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- Page 1 CPS ES Series Energy Storage System CPS ES-125kW/279.55kWH & CPS ES-250kW/559.1kWh Installation and Operation Manual - Rev 1.6 CPS ES-125kW/279.55kWh CPS ES-250kW/559.1kWh CHINT POWER SYSTEMS AMERICA CO. Revision 1.6 – September 2024...
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Page 2: Table Of Contents
Table of Contents Before You Start… ................................6 Important Safety Instructions ..............................7 Warnings and Markings on the Product ........................8 Owner Safety Requirements ............................9 Operation and Maintenance Personal Safety Requirements ..................10 1.3.1 Prerequisites ................................ 10 1.3.2 Responsibility ............................... 10 1.3.3 Operation and Maintenance Safety Instructions .................... - Page 3 2.11 Parallel Operation ..............................32 Shipping and Delivery ................................. 33 Shipping Requirements............................. 33 3.1.2 Product Package Weight and Dimensions ......................33 3.1.3 Transportation Process and Requirements ......................34 Lifting and Transportation ............................35 3.2.1 Lifting Precautions ..............................35 3.2.2 Lifting Procedures ..............................36 3.2.2.1 Hoisting Precautions ..........................
- Page 4 AC / DC Wiring ................................. 54 5.4.1 Precautions for AC / DC Connection ........................54 5.4.2 AC / DC Wiring Terminal Locations ........................55 5.4.3 Cable Specifications ............................. 58 Grounding Connection .............................. 59 5.5.1 Cabinet Internal Equipment Grounding ........................ 59 5.5.2 Cabinet Chassis Grounding ..........................
- Page 5 Acronym Key Acronym Meaning Acronym Meaning Authority having jurisdiction NFPA National Fire Protection Association Cell supervision circuits OCPD Overcurrent protection device Digital signal processor P&O Perturb and observe Equipment grounding conductor Printed circuit board Energy storage system Power factor GFCI Ground-fault circuit interrupter Powerline communication HVRT...
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Page 6: Before You Start
Installation, commissioning, troubleshooting, and maintenance of the inverter must be done only by qualified personnel. Thank you for choosing a CPS ES Series Energy Storage System. These are high performance and highly reliable products specifically designed for the North American solar market. -
Page 7: Important Safety Instructions
1 Important Safety Instructions (SAVE THESE INSTRUCTIONS) Please read this user manual carefully before installing the inverter. CPS reserves the right to refuse warranty claims for equipment damage if the user fails to install the product according to the instructions in this manual. -
Page 8: Warnings And Markings On The Product
Warnings and Markings on the Product WARNING: RISK OF ELECTRIC SHOCK This equipment works with high voltages. All work on the product must ONLY be performed as described in this document. INFORMATION: Please check the user manual for more details. WARNING: For continued protection against risk of fire, replace fuses only with the same type and ratings of fuse. -
Page 9: Owner Safety Requirements
Owner Safety Requirements WARNING: ARC FLASH HAZARD There is an arch flash hazard associated with all electrical equipment and an increased risk of arc flash with any equipment modification (e.g., open doors). Serious injury can occur in arc flash incidents; appropriate PPE and training per local codes and regulations is required.. -
Page 10: Operation And Maintenance Personal Safety Requirements
Operation and Maintenance Personal Safety Requirements 1.3.1 Prerequisites Qualified O&M personnel must have training, knowledge, and experience in: Compliance with all regulations and standards. How to assemble, install, and turn on the system, as well as how to ground, prevent short-circuit conditions, and maintain and disassemble the systems. -
Page 11: Operation And Maintenance Safety Instructions
1.3.3 Operation and Maintenance Safety Instructions O&M of the ESS must be done by qualified personnel ONLY. Check for any hazardous situations before operating and maintaining the equipment. Ensure the cabinet door is closed and do NOT touch any conductors while the system is operating. ... -
