Summary of Contents for CPS Power Block 2.0 Series
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Power Block 2.0 Series CPS ES-5015KWH-US-M Liquid Cooling Battery Energy Storage System Installation Manual Shanghai Chint Power Systems Co., Ltd. Version 1.2 Jan 2024...
Contents Contents Foreword ....................4 Safety Information Instruction ............5 2.1 Relevant warnings in this Manual ............6 2.2 Warnings on personnel and equipment ..........8 2.3 Safety requirements for the Owner ........... 9 2.4 Locking/marking guidance .............. 10 System introductions ................ 12 3.1 System scope of supply ..............
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Contents BMS System Configuration............... 71 7.1 BMS system architecture ..............71 7.2 System configuration preparation ............ 72 7.3 BMS System Configuration ............. 72 7.4 BAMS configuration ................ 73 7.5 Configuration of network interface ........... 76 7.6 Typical protection policy ..............76 8 Annex ......................
Foreword 1 Foreword This Installation Manual is applicable to the Power Block 2.0 Series CPS ES- 5015KWH-US-M Liquid Cooling Battery Energy Storage System (BESS) developed and produced by Shanghai Chint Power Systems Co., Ltd. Main content This Manual includes instructions on how to operate BESS, such as how to install and debug BESS.
Safety Information Instruction 2 Safety Information Instruction Obeying the following warnings, safety instructions and precautions can ensure safety, prolong the service life of products and prevent property losses. The location of the system should be solved by effective equipment operation, design, specification and installation, so as to minimize the electrical hazard of personnel contact.
Safety Information Instruction 2.1 Relevant warnings in this Manual Please pay attention to several safety warning messages before reading the Manual, which are very important. Being familiar with them can make you safer in installation and operation. Qualified operators: The operator must be fully familiar with all warnings and installation procedures described in the Installation Manual.
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Safety Information Instruction eyes! Do not place tools or any metal parts on the top of the battery! Take off watches, rings and other metal accessories! Use tools with insulated handles to avoid accidental short circuit! Before connecting or disconnecting the terminal, please disconnect the charging power supply and load! Use proper lifting methods when handling batteries, and wear all appropriate safety clothes and equipment!
Safety Information Instruction 2.2 Warnings on personnel and equipment Symbol Meaning Warning - Electric shock hazard! Do not touch the system connectors or terminals. Do not open the closed door unless proper locking/tag procedures and related training are carried out in accordance with local laws and regulations. Warning - Arc flash hazard! All electrical equipment has the risk of arc flash.
Safety Information Instruction 2.3 Safety requirements for the Owner The Owner must follow the following requirements: 1) The personnel operating the energy storage system must be trained and qualified electrical workers, otherwise they cannot operate the energy storage system. Improper or wrong operation may cause serious injury to the operator; 2) The personnel operating the energy storage system should be fully familiar with the working principle of the energy storage system;...
Safety Information Instruction 2.4 Locking/marking guidance 2.4.1 Hazard Please always follow all applicable locking/marking procedures. Failure to follow the correct locking/marking procedure may result in serious injury or death. When power is applied to battery energy storage system (BESS), dangerous voltage exists on some components.
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Safety Information Instruction To avoid death, personal injury or product damage, please follow all safety procedures specified in EHS guidelines, and identify and isolate all power sources and stored energy sources. To minimize the risk of electric shock, death and burns, the approved grounding practices and procedures should be strictly observed.
System introductions 3 System introductions 3.1 System scope of supply Cell, PACK, battery cluster, cabinet, connecting power cable, communication cable, power supply equipment, communication equipment, protection equipment and accessories, so as to complete the installation and internal connection of the system. ...
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System introductions Fig. 3-1 Notes of System Components...
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System introductions 3.1.2 Detailed system parameters The technical parameters of this energy storage system are based on the test results of standard battery clusters at room temperature (25±2)℃ and humidity (55±20)%. See Table 3-1 for detailed parameters: Table 3-1 Battery System Detailed Specifications Item Parameter Condition...
