Sungrow PowerStack-ST535kWh-250kW-2h Operation & Maintenance Instructions Manual

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Operation & Maintenance Instruction

PowerStack-ST535/570kWh-250kW-2h

PowerStack-

& Maintenance

InstructionPowerStack O&M

Instruction-OEN-Ver11-202410

PowerStack O&M Instruction-OEN-Ver11-202410

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Summary of Contents for Sungrow PowerStack-ST535kWh-250kW-2h

Page 1 Operation & Maintenance Instruction PowerStack-ST535/570kWh-250kW-2h PowerStack- ST535/570kWh-250kW-2hOperation & Maintenance InstructionPowerStack O&M Instruction-OEN-Ver11-202410 PowerStack O&M Instruction-OEN-Ver11-202410...
Page 3: All Rights Reserved
Software Licenses • It is prohibited to use data contained in firmware or software developed by SUNGROW, in part or in full, for commercial purposes by any means. • It is prohibited to perform reverse engineering, cracking, or any other operations that...
Page 4: About This Manual
About This Manual This manual describes the commissioning, troubleshooting, and maintenance of the energy storage system. Target Group This manual is for operators of the power storage plant and qualified technical personnel. The ESS must and can only be installed by professional technicians who meet the following requirements: •...
Page 5 Indicates a slightly hazardous situation which, if not avoided, may result in minor or moderate injury. Indicates a potential hazard which, if not avoided, will result in device malfunction or property damage. “NOTE” indicates additional information, emphasized contents or tips that may be helpful, e.g., to help you solve problems or save time.
Page 6 Explanation Marks It is required to wear goggles. This symbol indicates that the product can be recycled. This symbol indicates that lithium batteries can be recycled.
Page 7: Table Of Contents
Contents All Rights Reserved .....................I About This Manual......................II 1 System Description ..................1 1.1 System Description..................1 1.2 System Configuration ..................1 1.3 Communication Architecture ................3 2 Introduction to System Subunits ..............5 2.1 Battery......................5 2.2 Power Conversion System ................6 2.3 Switch Gear ....................7 2.4 Local Controller (LC)..................8 2.5 Temperature Control System ................9 2.6 Fire Suppression System (FSS)..............
Page 8 4.4 Battery Maintenance..................28 4.4.1 Regular Maintenance and Maintenance Cycle........28 4.4.2 Maintenance Precautions ..............33 4.4.3 Maintenance..................33 4.5 Maintenance of Liquid Cooling System............35 5 Common Maintenance Operations ..............37 5.1 Safety Instructions ..................37 5.2 Coolant Filling and Drainage Operations ............38 5.2.1 Liquid Cooling System Introduction............38 5.2.2 Coolant Change Intervals ..............41 5.2.3 Safety Precautions ................42 5.2.4 Tooling Introduction ................44...
Page 9 5.3.5.6 Close Cabinet Door ..............78 5.4 Replace S/G ....................78 5.5 Replace Liquid-cooled Unit................81 5.6 BMU Replacement ..................82 5.7 Fuse Replacement ..................83 6 Troubleshooting ....................84 6.1 Overview .....................84 6.2 PCS Troubleshooting..................84 6.3 Battery Fault Diagnosis .................97 6.4 BSC Troubleshooting.................. 103 6.5 LC Troubleshooting ..................105 7 Appendix ......................
Page 11: System Description
System Description System Description The following standard liquid-cooled energy storage system is selected for illustration. The typical functional block diagram of the energy storage system is shown below, the core equipment mainly consists of batteries, switching gear (S/G), energy management systems (EMS), local controllers (LC), and power conversion system (PCS), etc., and the auxiliary systems mainly include liquid-cooled units (LCS), fire suppression system (FSS), and lighting systems.
Page 12 1 System Description Operation & Maintenance Instruction *The above image is for reference only. Please refer to the actual product you received! Name Liquid cooling unit Battery clusters Switch gear The internal layout of power converter system (PCS) is shown in the figure below. *The above image is for reference only.
Page 13: Communication Architecture
Operation & Maintenance Instruction 1 System Description Name Network port SC50HV The physical diagram of the system is shown below. *The above image is for reference only. Please refer to the actual product you received! Communication Architecture The system is mainly composed of EMS, LC, BSC, PCS and CMU. •...
Page 14 1 System Description Operation & Maintenance Instruction figure 1-2 Communication Architecture Diagram *The above image is for reference only. Please refer to the actual product you received!
Page 15: Introduction To System Subunits