Page 12: Overview
279.55 kWh 2 sets The model name of the 125kW PCS cabinet is CPS ES-125kW and the model name of the 250kW PCS cabinet is CPS ES- 250kW. The cabinet dimensions for the ES-125kW and ES-250kW models are the same. -
Page 13: Key Features
Key Features Fully integrated turnkey energy storage solution LFP batteries with high thermal stability and high energy density Fully integrated fire protection system Smart liquid cooling system Modular design with flexible scalability Active control and management PCS Cabinet Nameplate Users can find the PCS product details on the nameplate located on the front door of the PCS cabinet: Figure 2-2 PCS Cabinet Nameplate... -
Page 14: Battery Cabinet Design
Battery Cabinet Design 2.3.1 Battery Cabinet Appearance FRONT VIEW SIDE VIEW The front of the container is equipped with two Removable side plates are provided on doors and indicator lights. Its external grounding the sides of the cabinet. point is located on the front of the container. TOP VIEW There are four lifting rings on top of the cabinet enclosure. -
Page 15: Battery Cabinet Dimensions
2.3.2 Battery Cabinet Dimensions The dimensions of the battery cabinet are shown below. Figure 2-3 Battery Cabinet Dimensions Width Depth Height Weight 6613 lb ± 110 lb 51.2 in 51.2 in 92.1 in (3000 kg ± 50 kg) (1300 mm) (1300 mm) (2340 mm) including internal equipment... -
Page 16: Battery Cabinet Internal Components
Battery Cabinet Internal Components The 279.55 kWh battery cabinet contains six (6) battery packs, one (1) high voltage (HV) control box, a battery management system (BMS), a battery thermal management system (BTMS), and a fire protection system. The BMS manages the collection of data and information for the battery cells, the battery modules and cabinet, as well as communication with other equipment. -
Page 17: Battery Cabinet Cable Entry
Battery Cabinet Cable Entry Cables within the ESS and between the ESS and other external equipment must be routed through the holes on the bottom of the cabinet. All cables entering the cabinet must run through cable tray or conduit for proper protection from corrosion and rodents. -
Page 18: Pcs Cabinet
PCS Cabinet 2.6.1 PCS Cabinet Appearance FRONT VIEW REAR VIEW The front of the cabinet is designed with a single door and an The back of the cabinet is designed with a air inlet for heat dissipation; the front door has equipment single door and an air outlet for head dissipation. -
Page 19: Pcs Cabinet Dimensions
2.6.2 PCS Cabinet Dimensions The dimensions of the PCS cabinet are shown below. Model Weight Width Depth Height 1455 lb 125 kW PCS Cabinet (0.73 T) 29.8 in 52.4 in 89.8 in 757 mm (1330 mm) (2280 mm) 1653 lb 250 kW PCS Cabinet (0.83 T) -
Page 20: Pcs Cabinet Internal Components
2.6.3 PCS Cabinet Internal Components The following figure shows the interior views of the PCS cabinet; the example shown is the 250 kW PCS cabinet. (See Table 2-2 below for details.) Figure 2-6 PCS Internal Cabinet Components... - Page 21 Table 2-2 PCS Cabinet Internal Components Equipment Description Disconnect switches and DC surge protection devices. Insulation switches Molded case AC circuit breakers (200 A for each 125 kW PCS module). AC power distribution area Miniature circuit breakers and components for the control module, etc. Power distribution area 125 kW PCS cabinet: One 125 kW PCS is comprised of two 62.5 kW energy storage inverters.
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Page 22: Pcs Cabinet Cable Entry
2.6.4 PCS Cabinet Cable Entry Cables within the ESS and between the ESS and other external equipment must be routed through the holes on the bottom of the cabinet. All cables entering the cabinet must run through the cable tray or conduit for proper protection from corrosion and rodents. -
Page 23: Built-In Pcs Inverters
Dimensions Model Weight Orientation AC Termination (W × H × D) 19.1 × 8.7 × 29.8 in CPS ECB62.5KTL-M 110 lb (53 kg) (486 × 221 × 756 mm) Rack- Screw clamp terminal block mounted (wire range: 4-3/0 AWG CU) 19.1 ×... -
Page 24: Pcs Module Front Panel
PCS Schematic Diagram and Circuit Design The basic electrical schematic diagram of the CPS ECB62.5KTL-M inverter is shown below (Figure 2-10). The DC input from the batteries connects to the DC side of the PCS inverter, passes through the DC contactor, then converts to the three-phase AC waveform through three-level inverting technology. - Page 25 Figure 2-10 125 kW Diagram...
