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CPS Power Block2.0 Series Operation And Maintenance Manual

Liquid cooling battery energy storage system
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Power Block2.0 Series CPS ES-5015KWH-US-M
Liquid Cooling Battery Energy Storage System
Operation and Maintenance Manual
Shanghai Chint Power Systems Co., Ltd.
Rev V1.0
Jan, 2024

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Summary of Contents for CPS Power Block2.0 Series

  • Page 1 Power Block2.0 Series CPS ES-5015KWH-US-M Liquid Cooling Battery Energy Storage System Operation and Maintenance Manual Shanghai Chint Power Systems Co., Ltd. Rev V1.0 Jan, 2024...

  • Page 2: Table Of Contents

    Table of content Content Foreword ..................6 Safety Instructions ................7 Warning identifications in this Manual ..........8 Warning identifications on equipment ..........10 Safety requirements for the Owner ..........10 Safety requirements for operation and maintenance personnel ..11 2.4.1 Qualifications ..................
  • Page 3 Table of content Fire risk assessment ............... 26 5.2.1 General principles ................26 5.2.2 Overview ..................26 5.2.3 Management system ..............26 5.2.4 Classification of fire sources ............27 5.2.5 System security protection ............. 28 5.2.6 Fire protection system ..............30 5.2.7 Identification of fire hazards ............
  • Page 4 Table of content Annex 3 List of Tools ................... 74 Annex 4 Terms and Definitions ..............77...

  • Page 5: Version Date

    Change Record Version Date Change Description V1.0 31/10/2023 First issue...

  • Page 6: Foreword

    Foreword Foreword This O&M Manual is applicable to the CPS ES-5015KWH-US-M Liquid Cooling Battery Energy Storage System (BESS) developed and produced by Shanghai Chint Power Systems Co., Ltd. Important: Please read this Manual carefully and make sure that you fully understand all contents before performing any operation.

  • Page 7: Safety Instructions

    Safety Instructions Safety Instructions The following warnings, safety instructions and precautions are the safety measures provided and the measures to prevent damage to products or the equipment parts connected. This Manual summarizes the warnings and safety precautions which are generally effective during the application of BESS system.

  • Page 8: Warning Identifications In This Manual

    Safety Instructions 2.1 Warning identifications in this Manual Prior to utilizing this system, kindly take note of the following safety warning messages as they are of utmost importance. Familiarizing oneself with these messages will enhance both the safety of your operations and maintenance procedures: Do not smoke or ignite flame near the battery! No Smoking Do not use organic solvents to clean the battery!
  • Page 9 Safety Instructions electrical operations, certificated personnel should disconnect and verify that equipment de-energized, while also following appropriate lockout/tagout procedures.  Before performing any operations or maintenance tasks, relevant personnel shall undergo safety training and complete the Safety Training Record Form as outlined in Annex 1.

  • Page 10: Warning Identifications On Equipment

    Safety Instructions 2.2 Warning identifications on equipment Warning signs inside container Please read the Warning Electric shock hazard Recycle Manual carefully Warning signs outside container Fire Emergency Extinguisher Protective earthing shutdown General Accumulator No Smoking Warning Sign Battery Room 2.3 Safety requirements for the Owner The Owner must follow the following requirements: ...

  • Page 11: Safety Requirements For Operation And Maintenance Personnel

    Safety Instructions  Any warning signs on the equipment that are damaged or illegible shall be replaced immediately;  The ground on which the energy storage system products are stored must be firm and reliable;  Transportation, installation and debugging can only be carried out by professional personnel recognized by the manufacturer;...

  • Page 12: Safe Operation And Maintenance

    Safety Instructions Use appropriate inspection equipment to check that the components are completely de-energized before maintenance; Before using the inspection equipment, ensure that it can function properly. If you are not familiar with the equipment, please read this User manual carefully.
  • Page 13 Safety Instructions completely de-energized;  At least two persons, one for operation and the other for ensuring safety, shall be on site during maintenance;  Inspections shall be carried out after maintenance to make sure that no tool is left inside the system; ...

  • Page 14: System Introduction

    System Introduction 3.1 System application The CPS ES-5015KWH-US-M Liquid Cooling Battery Energy Storage System (BESS) is a modular design idea that is widely used in MW-scale energy storage systems for renewable energy integration, commercial and industrial (C&I), and utility applications.

  • Page 15: System Description And Parameters

    System Introduction High flexibility: The energy storage system of the whole station can be configured flexibly according to users' requirements. It can be designed for grid-connected wind power/PV energy storage, off-grid energy storage, etc. It is a set of energy storage products with powerful functions, stability and reliability and complete technical indicators.