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System introductions Item Parameter Condition System thermal management Liquid cooling N.A. mode It can be replaced with other gas extinguishing chemicals according Fire protection FM200 to customer's system requirements and optional equipped with water spraying system. IP rating IP54 N.A. A distance of 1 m, Noise 80dB...
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System introductions 3.1.3 System communication architecture diagram Fig. 3-2 System Communication Architecture...
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System introductions 3.1.4 Electrical architecture diagram Fig. 3-3 System Electrical Architecture...
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System introductions 3.1.5 Arrangement of system equipment Fig. 3-4 Equipment Arrangement in Energy Storage System...
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System introductions Description of each view of the system is as follows: Front view: 1. The front view of the container includes three pairs of double-leaf folding doors; 2. An air inlet system is arranged below the left door; a pressure relief valve is arranged at the upper left corner;...
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System introductions Left view: 1. The left view of the container includes a single-leaf door; 2. The right door is equipped with fire-fighting deflation indicator, audible and visual alarm, fire manual/automatic starter and system emergency stop button. Right view: 1. No equipment or openings are arranged in the right view of the container;...
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System introductions 3.1.6 Design of system incoming and outgoing lines In order to facilitate the on-site cable connection, all cables between the internal equipment of the energy storage system should be connected before leaving the factory. Cables of the energy storage system and external equipment should be routed through the bottom of the container.
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System introductions 3.1.7 Nameplate of energy storage system Users can identify the energy storage system products through the nameplate, which is located in the lower left corner of the end door of the battery container, as shown in Fig. 3-6, and the detailed nameplate information is shown in Fig. 3-7. Fig.
System introductions The information contained in the nameplate includes: (a). Product name, specification and model; (b). Name and trademark of the manufacturer; (c). Factory number (identified by serial number) and date of manufacture; (d). Technical parameters: System operating parameters: Rated output voltage (V), rated output current (A), rated capacity (kWh), rated working frequency (Hz), etc.
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System introductions Fig. 3-8 Schematic Diagram for Connection of Battery Cluster 3.2.1 PACK PACK consists of lithium iron phosphate battery cell 1P52S. The corresponding plugs and sockets of positive and negative power cables are orange and black, as shown below:...
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System introductions sockets of positive and negative power cables Fig. 3-9 Name Positive power cable interface Negative power cable interface Coolant outlet port Coolant inlet port Communication cable interface 3.2.2 Battery protection unit The disconnect switch and ESBCM of battery protection unit are shown as below: Disconnecting switch ESBCM Fig.
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System introductions and "B-" sockets, and connected to the copper bus bar through "P+" and "P-" terminals. The schematic diagram of battery protection unit interface is shown below. Fig. 3-11 Battery protection unit Interface Detailed views of power supply and communication input/output interfaces on the battery protection unit are shown in the following figure: Fig.
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System introductions Definitions of Power Supply and Communication Input/Output Interfaces of Battery protection unit, please refer to the following table. Table 3-2 Definition of Power Supply and Communication Input/Output Interfaces Port name Definition Function description Remarks External AC230V power input, supplying power to BMS switching power BMS-AC220V supply inside the battery...
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System introductions Port name Definition Function description Remarks Reserved Reserved Reserved Reserved Daisy-chain Display control IP2/IM2 of communication communication the first Daisy-chain port J5 ESBMM communication Reserved Reserved Intranet debugging interface Debugging interface J6 Extranet debugging interface Used for connection between the ESBCM to the ESMU...
System introductions 3.3 BMS system BMS adopts a 3-level architecture, its hardware consists of ESBMM, ESBCM and ESMU. Their installation positions are described as the following table: Table 3-3 Installation Positions of BMS Components Level Name Position Function Level 1, Check voltage and Inside the PACK's PACK...
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System introductions Fig. 3-13 Installation Position of ESMU Fig. 3-14 Schematic Diagram of ESMU Interface ESMU has eight interfaces. Interface A is the power port, and LAN is the Ethernet communication port. Interfaces B, C, D, E and F are communication ports, and USB is the port for exporting data and importing upgrade programs.