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Page 26: Pcs Key Features
2.7.5 PCS Key Features High operating efficiency boosted by advanced three-level inverting technology. Peak discharging efficiency: 98% Peak charging efficiency: 97.6% Grid adaptability Selectable grid standards: IEEE 1547, CA Rule 21, HECO. Smart inverter functions, including voltage ride-through (LVRT/HVRT), adjustable reactive power and power factor (PF) value from 0.8 leading to 0.8 lagging. -
Page 27: Battery Rack Design
Battery Rack Design The CPS ES series ESS implements a modular design concept. It is equipped with a three-level BMS that collects cell voltages, temperatures, module and string current, capacity, as well as other information from the battery rack. This system includes functions such as undervoltage protection, overvoltage protection, overcurrent protection, overtemperature and under-temperature protection, as well as real-time data monitoring and fault reporting features. - Page 28 Item Specification Note Rated 140 A Charging current Maximum 160 A (lasts 1 min) Rated 140 A Discharging current Maximum 160 A (lasts 1 min) Nominal power 279.55 kWh Electrical Voltage range 873.6-1123.2 V 2.8-3.6 V performance Nominal voltage 998.4 V 3.2 V Max.
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Page 29: Battery Thermal Management
Battery Thermal Management The liquid-cooling chiller is equipment that can control the temperature of the antifreeze liquid of the energy storage battery and reduce the environmental humidity. It has frequency conversion control, including the refrigeration function, heating function, control module, high and low voltage power supply module, supporting and protecting structure module, and other functional modules. - Page 30 Table 2-4 Battery Thermal Management Specifications Specification Parameters / Requirements 0-13123.4 ft (0-4000 m); refrigerating capacity derates ≤ 3% per 3280.8 ft (1 km). Ambient temperature Relative humidity 0-95% Coastal / seaside environment requires C5 anti-corrosion level Rated value 3 kW @ 113°F (45°C) ambient temperature / Cooling power coolant effluent temperature 64°F (18°C) Heating power...
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Page 31: Fire Suppression System
2.10 Fire Suppression System Component Image Function Detects smoke using a light source and a photo sensitive sensor; when smoke particles enter the Smoke detector light path, some of the light is scattered by reflection and refraction onto the sensor. Detects fire by using heat sensitive elements. -
Page 32: Parallel Operation
Parallel Operation The cabinet dimensions for the CPS ES-125 kW and CPS ES-250 kW models are the same; two 125 kW modules can operate in parallel. The AC output of the two modules have their own built-in 200 A circuit breaker and the outputs are combined, thus... -
Page 33: Shipping And Delivery
3 Shipping and Delivery Shipping Requirements The internal components of the PCS and battery cabinets listed in this manual are pre-installed prior to shipment. The following two lifting methods can be used: Use a crane to lift and transport the PCS and battery cabinets. Use a forklift to lift and transport the battery cabinets. -
Page 34: Transportation Process And Requirements
3.1.3 Transportation Process and Requirements During transportation, avoid external mechanical impact. During loading and unloading, handle the product with care and do NOT throw, roll, or apply heavy pressure to the product. Battery rack transportation requirements for land transport: The transportation plan for bulky cargo must be evaluated in advance. -
Page 35: Lifting And Transportation