  • Page 16: Detailed System Parameters

    System Introduction 3.3.2 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 Container Detailed System Specifications Item Parameter Condition...
  • Page 17 System Introduction Item Parameter Condition current Communication CAN、RS485、TCP/IP N.A. mode Operating -25~50℃ N.A. temperature range Storage -30~60℃ N.A. temperature range Service life of the product (25±5)℃ guaranteed under N.A. the operating condition System thermal management Liquid cooling N.A. mode It can be replaced with other gas extinguishing media according to Fire protection FM200...

  • Page 18: System Structure Diagram

    System Introduction 3.4 System Structure Diagram 3.4.1 Communication architecture diagram Fig. 3-2 System Communication Architecture...

  • Page 19: Electrical Architecture Diagram

    System Introduction 3.4.2 Electrical architecture diagram Fig. 3-3 System Electrical Architecture...

  • Page 20: Arrangement Of System Equipment

    System Introduction 3.4.3 Arrangement of system equipment Fig. 3-4 Equipment Arrangement in Energy Storage System...

  • Page 21: Preparation

    Preparation Preparation The following personnel requirements and items are required before continuing to operate and maintain the CPS ES-5015KWH-US-M Liquid Cooling Battery Energy Storage System (BESS). 4.1 Personnel requirements All operation and maintenance personnel shall have received training on Chint BESS system and have relevant experience, so that they can perform operation and maintenance tasks in a safe manner and fully understand the risks involved.

  • Page 22: System Inspection

    Preparation 4.3 System inspection 4.3.1 Container Overview Table 4-1 Record of Container Overall Inspection Specification Size Weight and load Side Front Container appearance Liquid Fire Fire Power Confluen Battery (battery cooler detection extingu distribu rack protectio and alarm ishing tion assembly n unit) pipeline...

  • Page 23: Equipment State Inspection

    Preparation checked for good maintenance and the escape route for smoothness. The energy storage system shall be free of insulation fault, and the insulation resistance of all busbars to ground shall not be less than 2.5 MΩ specified in national standards. Connection points of all wires shall be checked to ensure secure connection.

  • Page 24: Inspection Records

    Preparation Check the fire controller for normal operation and its display screen for alarm message. If any, refer to Chapter 6 for troubleshooting. 4.3.4 Inspection records Each BESS produced by Chint is checked and tested before delivery. After the final installation, BESS shall receive another safety review before being shipped to the customer for operation.

  • Page 25: Emergency Disposal Procedures

    Emergency Disposal Procedures Emergency Disposal Procedures 5.1 First aid measures for chemical leakage Measures to be taken in case of leakage or overflow of electrolyte and other substances:  In the event of electrolyte or other material leakage, evacuate the area immediately.

  • Page 26: Fire Risk Assessment

    Emergency Disposal Procedures 5.2 Fire risk assessment 5.2.1 General principles Chint's principle is to protect all people, including employees, customers and contractors, from potential injuries and health damage that may be caused by work activities. Chint will provide and maintain a safe and healthy working environment, equipment and work system for all employees, and provide them with necessary information, training and supervision for this purpose.

  • Page 27: Classification Of Fire Sources

    Emergency Disposal Procedures Chint decides the safety protection and preventive measures for firefighting, and the customer is responsible for notifying other responsible persons. The following requirements needs to be met:  Make sure that these recommendations implemented communicated to other employees ...

  • Page 28: System Security Protection

    Emergency Disposal Procedures 5.2.5 System security protection Consideration is given to five aspects: component safety, battery cell safety, electrical safety (BMS), mechanical safety and environmental safety. Safety of parts and components Table 5-2 Compliance of Parts and Components with UL Standards Name of parts and Standard No.
  • Page 29 Emergency Disposal Procedures Discharge recovery voltage threshold 156 V Discharge overcurrent protection delay time 1 Discharge overcurrent protection 2 205A Overcurrent protection Discharge overcurrent protection delay 500±50ms time 2 Charge overcurrent protection 205A Short-circuit protection Short circuit Protection condition Load short circuit Load Recovery condition...

  • Page 30: Fire Protection System

    Emergency Disposal Procedures Dual protection mechanism Mechanical safety  Comply with UN38.3 standard and pass static pressure, punching ball, dropping, installation and other tests. Environmental safety  Preventive measures: temperature monitoring, UL94-V0 material, metal housing, safety valve design, BMS high temperature protection, etc. 5.2.6 Fire protection system Fire detection ...