Introduction to System Subunits Battery Standardized and unitized battery modules are developed based on lithium iron phosphate cells. Battery modules are connected in series to form a battery cluster. The battery clusters are connected to the supporting power conversion system (PCS) to form energy storage systems(ESS) and store and release electric energy.
Page 16: Power Conversion System
2 Introduction to System Subunits Operation & Maintenance Instruction Battery Cluster The battery cluster is composed of PACKs, fuse, etc. Battery cluster parameters are shown as follows: table 2-3 Battery cluster parameters DC output Short-circuit Rated power Model Max. current voltage range current R268BL-111...
Page 17: Switch Gear
Operation & Maintenance Instruction 2 Introduction to System Subunits Description Name The fan is located on the back of the cover plate and Cover plate of the used for the forced cooling of the device. To disconnect the device from the AC output safely. AC switch Second PE Second protective earth terminals as specified in EN...
Page 18: Local Controller (Lc)
2 Introduction to System Subunits Operation & Maintenance Instruction Description Name P+/P- PCS side terminal block. BSC vertical transfer interface, which can log in to NET1 BSC's web interface. NET2 BSC vertical transfer interface, connecting the switch to communicate with LC. High voltage DC switching.
Page 19: Temperature Control System
Operation & Maintenance Instruction 2 Introduction to System Subunits Item Remark Name Description Used for hardware reset of the local Reset port controller Relay output ports (relay specification: Digital output DO1~DO4 250Vac/3A or 30Vdc/3A) PT1、PT2、 Analog input Reserved function AI1~AI4 RS485 Support 6 inputs of RS485, or can be A1B1~A6-...
Page 20 2 Introduction to System Subunits Operation & Maintenance Instruction liquid cooling unit via the return line, thus forming a cycle. If the number of packs that make up the cluster is reduced, the number of branch circuits is also reduced. The switch gear is located at the bottom right of the battery cabinet, and there is a disturbance fan inside the switch gear.
Page 21: Fire Suppression System (Fss)
Operation & Maintenance Instruction 2 Introduction to System Subunits figure 2-4 Schematic Diagram of PCS Cooling Method *The above pictures are for reference only, please refer to the actual object received! Fire Suppression System (FSS) The BESS has a aerosol fire suppression system that can effectively extinguish the fire. It is equipped with combustible gas detectors, smoke detectors, and temperature detectors.
Page 22 2 Introduction to System Subunits Operation & Maintenance Instruction figure 2-5 Diagram of fire fighting system composition *The above pictures are for reference only, please refer to the actual object received! table 2-4 Introduction to the main components of FSS Description Items Each battery cabinet is equipped with a combustible gas...
Page 23 Operation & Maintenance Instruction 2 Introduction to System Subunits Description Items The automatic fire alarm system includes smoke detectors (smoke sensors for short) and heat detectors (temperature sensors for short). Each battery cabinet is equipped with Automatic fire one smoke sensor and one temperature sensor. When alarm system either the smoke sensor or the temperature sensor detects a fire in the battery cabinet, the detector base will send a...
Page 24: Commissioning
Commissioning Check Before Power-up Personnel requirements • Personnel engaged in on-site commissioning must have no severe physical or sensory defects and must possess a certificate recognized by the relevant national labor safety inspection authority after undergoing training, examination, and qualification evaluation conducted by the relevant authorities before performing electrical operations.
Page 25 Operation & Maintenance Instruction 3 Commissioning Step 1 Preparations: Connect the power cords and communication cables between the BESS cabinet and the PCS cabinet. PCS cabinet: Rotate the handle of load switches of each PCS to "ON" in sequence, and ensure that the emergency stop button on the cabinet is in reset status.
Page 26: Pre-Run Preparation
3 Commissioning Operation & Maintenance Instruction If the circuit breaker is de-energized during power-up, pause to close the other circuit breakers and immediately check the lower load of the de-energized circuit breaker for short circuits, etc. • Auxiliary power supply supplies power to devices such as switches, LCs, and fans.
Page 27: Start-Stop Function Debugging
Enter your username and password. Click Login. The system has two user roles operator and admin. User passwords need to be obtained by contacting Sungrow. In the upper right corner of the interface, select the desired language. Step 2 Click the Start button on the LC main interface and observe whether the power, voltage,...
Page 28: Charge/Discharge Cycle Commissioning
3 Commissioning Operation & Maintenance Instruction Step 3 Click “Param settings→Running parameters→Mode settings” to gradually add power to full power operation. The discharge power of 10kW is given first. Click “Running info→PCS info” to view the current system power value of the PCS. Step 4 Repeat the operation in step 3, and the grid power is given as 50kW, -10kW, -50kW, respectively, and check whether the PCS power is the set value.