Lifting and Transportation 3.2.1 Lifting Precautions WARNING: Local safety regulations for crane and forklift operation MUST be followed. A safety clearance of at LEAST 32.8 ft (10 m) must be kept to avoid personnel from stranding under the machinery and to avoid serious injury. -
Page 36: Lifting Procedures
The following figure shows the crane lifting operation area for reference. The inner circle (A) indicates the working range of the crane and the outer circle (B) indicates the safety clearance around the crane’s working range. Figure 3-2 Crane Lifting Operational Area 3.2.2 Lifting Procedures CAUTION:... -
Page 37: Hoisting Precautions
3.2.2.1 Hoisting Precautions Before lifting: Ensure that the lifting capacity and working radius of the crane meet the requirements. If the onsite working conditions do not meet the requirements, seek professional evaluation. For outdoor use, it is recommended to lift the racks when the weather is clear and there is no wind or rain. ... -
Page 38: Hoisting Risk Identification
3.2.2.2 Hoisting Risk Identification WARNING: To prevent personal injury or equipment damage, risk identification must be completed before hoisting. Possible risks to account for: During operation, the crane can crush or impact the human body. Crane hook overloading fracture due to lifting when the sling has slipped out of the hook. ... -
Page 39: Hoisting Safety Measures
3.2.2.3 Hoisting Safety Measures WARNING: Safety measures MUST be followed to prevent personal injury or equipment damage. Before and during hoisting: Strengthen the management of the construction site. Set up a warning area on the hoisting site. Send full-time safety personnel to supervise and alert. -
Page 40: Ambient Thermal Insulation
3.2.3 Ambient Thermal Insulation The battery system must stay within the range of optimum operating temperature to extend the battery service life and improve the battery safety performance. The temperature range must completely comply with the specified storage temperature range and operating temperature range (see Section 7.1 Datasheet). - Page 41 The lateral pin on the clevis hook must be tightened securely. All local safety regulations must be followed during lifting and transportation. CPS is not responsible for any property damage and/or personnel injury caused by violation of any relevant safety requirements, standards, or regulations.
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Page 42: Lifting Using Forklift
Lifting Using Forklift If the ground of the installation site is flat, forklifts may be used to carry the ESS. The bottom of the ESS is designed with standard forklift pockets. When lifting and transporting the ESS with a forklift, insert forks into the forklift pockets at the bottom of the cabinet and move the ESS to an appropriate position for installation. -
Page 43: Inspection
Inspection The CPS ES series products go through thorough factory testing before shipment and delivery. However, there is a possibility that the units or components may be damaged during shipment. Therefore, when the units are delivered, the following must be checked: Ensure the components and quantity delivered to the site match the BOL. -
Page 44: Mechanical Installation
4 Mechanical Installation Components Checklist The major components of the CPS ES series energy storage system are shown below. NOTE: The 250 kW / 559.1 kWh ESS has two battery cabinets and two 125 kW PCS modules in the same PCS cabinet. - Page 45 Table 4-2 250 kW / 559.1 kWh ESS Components Item Qty. Note Includes power cables, MSD, communication cables, Battery packs and cell-level BMS assembled in the pack; six packs per cabinet, two cabinets total. Includes power cables, communication cables, power HV control box supply, AC breakers, and DC insulation switch;...
