maximum power of charging and discharging the system. It depends, for example, on the battery’s state of charge or the temperature. Remaining runtime with current active power (5029) Time in which the system is able to run with the current active power until the battery has reached its maximum or minimum SoC.
Page 116: System Information (Registers 5051-5099)
Operating Instructions – INTILION | scalebloc 2.4 System information (registers 5051–5099) Function code 0x04 (read input registers) Resolu- Register Type Unit Description tion 5051 UINT INTILION | scalebloc error code 5052 UINT INTILION | scalebloc error code 5053 UINT INTILION | scalebloc battery voltage...
Page 117 INTILION | scalebloc SoH Table 33: Function code 0x04 (system information) The data of all further INTILION | scaleblocs in the system can be found accordingly in registers 5101 to 5250. Example: One "master“ INTILION | scalebloc and three "slave“ INTILION | scaleblocs:...
Page 118 Table 35: INTILION | scalebloc error codes INTILION | scalebloc voltage/current/SoC (5053–5055) Battery voltage and battery current of an INTILION | scalebloc, plus the battery's state of charge. Operating state (5056) An INTILION | scalebloc can have the following operating states: 0 ->...
Page 119 Power circuit breaker tripped; after problem resolution, system reset is necessary 82 -> Alarm E–STOP INTILION | scalebloc in emergency stop; after problem resolution, sys- tem reset is necessary 130 -> Starting DC INTILION | scalebloc switches on the battery 131 ->...
Page 120 Operating Instructions – INTILION | scalebloc 2.4 INTILION | scalebloc SoH (5099) The battery’s state of health (SoH). If this value is below 70 %, then the battery should be replaced.
Page 121: Grid Parameters From Energy Meter
Grid parameters from energy meter If an energy meter is connected to INTILION | scalebloc. then the following parameters can be read. Function code 0x04 (read input registers) Resolu- Register Type Unit Description tion 6000 UINT Voltage L1-N 6001 UINT...
Page 122: Setpoint Specification (Registers 9000-9006)
Operating Instructions – INTILION | scalebloc 2.4 Setpoint specification (registers 9000–9006) The application ‘setpoint specification’ supports the following function codes: 0x03 Read holding registers 0x06 Write holding registers 0x10 Write holding registers Table 38: Supported function codes The application ‘setpoint specification’ provides the following functions:...
Page 123 Setpoint for active/reactive power (9001–9002) Grid-connected If setpoint specification is enabled, and the system state is 40 to 42, then power operation can be specified using this register. If the power value is within the charging lim- it, then it will be supplied by the system. In case of negative values, power will be drawn from the grid.
Page 124 Operating Instructions – INTILION | scalebloc 2.4 Specification of reference voltage for island grid (9005) In grid-forming operation, the nominal voltage changes depending on the actual reactive power ac- cording to the pre-set Q-U characteristic. By defining the reference voltage, the nominal voltage in the island grid can be set in the range of 208 V to 253 V (90 % to 110 % of the nominal 230 V voltage) at runtime.
Page 125: Error Messages
Error messages In the following, all information regarding error messages of INTILION | scalebloc that can be read via Modbus TCP/IP or the INTILION Cloud is provided. Using the external interface XF13 (see "Ethernet ports"), the error codes can be read directly via Mod- bus TCP/IP.
Page 126: Error Types
The software knows three types of error messages: Warning If INTILION | scalebloc is in the “Warning” state, then the system continues to be operable. However, some system features may be compromised. After resolving the warning, the system resumes automatically.
Page 127: Error List
Error Low temperature in cabinet Check air condition unit Error Emergency stop circuit opened Close emergency stop circuit Error UPS battery almost flat Connect supply voltage Table 45: Error list INTILION | scalebloc Error messages – Error list | 127...
Page 128 Operating Instructions – INTILION | scalebloc 2.4 Class Message Solution Error Power circuit breaker tripped Contact "Customer service" Error Door open for more than 30 minutes Close door Error Power circuit breaker does not close Contact "Customer service" Error UPS battery not connected...
Page 129 Contact "Customer service" Warning Elevated humidity Contact "Customer service" Warning Grid and plant protection signal tripped Check grid and plant protection Warning Door open Close door Table 45: Error list INTILION | scalebloc Error messages – Error list | 129...
Page 130 Operating Instructions – INTILION | scalebloc 2.4 Class Message Solution Warning Air condition unit pressure sensor Check air condition unit tripped Warning Communication error with battery Contact "Customer service" Warning Communication error with inverter Contact "Customer service" Warning External communication error Contact "Customer service"...
Page 131: Applicable Documents
Applicable documents The following documents are enclosed with the product: Assembly Instructions INTILION | scalebloc Overview wiring diagram for INTILION | scalebloc Commissioning report EU Declaration of Conformity Technical documentation of OEM components: Energy meter Janitza UMG 604 Pro (janitza-inst-umg604pro-de-en) Energy meter Carlo Gavazzi EM24 (EM24_E1_IM_USE) Applicable documents –...
Page 132: Abbreviations
Operating Instructions – INTILION | scalebloc 2.4 Abbreviations Abbr. Long form Alternating current Air circuit breaker European agreement concerning the international carriage of dangerous goods by road Application programming interface Apparent power system Apparent power unit Auxiliary BAMS Battery administration management system...
Page 133 Grid connection point Grid-forming operation (islanding) Human machine interface HVAC Heating, ventilation, air-conditioning INTILION Battery Unit INTILION Control Unit IGBT Insulated gate bipolar transistor INTILION | Grid Controller Inverter Ingress protection Industrial PC IPCS INTILION power conversion system Abbreviations – | 133...
Page 134 Operating Instructions – INTILION | scalebloc 2.4 Abbr. Long form Lithium ferrophosphate Level MBMU Main battery management unit MCCB Moulded case circuit breaker Originally MQ telemetry transport, open network protocol for machine-to-machine commu- MQTT nication Network access point Normally closed (contact)
Page 135 Abbr. Long form Technical connection rule Thermal management system TN-S Terre neutre séparé (grid type) Universal configuration software UCTE Union for the co-ordination of transmission of electricity UUID Universally unique Identifier Uninterruptible power supply German association for electrotechnology, electronics and IT Work on live equipment Abbreviations –...
Page 136: Figures
Operating Instructions – INTILION | scalebloc 2.4 Figures Fig. 1: Two INTILION | scaleblocs placed side by side..............33 Fig. 2: Power curve with two full cycles per day and 45 kVA load ..........34 Fig. 3: Power curve with two full cycles per day and 68.5 kVA load..........34 Fig.
Page 137 INTILION web visualisation – configuration interface ............76 Fig. 40: INTILION web visualisation – Configuration (detail central area)........76 Fig. 41: INTILION web visualisation – configuration interface (upper left area) ......77 Fig. 42: INTILION web visualisation – configuring the master system..........79 Fig. 43: INTILION web visualisation –...
Page 138 INTILION Aktiengesellschaft Wollmarktstrasse 115c 33098 Paderborn, Germany +49 (0) 5251 69 32 0 contact@intilion.com intilion.com...

INTILION scalebloc Operating Instructions Manual

1 Introduction

2 Safety

3 Decription of the Battery Storage

4 Commissioning

5 Operation

6 Maintenance

7 Malfunction

8 Communicating Via Modbus TCP/IP

9 Error Messages

10 Applicable Documents

11 Abbreviations

12 Figures

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