Page 29 Operation & Maintenance Instruction 3 Commissioning Step 4 Observe whether there is a large deviation in the cell voltage difference, temperature difference and SOC of the RACK. - - End...
Page 30: Routine Maintenance
Precautions Before Maintenance • Do not open the door to maintain the device in rainy, humid or windy days. SUNGROW shall not be held liable for any damage caused by violation of the warning. • Avoid opening the container door when the humidity is high in rain, snow or fog, and make sure that the seals around the container door do not curl when the door is closed.
Page 31: Maintenance (Every Half A Year)
Operation & Maintenance Instruction 4 Routine Maintenance 4.2.1 Maintenance (Every half a year) table 4-1 BESS Inspection Item Inspection Method • Clean the foundation (using a broom/vacuum). System status • Check the cabinet air intake filter for dust and dirt and clean it if and cleaning necessary.
Page 32 4 Routine Maintenance Operation & Maintenance Instruction table 4-2 PCS Inspection Item Inspection Method • Clean the foundation (using a broom/vacuum). System status • Check the cabinet air intake filter for dust and dirt and clean it if and cleaning necessary.
Page 33: Maintenance (Once A Year)
Operation & Maintenance Instruction 4 Routine Maintenance 4.2.2 Maintenance (Once a year) table 4-3 BESS Inspection Item Inspection Method • Check if there are any flammable objects around the cabinet. • Check if the welding points between the cabinet and the foundation steel plate are firm and whether there is rust.
Page 34 4 Routine Maintenance Operation & Maintenance Instruction Inspection Item Inspection Method Check if the lightning protection devices and fuses are intact and Components operational. Replace damaged lightning protection devices and fuses in time. • Perform a visual inspection of the detector. Is the device in good cosmetic condition, with no breakage, or crushed by peripheral equipment.
Page 35 Operation & Maintenance Instruction 4 Routine Maintenance table 4-4 PCS Inspection Item Inspection Method • Check if there are any flammable objects around the cabinet. • Check if the welding points between the cabinet and the foundation steel plate are firm and whether there is rust. •...
Page 36: Maintenance (Every Two Years)
4 Routine Maintenance Operation & Maintenance Instruction 4.2.3 Maintenance (Every two years) table 4-5 BESS Item Check method • Check if there is any damage or deformation to the equipment in the cabinet. • Check if there is any unusual noise from internal equipment System during operation.
Page 37 Operation & Maintenance Instruction 4 Routine Maintenance Name Source Cleaning cloth Water Not included in the scope of supply Alcohol or other non-corrosive detergent Wet the cleaning cloth (or other scrubbing tools) with water, and scrub the dirty parts on surface.
Page 38: Checking Door Locks And Hinges
4 Routine Maintenance Operation & Maintenance Instruction Name Source Abrasive paper Cleaning cloth Water Not included in the scope of supply Alcohol Zinc primer Brush Paint Polish the damaged parts with an abrasive paper to remove rust and other burrs for a smooth surface.
Page 39 “Total under voltage alarm”. End users must assign a high priority to above listed faults and alarms reported by the Sungrow local controller. When an alarm or fault is triggered, the user interface should prominently highlight these issues. Furthermore, end users should promptly contact Sungrow for timely resolution to prevent battery warranty loss due to over-discharge or overcharge.
Page 40 In order to avoid triggering the warranty expiration condition, when the “Cell Under-voltage Fault” or “Cell Over-voltage Fault” is triggered, the user must contact the local team of Sungrow within 24 hours and follow the requirements of Sungrow to carry out the next operation.
Page 41 Operation & Maintenance Instruction 4 Routine Maintenance Maintenance performed once every two years Inspection item Inspection method Check the following items. In case of nonconformity, take corrective actions immediately: • Check the battery cluster and internal devices for damage or deformation. •...
Page 42 4 Routine Maintenance Operation & Maintenance Instruction Maintenance performed once a year Inspection item Inspection method Check the following items. In case of nonconformity, take corrective actions immediately: • Check whether there are flammable objects at the top of the battery cluster. •...
Page 43: Maintenance Precautions
In case of any doubt on operation and maintenance of this product, contact the Customer Service Center of SUNGROW instead of operation without permission. 4.4.3 Maintenance Operating temperature: The working temperature should be kept between -30℃–50℃.
Page 44 4 Routine Maintenance Operation & Maintenance Instruction The RACK should not be charged or discharged with high magnifying power. The continuous charging and discharging current of a single rack should not exceed the rated current. When the energy storage system is not used in a long time, it should be charged once every six months, until its SOC is 30%–40%.