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Page 46: Pre-Installation Inspection
Pre-Installation Inspection Ensure the site’s environmental conditions (including temperature range, humidity, altitude, etc.) are within the equipment specifications. Ensure that the grid voltage is within the specified voltage range. Ensure the required permitting has been granted by the local utility service provider before beginning installation. ... -
Page 47: Installation Space Requirements
Installation Space Requirements The distance between the battery cabinets and surrounding objects must meet the following conditions: The minimum allowable clearance between the front of the cabinets and surrounding objects is 78.7 in (2000 mm). The minimum allowable clearance between the back of the cabinets and surrounding objects is 39.4 in (1000 mm). ... -
Page 48: Installation Site Surface Requirements
Installation Site Surface Requirements The energy storage system must be installed on a structure supported by a concrete foundation or channel steel with a surface made of flame-resistant materials. The foundation must be smooth, solid, safe, reliable, and have sufficient load- bearing capacity. -
Page 49: Base Mounting
4.6.1 Base Mounting NOTE: The ESS cabinet base is welded to the cabinet, as shown below: Figure 4-2 Cabinet Bases (Left: Battery Cabinet, Right: PCS Cabinet) Install anchor expansion bolts (eight for PCS cabinet and nine for battery cabinet) according to the following diagram and drill holes according to the specifications of the expansion bolts. -
Page 50: Installation Surface
4.6.2 Installation Surface Both the PCS cabinet and the battery cabinet must be mounted on top of the concrete pad installation surface, which has the following requirements: The foundation frame must be level. If installed on soft ground, long-term use may lead to uneven settlement, causing the frame installation to be uneven. The foundation frame can be made of heavy-duty material to prevent uneven stress during installation, which can prevent equipment tilting or cable connection deformation. -
Page 51: Electrical Connection
5 Electrical Connection WARNING: The utility grid voltage and frequency must be within the PCS inverter electrical specifications. Installation of the ESS must be completed by qualified personnel ONLY. The installation must comply with all local electrical codes and standards. NOTICE: ... -
Page 52: Opening The Cabinets
Opening the Cabinets The following sections cover how to wire the power cables, communication cables, and other electrical connections within the ESS. External wiring can be installed after opening the left front door of battery cabinet and the front door of PCS cabinet. Unlock the left door of the battery cabinet with a key and pull it 45 degrees outward to open. -
Page 53: Cabinet Door Closing Procedure
Cabinet Door Closing Procedure 5.3.1 Closing the Battery Cabinet Door Turn the door lock handle to its highest point (see Figure 5-4). NOTE: Avoid scratching the lock body with the handle during this process to avoid removing the paint. Figure 5-2 Close the door using the following steps: Press down on the upper part of the small door lock ①. -
Page 54: Battery Cabinet Door Inspection
5.3.2 Battery Cabinet Door Inspection When the small door is open, check from the electrical compartment side whether the upper and lower connecting rod pulleys on the inside of the cabinet door have slid into the welding pin seat of the cabinet. Check from the electrical compartment side for an overlapping area between the lock tongue on the inside of the cabinet door and the welding socket of the cabinet. -
Page 55: Ac / Dc Wiring Terminal Locations
5.4.2 AC / DC Wiring Terminal Locations Check the following items before wiring the cables: Completely shut off the main supply of AC voltage from the grid side. Check the AC voltage at the AC terminal busbar at the central bottom portion of the PCS cabinet. Ensure that the DC insulation switch and AC breaker inside the PCS cabinet are in the OFF position. - Page 56 The AC terminals of the PCS cabinet are for connection to the utility service panel or micro-grid switch terminals. Open the PCS cabinet door and remove the protective plate to access the copper busbar; the wiring location is shown in Figure 5-3 below.
- Page 57 Table 5-1 Cable Wiring Hole Cable Description One JX3 communication cable DC block communication cable #1 One JX3 communication cable DC block communication cable #2 P+ and P- positive power cable DC block power cable One JXH1 cable DC block auxiliary power cable #1 One ground cable Ground cable Three 150mm...