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System introductions Table 3-4 Definition of ESMU Interfaces Port name Definition Function Positive input of power supply Negative input of power Power input supply System ground LAN0 100M/1000M Ethernet LAN1 100M/1000M Ethernet LAN2 10M/100M Ethernet ESBCM Output positive electrode isolated power supply power...
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System introductions Port name Definition Function Detects a low level(24V-) DI7L Access control is effective Detects a low level(24V-) Water DI8L is effective immersion Detects a low level(24V-) DI9L Fuse is effective Detects a low level(24V-) DI10L Travel switch is effective Detects a low level(24V-) lightning DI11L...
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System introductions Port name Definition Function module RS485 terminal resistance; 19/17 suspended, there is no /15/1 RB0~RB4 internal resistor 120R; if RB is short-circuited to xB (0B/1B, etc.), there is an internal resistor 120R 20/18 /16/1 Shielding grounding point RG0~RG4 each RS485, /12/1...
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System introductions Port name Definition Function 1# normally open dry 12/25 D1+/D1- Fault indicator contact output Power-driven 2# normally open dry 11/24 D2+/D2- opening/shunt contact output tripping 3# normally open dry Power-driven 10/23 D3+/D3- contact output closing signal Power distribution 4# normally open dry breaking (fire...
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System introductions Port name Definition Function contact output RS232 sending port Internal RS232 receiving port debugging RS232 reference ground TypeA (firmware USB1 upgrade port) USB0 USB TypeA Auxiliary firmware button...
System introductions 3.4 Grounding wire In order to reduce and eliminate the electrical noise in the system and prevent the danger of electric shock, it is necessary to ground the system. Grounding methods and requirements will vary according to specific projects and system configuration.
System introductions 3.5 Connect power cable between battery PACK The power cable is used to connect the battery PACK in series to form a complete battery cluster, which is finally connected to the battery protection unit. Table 3-6 Specifications of Connecting cable Specification of connecting cable Connect between upper and lower PACKs Connect between the positive socket of PACK and B+ socket of battery...
Preparations 4 Preparations Before installing BESS equipment, the following items should be prepared 4.1 Personnel requirements All personnel engaged in installation activities should be trained and have relevant experience in Chint BESS. Individuals should meet all training prerequisites and must complete systematic training.
Preparations 4.3 Documents Before installation, all relevant documents, such as contracts, technical agreements, shipping lists and installation drawings, should be collected, and ensured in the final version. These electronic project documents should be handed over to the document management department for archiving. Technical service personnel should make all preparations before installation and know the initial installation status of the system.
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Preparations Steps Inspection item Record 5.2 Train the installation personnel and complete the Safety Installation Training Record Form Battery 6.1 Check the appearance of the battery for no damage or leakage. cluster system 6.2 Check whether the battery on the battery rack is inspection fixed and loose.
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Preparations Steps Inspection item Record 8.8 Supervise the connection of cells in the same cluster in a single row. 8.9 Supervise the connection of main positive and main negative with specific cables 8.10 Supervise the connection of the cables in the "safe area"...
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Preparations Steps Inspection item Record documents manuals and certificates. 11.2 Other document requirements Remarks After the above inspection items are completed, please tick in the inspection record, and then go to the next inspection item. Please underline this part.
Preparations 4.4 Transportation and delivery 4.4.1 Transportation conditions The internal equipment of the energy storage system has been installed and fixed before leaving the factory, and the whole system can be transported. The energy storage system can be lifted and transported with a crane; The energy storage system is transported to the power station site by the freight company, and the site management personnel of the power station will be contacted in advance to negotiate and arrange the specific delivery and unloading.
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Preparations ⚫ If it is necessary to move on a slope, etc., additional traction devices may be required. ⚫ All obstacles that exist or may exist during moving should be removed, such as trees and cables. ⚫ The energy storage system should be transported and moved under better weather conditions as far as possible.