  • Page 31: Identification Of Fire Hazards

    Emergency Disposal Procedures light alarm when being started.  Audible and visual alarms are set up indoor and outdoor, so that people entering and leaving the container can notice the fire alarm immediately. Fire extinguishing system  A sufficient number and types of fire extinguishers are arranged throughout the container system.

  • Page 32: Emergency Measures

    Emergency Disposal Procedures 5.3 Emergency measures 5.3.1 Emergency measures Safety assembly point will be determined by the final customer. Measures to be taken after discovering fire are as follows:  Use the nearest fire alarm call point to give an alarm ...

  • Page 33: Operating Procedures

    Operating Procedures 6 Operating Procedures 6.1 Container operating procedure Turn on the control power supply inside the external distribution box (BMS, switching power supply, lighting, liquid cooler, fire protection, etc.), as shown in the following figure: Fig. 6-1 Internal Layout of Distribution Box Electrical code Electrical component name Circuit breaker of equipment compartment fan power...
  • Page 34 Operating Procedures Electrical code Electrical component name 1QF1 Micro circuit breaker 1 of BMS power Surge Protective Device of distribution main inlet wire Turn on power supply of the control panel in the equipment compartment, and turn on the system circuit on the display (1). BAMS BAMS Fig.

  • Page 35: Bms System Operating Procedure

    Operating Procedures 6.2 BMS system operating procedure 6.2.1 BMS operation inspection BMS shall run according to the following procedure: Check whether there are system status faults in battery charge and discharge state, voltage, current, SOC, rack operation state, etc. through display control. The fault will be shown in “Warning info”.
  • Page 36 Operating Procedures Please check the protection threshold parameter settings according to Table 5-3 Protection Thresholds to ensure consistency. Click the “Parameter settings” to check the settings:...

  • Page 37: Automatic Calibration Of Bms

    Operating Procedures Check the interface with thermal management system for communication, operation state, temperature range and other faults. The interface is as follows (for reference): 6.2.2 Automatic calibration of BMS The SOC of the battery system needs to be calibrated during maintenance. This calibration requires a full-charge and full-discharge process, and is an automatic process.

  • Page 38: Bms System Test

    Operating Procedures 6.3 BMS system test The parameters of BMS Test may vary depending on the project. The following tests shall be carried out once every year. 6.3.1 Communication and control function test Table 6-1 Communication and Control Function Test Test purpose: 1.

  • Page 39: Parameter Setting

    Operating Procedures 6.3.2 Parameter setting Table 6-2 Inspection Of Parameter Setting Test purpose: BMS parameter settings shall be correct. Preconditions: Communication and control function test has been completed. Test process: 1. Check parameter settings on the HMI against the standard table. 2.
  • Page 40 Operating Procedures 6.3.3 Alarm and protection function test Table 6-3 Overvoltage Alarm and Protection Function Test Test purpose: Make sure that BMS can realize the protection function in case of primary, secondary and tertiary overvoltage alarms. Preconditions: Monitoring function and accuracy test is completed Test process: 1.
  • Page 41 Operating Procedures Table 6-4 Undervoltage Alarm and Protection Function Test Test purpose: Make sure that BMS can realize the protection function in case of primary, secondary and tertiary undervoltage alarms Preconditions: Monitoring function and accuracy test is completed Test process: 1.
  • Page 42 Operating Procedures Table 6-5 Overcurrent Alarm and Protection Function Test Test purpose: Make sure that BMS can realize the protection function in case of secondary and tertiary overcurrent alarms Preconditions: Monitoring function and accuracy test is completed Test process: 1. Reset the current protection threshold so that the current reaches the secondary and tertiary overcurrent alarms respectively.
  • Page 43 Operating Procedures Table 6-6 Over-temperature Alarm and Protection Function Test Test purpose: Make sure that BMS can realize the protection function in case of primary, secondary and tertiary over-temperature alarms Preconditions: Monitoring function and accuracy test is completed Test process: 1.

  • Page 44: Troubleshooting

    Troubleshooting Troubleshooting  BESS is a HV DC system and can only be operated by qualified and authorized personnel!  Make sure to check the inverter and all cables of BMS for correct connection and settings and check the BESS system for normal startup before checking for fault.