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Page 58: Cable Specifications
Based on the information above, route the JX3 and JXH1 cable(s) through the conduit and plug them into the corresponding DC block connector ports. (These two cables have white labels on their black insulation housing.) Route the ground cable(s) through the conduit between the DC block and PCS cabinet. For external ground rod installation and connection, see Section 5.4 Grounding Connection. -
Page 59: Grounding Connection
For the correct grounding resistance threshold, refer to the local codes and standards. WARNING: The local codes and standards must be followed when grounding the unit. CPS is not responsible for any equipment damage and/or personnel injury caused by violation of any relevant safety requirements, standards, or regulations. -
Page 60: Inspections Before Startup
Inspections Before Startup Before startup and operation, the installation of the ESS must be thoroughly checked for the following: All cables are properly crimped, no strands are exposed, cable insulation is not damaged, all cables are properly bent without damage, and all screws are properly torqued. ... -
Page 61: Power-On Procedure
Power-On Procedure The ESS can only be powered on after all above requirements (Section 5.5) are strictly followed. The power-on procedures are as follows: When the grid voltage is present, turn ON the AC fused disconnect or circuit breaker on the utility side. Confirm that 480 Vac voltage is present on the PCS cabinet's AC terminals. -
Page 62: Troubleshooting And Maintenance
6 Troubleshooting and Maintenance WARNING: Operation and maintenance of the ESS must be performed by qualified personnel ONLY. WARNING: During operation and maintenance of the ESS, the right-side door of the battery cabinet must remain CLOSED to prevent exposure to hazardous high voltage. General Maintenance Regular maintenance of major components must be conducted to ensure the ESS operates properly and efficiently. - Page 63 Item Maintenance Cycle Time Notes Inspect and clean the Transformer fan Every 5 months transformer fan. For areas with harsh environments and high airborne Air inlet filter Inspect and clean the air inlet Every 5 months dust content, the recommended screen filter screen.
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Page 64: Faults And Troubleshooting
The causes of a fault can be identified based on the faults listed in the table below (Tables 6-2 and 6-3). Proper analysis is highly recommended before contacting CPS Customer Service. There are three levels of faults in the energy storage system: Warning, Protective Notice, and Failure. - Page 65 TempSensorErr 1. Observe temperature display. 2. Turn OFF the three-phase working power supply and reboot the system. 3. If the fault persists, contact CPS Customer Service. 4. x Definition: Communication failure. Possible causes: Terminal block connectors for the internal communication wires have poor contact.
- Page 66 EepromErr 1. Observe for five minutes to see whether the alarm will be eliminated automatically. 2. If the fault persists, contact CPS Customer Service. Definition: Ambient or internal temperature is too high. Possible causes: Ambient temperature outside the inverter is too high.
- Page 67 2. Check whether the grid frequency is within the specified range. 3. Check whether the cable between the inverter and the power grid is disconnected or has any fault. 4. If the fault persists, contact CPS Customer Service. Definition: Battery voltage exceeds specified value. Possible causes: Battery over-voltage.
- Page 68 PROTECTION 0010-0620 1. Observe for 10 minutes to see whether the alarm will be eliminated automatically. 2. If the fault persists, contact CPS Customer Service. Definition: Internal fault of the inverter. Possible causes: Fault occurs inside the inverter. IntFault Recommended solutions:...
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Page 69: Technical Data
CPS ES-250 kW PCS inverter model name (1) ECB125KTL-M/US-480 (2) ECB125KTL-M/US-480 Battery cabinet model name O652280-E Configurations (1) CPS ES-125 kW + (1) O652280-E (1) CPS ES-250 kW + (2) O652280-E Battery Parameters Battery capacity 279.55 kWh 559.1 kWh Rated voltage 998.4 V... - Page 70 Equipment Specifications PCS cabinet: 29.8 × 89.8 × 52.4 in (757 × 2280 × 1330 mm) Dimensions (W × H × D) Battery cabinet: 51.2 × 92.1 × 51.2 in (1300 × 2340 × 100 mm) 125 / 250 kW PCS cabinet: 0.73 T / 1455 lb (662.2 kg) Weight 279.55 kWh Battery cabinet: 3.0 T / 6613.9 lb (2721.6 kg) Handling method...
- Page 71 CHINT POWER SYSTEMS AMERICA CO., LTD. Address: 1380 Presidential Drive, Richardson, Texas 75081 Service Hotline: 855-584-7168 Email: AmericaSales@chintpower.com Website: www.chintpowersystem.com SHANGHAI CHINT POWER SYSTEMS CO., LTD. Headquarters: Building 4, No. 3255, Sixian Road Songjiang District, Shanghai, China Tele: +86-21 -3779 1222-866300 Fax: +86-21 -3779 1222-866001 This manual is subject to change without prior notification.
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