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Preparations ⚫ See the lifting schematic diagram below for the sling used, lifting angle and lifting speed. ⚫ The crane shall have sufficient arm length and radius of rotation. Ensure that all sling joints are safe and reliable, and all slings connected ⚫...
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Preparations Technical requirements: Recommended lifting scheme: Vertical lifting at both ends; The force applied by the lifting equipment on the corner of the container should be vertical and upward; The lifting speed should not exceed 5 meters per minute; Protection measures should be taken for the container during lifting, especially at the areas where the lifting rope contacts with the box body.
Preparations 4.5 Installation requirements for energy storage system The installation clearance requirement for 5MW BESS is as follows: Distance from container to left object:≥0 mm Distance from container to upper object:≥1500 mm Distance from container to right object:≥2000 mm Distance from container to front object:≥2000 mm The energy storage system shall be installed on the structure supported by cement foundation or channel steel.
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Preparations and above the maximum precipitation height of the project site; This project involves fully loaded containers with equipment and battery modules, with a maximum total weight of approximately 42 tons. The foundation requires sufficient strength, and the load on each support point C1-C4 and D1-D2 should be greater than 10.5 tons;...
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Preparations Fig. 4-3 Supporting Points of Energy Storage System...
Preparations 4.6 Unpacking Warning: Do not wear watches, rings, jewelry or other metal objects. Wear insulating gloves and safety shoes. Store in a dust-free place, with humidity not exceeding 60% and temperature not exceeding 23℃±5℃. Avoid direct sunlight. Please check the following parts when unpacking.
Preparations 4.7 Checking The installation personnel shall make records according to the checklist after unpacking. After unpacking, check the following items, fill in the Goods Receipt, and sign it by the customer (customer representative) and the installation personnel. If any defects are found during the inspection, please contact the After-sales Service Department of Chint to solve the problem.
General Installation 5 General Installation 5.1 Installation time The estimated time required for battery cluster installation is shown in the following table. Table 5-1 Time Required for Installation of Single Cluster Battery Accessories Estimated time Step Operation content (hour: minute) Unpacking 00:15 Checking...
General Installation 5.2 General principles of installation Instructions: Please read the following installation sequence carefully before installation. ⚫ Ensure that the battery protection unit is always at the bottom layer; meanwhile, the handle of disconnecting switch of the battery protection unit needs to be in "OFF"...
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General Installation In the standard battery cluster configuration, all the battery PACKs have the same structure and configuration, all their positive and negative poles are the same. In addition, all batteries have been installed in place when the system is delivered, so it is only necessary to connect the cables in series.
Connection of Power Cables 6 Connection of Power Cables 6.1 Safety instructions Warning: Please operate carefully to avoid short circuit of the positive and negative poles of battery PACK. Take extra care to prevent the positive and negative terminals from touching any position other than the predetermined installation point.
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Connection of Power Cables Fig. 6-1 disconnect switch of battery protection unit Connect plugs of main negative cable to negative socket of 1# battery PACK and B- socket of the battery protection unit (sockets have the same color with plugs). If a "click" sound is heard, it indicates that they are plugged in place. Fig.
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Connection of Power Cables Fig. 6-3 Insert the cable plugs to positive sockets Connect plugs of PACK connecting cable into the negative socket of 8# battery PACK and the positive socket of 7# battery PACK (sockets have the same color with plugs).
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Connection of Power Cables Repeat step 4 and install it downward in turn until inserting the cable plug into the negative socket of 2# battery PACK and the positive socket of 1# battery PACK. 3# battery PACK 2# battery PACK 1# battery PACK Fig.
Connection of Power Cables 6.2 Installation of communication harness 6.2.1Harness installation between battery protection unit and battery PACK, and between PACK and PACK Warning: Use signal cables that meet the following specifications. Do not plug both ends of the harness into the same "battery PACK". The specifications of the signal cables connected between the battery protection unit and PACK are as follows, the connector pinout can be found from the back of the battery pack:...