  • Page 45: Battery Replacement

    Troubleshooting Remove the battery PACK and check BMU does not perform whether the sampling fuse is blown; balancing function replace the BMU module and check it for recovery to normal status. The display control shows Check the Rack circuit for increased that the total voltage of the contact resistance;...
  • Page 46 Troubleshooting Fig. 7-1 Isolating switch Find the faulty battery, locate the faulty PACK and pull out the MSD (1). As shown below: Fig. 7-2 MSD...
  • Page 47 Troubleshooting Remove connecting cables (1, 2), communication harnesses. As shown in the following figure: Fig. 7-3 Remove the cable and communication harnesses Remove the communication harness; Close the valve (1) on the Liquid cooling pipeline; Fig. 7-4 Close the valve...
  • Page 48 Troubleshooting Remove the coolant input pipeline (1) and output pipeline (2), drain the remain coolant in the pipelines, and place the disassembled components in designated positions. Fig. 7-5 Remove the coolant pipeline Remove the 4 screws (1) fixed on the side beam of PACK, and place them in the specified position.
  • Page 49 Troubleshooting Remove the battery from the battery rack: secure it on the threaded hole of the PACK side beam using a wristband or a special tool as shown in the figure, and pull it out to a distance of approximately 50cm. Protective measures shall be taken during handling to prevent falling of personnel or PACK.
  • Page 50 Troubleshooting Fig. 7-8 Place the battery on the lifting tool Fig.7-8 Forklift 11. Install a new PACK and reconnect the system according to the Installation Manual. Pay attention to the following when replacing with a new PACK: Before installing the new PACK, please verify whether the capacity of the ...

  • Page 51: Troubleshooting Of Liquid Cooler

    Troubleshooting 7.3 Troubleshooting of liquid cooler The liquid cooler is a professional equipment and can only be operated by qualified and authorized personnel.   The power supply and communication must be cut off before the replacement of main components. ...
  • Page 52 Troubleshooting Fault Possible Cause Inspection Item Or Treatment Method Refer to the handling method for compressor not Compressor is not started started in the instructions of water cooling unit Replace the control panel according to the Control panel fault instructions of water cooling unit. Replace the fan, and replace the external circulation Fan fault fan according to the instructions of water cooling unit...
  • Page 53 Troubleshooting Fault Possible Cause Inspection Item Or Treatment Method Check the output status of outlet liquid temperature There is no need for cooling compressor on the display screen interface. Check whether the operation interface is in cooling state. compressor The compressor has the shortest shutdown time does not work under normal conditions.
  • Page 54 Troubleshooting Fault Possible Cause Inspection Item Or Treatment Method Check whether the outlet temperature and heating No heating demand is required setpoint are reasonably set. Circuit connection is loose Tighten the circuit connector. The electric heating Wait for a period of time and restart the electric tube does not work Overheating protection is activated heater to observe whether it works normally.

  • Page 55: Spare Parts

    Troubleshooting 7.4 Spare parts A list of spare parts shall be prepared during minor repairs and minor equipment maintenance in order to ensure daily operation and maintenance of the energy storage system. It is necessary to communicate with customers to clarify the list of spare parts in the early stage of the Project.
  • Page 56 Troubleshooting...

  • Page 57: Performance Maintenance

    Performance Maintenance Performance Maintenance  The operation and maintenance of batteries, liquid coolers and fire protection must be carried out by qualified and authorized personnel.  The system must be shut down before some maintenance items. The system which has been running for more than six months or does not run for a long time shall receive a safety maintenance, and corresponding records shall be kept.

  • Page 58: Battery Maintenance Procedure

    Performance Maintenance 8.1 Battery maintenance procedure Table 8-1 Battery Maintenance Procedure Maintenance Category Maintenance content Remarks frequency Check the voltage of battery system with a monitoring system. Voltage inspection Check for normal system voltage. For example, whether the voltage of a single battery is too high or too low.
  • Page 59 Performance Maintenance Maintenance Category Maintenance content Remarks frequency which is completed automatically by the communication between the system and external equipment under normal circumstances. The output relay is turned off and on under low load Output relay conditions (low current), and the relay can be inspection disconnected and connected normally if a click sound is heard.
  • Page 60 Performance Maintenance Maintenance Category Maintenance content Remarks frequency For example, whether the voltage of a single battery is too high or too low. It is necessary to maintain some system functions Shutdown and every 6 months during the restart of network maintenance management.
  • Page 61 Performance Maintenance Table 8-2 Record of capacity test results Discharge Discharge time System capacity current...

  • Page 62: Maintenance Procedure For Liquid Cooler

    Performance Maintenance 8.2 Maintenance procedure for liquid cooler Table 8-3 Maintenance Procedure for Liquid Cooler Test Frequency Category Maintenance standard Treatment method Remove dust and dirt from the Appearance of The unit is clean and free of dust Visual unit with a brush or cotton cloth 10 unit and dirt;...
  • Page 63 Performance Maintenance Test Frequency Category Maintenance standard Treatment method annually power cables terminals are not loose. inspection screwdriver 10 minutes after and terminals on power failure. the wiring panel Electrical cables are free of aging, Visual Replace the power cable 10 damage, abnormal heating and inspection minutes after power failure.
  • Page 64 Performance Maintenance Test Frequency Category Maintenance standard Treatment method 3. No dirt, sediment and algae is detected...