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Connection of Power Cables J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 J2-1 J2-2 J2-3 J2-4 J2-5 J2-6 Res. Res. Figure 6-7 Communication Harness Plug-Socket Between ESBMMs and Definitions Installation steps of Communication/power Supply Harness Between Battery protection unit and ESBMM and Between ESBMMs are as below: Connect the communication/power supply harness between the ESBCM communication port of battery protection unit and communication port of #1 battery PACK.
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Connection of Power Cables Connect the communication/power supply harness between communication port of #1 battery PACK and communication port of #2 battery PACK. Figure 6-8b Connect the communication/power supply harness Connect the communication/power supply harness between communication ports of PACKs in the cluster Figure 6-8c Connect the communication/power supply harness...
Connection of Power Cables 6.3 Installation of battery protection unit power supply cable Warning: Use power supply cables that meet the following specifications. Specifications of power supply cables are shown in the following context: Figure 6-11 Main power supply to 1# cluster power supply harness Figure 6-12 Inter-cluster power supply harness Connect the power supply harness of battery protection unit in the order of battery cluster as below.
Connection of Power Cables 6.4 AC input debugging Warning: After the above harness is installed, check the bolt fastening, screw fastening torque, high-voltage power cable connection, battery connection and battery protection unit connection by sampling. After the battery system is installed, turn on the AC input power of BMS before turning on the BMS.
Connection of Power Cables Check the color of the indicator: If the indicator lights up as red, it indicates that the power supply of the battery protection unit is normal. If the indicator is not on, it indicates that the power supply of the battery protection unit is abnormal. Figure 6-16 Check the color of the indicator 6.5 Installation of liquid cooling pipeline Warning:...
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Connection of Power Cables Blue tag Blue tag Fig. 6-17 Connect secondary pipe connector to male connector of primary pipe Connect the tertiary inlet pipe connector to the male connector of the battery packs from #1 PACK to #8 PACK in turn, and fasten the clips. A "click" sound shall be heard to confirm that the connector is fastened and cannot be pulled out.
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Connection of Power Cables Each secondary inlet pipeline is fixed to the inner hole of the sheet metal part with 4 plastic pipe clamps. The pipe clamp needs to reduce the inner diameter to clamp the pipeline and to be inserted into the hole of fixing the sheet metal part, making sure that there is no loose insertion.
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Connection of Power Cables 6.5.2 Install secondary and tertiary outlet pipelines in the cluster The secondary and tertiary pipes have been assembled when leaving the factory. The secondary pipe connector pasted with a red label is connected to the male connector of the primary pipe pasted with a red label.
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Connection of Power Cables with 4 plastic pipe clamps. The pipe clamp needs to reduce the inner diameter to clamp the pipeline and to be inserted into the hole of fixing the sheet metal part, making sure that there is no loose insertion. Fig.
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Connection of Power Cables 6.5.3 Install MSD on PACK panel Make sure that the battery protection unit disconnecting switch is in "OFF" state Fig. 6-23 Make sure disconnecting switch is in "OFF" state Align the upper cover handle of the maintenance switch vertically with the base guide groove on 8# PACK panel and push it in.
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Connection of Power Cables Repeat step 2 to install MSD on the remaining PACKs in turn until 1# battery PACK is installed. Fig. 6-25 install MSD on the remaining PACKs in turn...
BMS System Configuration 7 BMS System Configuration 7.1 BMS system architecture CHINT strongly recommends that authorized factory representatives configure and debug BMS. Multiple system-level ESMU can communicate with EMS through Ethernet /ModbusTCP. ESMU does not communicate with each other and should be treated as an independent subsystem.
BMS System Configuration 7.2 System configuration preparation Before system configuration, the following materials shall be prepared: ⚫ BMS communication cable: Used for direct connection of CAN, it is a debugging communication line for BMS system debugging ⚫ Adapter: the tool used is USB to 485 ⚫...