  • Page 65: Fire Protection Maintenance Procedure

    Performance Maintenance 8.3 Fire protection maintenance procedure Table 8-4 Fire Protection Maintenance Procedure Frequency Category Maintenance content Remarks Check warning signs in the protection area, including those of manual starter, emergency stop switch and Signboard inspection manual/automatic change-over switch (emergency service switch), to confirm that all of them are in their original positions, installed firmly, and not damaged.
  • Page 66 Performance Maintenance Frequency Category Maintenance content Remarks Check the pressure switch for secure installation and normal operating conditions; Check whether the pressure gauge of each cylinder is within the green normal pressure range; Check the electromagnetic starter, starter connector and emergency mechanical starter of each active cylinder for normal operating conditions.
  • Page 67 Performance Maintenance Frequency Category Maintenance content Remarks the cylinder head valve before pressure measurement; Re-install them to the cylinder head valve after the pressure measurement if it is confirmed that the control panel works normally. Repeat Repeat the monthly maintenance and inspection. Investigate whether the protection area is consistent Integrity of protection with the originally designed system protection area and...
  • Page 68 Performance Maintenance Frequency Category Maintenance content Remarks a pipeline purging scheme according to the actual situation on site. Check all cylinder supports and confirm that all cylinders Cylinder support are installed firmly on the supports. Check for corroded, damaged or missing parts. Check the condition of all cylinder high-pressure release High-pressure release hoses.
  • Page 69 Performance Maintenance Frequency Category Maintenance content Remarks each detector according to the procedures of the detector manufacturer if necessary. Check each buzzer, flashing light and alarm bell. Check the alarm condition and verify that it can operate Warning indicator correctly when being energized. Reset the alarm circuit after each alarm device is tested.
  • Page 70 Performance Maintenance Table 8-5 Fire Protection Maintenance Records Maintenance Equipment name Description Maintenance date personnel...

  • Page 71: Annex 1 Safety Training Record Form

    Annex Annex 1 Safety Training Record Form Customer name Training place Training purpose Contact number Trainer Training time Training contents Wear PPE before entering the site. Installation personnel on site shall not use metal accessories Basic (i.e. watches and necklaces). requirements Special types of construction projects must be carried out by the holder within his/her scope of work.

  • Page 72: Annex 2 List Of Personal Protective Equipment (Ppe)

    Annex Annex 2 List of Personal Protective Equipment (PPE) Category Sample Qty. Requirements Remarks 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: Safety ...
  • Page 73 Annex Wear protective shoes during battery transportation and Protective installation. shoes Service personnel on site shall wear protective shoes. Insulating Grid: Maintenanc e personnel on site shall wear insulating gloves. gloves 480V Insulating Battery: Maintenance personnel on site shall wear insulating gloves. gloves 1500V Masks...
  • Page 74 Annex Annex 3 List of Tools Calibration Term of Name Material Specification Sample Qty. Remarks date validity Important Laptop tools Important Tape measure Steel tools Wrench Stainless 1 complete Important (Insulation) steel tools Socket wrench Stainless 1 complete Important (Insulation) steel tools...
  • Page 75 Annex Calibration Term of Name Material Specification Sample Qty. Remarks date validity Insulation Stainless 1 complete Important torque steel tools Wrench Stainless 1 complete Important Screwdriver steel tools Gradiometer Aluminum Important 1000mm (Gradienter) alloy tools Electric Important wrench tools Important Electric drill tools...
  • Page 76 Annex Calibration Term of Name Material Specification Sample Qty. Remarks date validity Multimeter Important DC 2000V tools Battery tester HIOKI 3564 Lift truck...
  • Page 77 Annex Annex 4 Terms and Definitions Battery assembly consisting of battery cells connected in series, parallel or both and having only a pair of positive and negative Battery module output terminals, which should also include housings, management and protection components It is used for the protection and control during charging and High-voltage discharging of battery cluster, and consists of the cluster-level...
  • Page 78 Annex communicates with the background to query in the corresponding 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.
  • Page 79 Annex  Unit of voltage: "V" (volt)  Unit of current: "A" (ampere)  Unit of power: "W" (watt)  Unit of capacity: "Ah" (Ampere-Hour)  Unit of energy: "Wh" (Watt-Hour)  Unit of internal resistance: "mΩ" (milliOhm) Unit of measurement ...
  • Page 80 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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