BMS System Configuration Fig. 7-2 Communication Architecture of Multiple ESBCMs 7.3.3 Software upgrading The internal software of ESBMM can be upgraded through the daisy chain. In order to simplify the upgrading process, BMS can upgrade all ESBMM software through daisy-chain communication. Software upgrading can be finished easily just by importing latest procedures via ESMU.
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BMS System Configuration Fig. 7-3 Display of Multi-cluster Parameters on HMI (for reference) Click "Cell info" on the top right side of the page to display the voltage of each battery, temperature at each position, alarm/fault information, etc. Fig. 7-4 Display of Single Cluster Parameters on HMI (for reference)
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BMS System Configuration 7.4.2 Parallel connection of battery cluster Considering the circulating current and other faults when multiple battery clusters are connected in parallel, a self-check process has been configured for the BMS program before parallel connection. If the self-check process is completed and no faults are found, the system will automatically connect to the grid;...
BMS System Configuration 7.5 Configuration of network interface After installation, wiring and configuration are completed, connect the Ethernet cable to ESMU, communicate through MODBUS, and check whether the system BMS provides the correct data. The default IP address is: 192.168.1.199 (which may vary in different systems). Port No.: 502 7.6 Typical protection policy The basic protection policy is summarized as follows (which may vary according to...
Annex 8 Annex Annex 1 Safety Training Record Form Customer name Training place Training purpose Contact no. Trainer Training time Training contents 1) Wear PPE before entering the site. 2) Installation personnel on site shall not use metal accessories (i.e. Basic watches and necklaces).
Annex Annex 2 List of Personal Protective Equipment (PPE) Notes Category Sample Requirements Your hard hats must meet one of the two types: TYPE I: Protects the top of the head; TYPE 2: Protects both the top and the sides of the head. Your hard hats must meet with one of the three classes: CLASS G: These are general hard hats rated for 2,200 volts.
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Annex Notes Category Sample Requirements Electrician Service personnel on site shall wear electrician’s clothes. clothes 1) Wear protective shoes during battery transportation and Protective shoes installation. 2) Service personnel on site shall wear protective shoes. Insulating Maintenance personnel on site shall wear insulating gloves. gloves-480V ac Insulating Maintenance personnel on site shall wear insulating gloves.
Annex Note: Other types of PPE and their corresponding quantity depend on the requirements on site. Annex 3 List of Tools Name Material Spec. Sample Qty. Calibrate date validity Laptop Tape measure Steel Wrench (insulated) Stainless steel 1 set...
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Annex Name Material Spec. Sample Qty. Calibrate date validity Socket wrench Stainless steel 1 set (Insulation) Insulated Stainless steel 1 set torque wrench Screwdriver Stainless steel 1 set Gradiometer Aluminum 1000mm (Gradienter) alloy...
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Annex Name Material Spec. Sample Qty. Calibrate date validity Electric wrench Electric drill Multimeter- DC 2000V...
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Annex Name Material Spec. Sample Qty. Calibrate date validity HIOKI Battery tester 3564 Lift truck...
Annex Annex 4 Terms and Definitions Battery assembly consisting of battery cells connected in series, Battery parallel or both and having only a pair of positive and negative output module terminals, which should also include housings, management and protection components It is used for the protection and control during charging and Battery discharging of battery cluster, and consists of the cluster-level battery...
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Annex background; communicates with PCS to control the charging and discharging of PCS; and inputs and outputs dry contacts as required, and communicates with air conditioning, fire protection and other system equipment as required. Energy management system of the whole power station, which is used for dispatching, monitoring and management of the whole power station.
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Shanghai Chint Power Systems Co., Ltd. Headquarters: Building 4, No. 3255, Sixian Road, Songjiang District, Shanghai, China Switchboard: +86-21-37791222 Fax: +86-21-37791222-866003 Website: www.chintpower.com Service hotline: +86-21-37791222-866300 E-mail: service.cps@chint.com The above information is subject to change without prior notice. Any unauthorized copying and plagiarism are prohibited.
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