Page 45: Maintenance Of Liquid Cooling System
Operation & Maintenance Instruction 4 Routine Maintenance Maintenance of Liquid Cooling System The following provides the recommended maintenance periods. The actual maintenance period shall be adjusted reasonably in consideration of the specific installation environment of the product. Factors like the power plant scale, the location, and the site environment can affect the maintenance period of the product.
Page 46 4 Routine Maintenance Operation & Maintenance Instruction If the BESS has a "communication failure or failure of the liquid-cooled unit", please contact the after-sales service personnel in time to ensure the functional integrity of the system.
Page 47: Common Maintenance Operations
Common Maintenance Operations Safety Instructions • Do not install or remove power cord with power on. Turn off the power switch before installing and removing the power cord. • Perform the maintenance only after the power is off and do not switch on the power during operation.
Page 48: Coolant Filling And Drainage Operations
5 Common Maintenance Operations Operation & Maintenance Instruction • Operators should have certain expertise on electronics, electrical wiring, and mechanics and be familiar with electrical and mechanical schematics. And they should be familiar with the composition and working principle of ESS and its front-end and back-end devices.
Page 49 Operation & Maintenance Instruction 5 Common Maintenance Operations Battery energy storage system - Battery cabin The battery compartment contains 2 columns of battery Rack, the key components of the battery compartment piping are shown in the figure below, the left side of each column is the inlet pipe, the right side is the outlet pipe, the inlet and outlet pipes are integrated with ball valves and exhaust valves;...
Page 50 5 Common Maintenance Operations Operation & Maintenance Instruction figure 5-4 Switch gear panel *The above pictures are for reference only, please refer to the actual object received! Power converter system - Electric cabin The left side of the power converter system is the electrical compartment, and the location of the devices directly related to the power supply of the liquid-cooled unit is shown in the figure below.
Page 51: Coolant Change Intervals
2. The coolant color is Note: Please contact 5–6 years Coolant significantly darker; 3. Sungrow Customer Service The coolant PH value to replace hardware is below 7.3. facilities Operating instructions for coolant PH testing Step 1 A shutdown command is given using the LC software and the system is shut down.
Page 52: Safety Precautions
5 Common Maintenance Operations Operation & Maintenance Instruction 5.2.3 Safety Precautions Normally coolant is not a health hazard, excessive exposure may cause irritation to the eyes, skin and breathing. Personal protection Wear personal protective equipment (PPE) when changing coolant. PPE should comply with relevant national standards, including but not limited to the following protective equipment.
Page 53 Operation & Maintenance Instruction 5 Common Maintenance Operations Disposal considerations Waste types Disposal measures Discharges are made in accordance with local regulations and Coolant are not disposed of haphazardly. Separate and recycle, and if it meets the relevant regulations, it Rubbish remnant can be burned or reused.
Page 54: Tooling Introduction
5 Common Maintenance Operations Operation & Maintenance Instruction Contact method Measures Flush eyes with plenty of water for at least 15 minutes. Seek medical Eyes contact attention. If ingested, but conscious, water or milk to drink and actively seek medical help, do not induce vomiting unless instructed by healthcare Ingestion patients.
Page 55: System Drainage
Operation & Maintenance Instruction 5 Common Maintenance Operations table 5-1 Technical Parameters of Filling-draining Kit Parameter Name Parameter Value Dimensions 270mm*300mm*300mm Weight ≤10kg Voltage range 100V~250V 50/60Hz Load Current ≤4A Power ≤96W Flow Rate 12L/min Headlift 2.5Bar Non-return function, line storage compartment can be Other Functions stored at the same time the pipeline supporting the drain tube.
Page 56 5 Common Maintenance Operations Operation & Maintenance Instruction Step 4 Remove the line drain plug by squeezing the ends of the drain plug catch. Remove the drain port D1 plug if you need to drain coolant from the left battery cluster, and remove the drain port D2 plug if you need to drain coolant from the right battery cluster.
Page 57: System Drainage
Operation & Maintenance Instruction 5 Common Maintenance Operations Step 6 Open the ball valve V7 of the fluid injection and discharge workpiece discharge pipe. Step 7 Open the liquid injection and discharge device discharge valve, at this time there is coolant outflow.
Page 58 5 Common Maintenance Operations Operation & Maintenance Instruction Step 2 Prepare a coolant storage bucket by removing the suction hose from the fill and drain tool line storage compartment and plugging it into the bucket. Step 3 Drain the liquid from the two battery clusters separately by opening the ball valves V3, V4, V5, and V6 of the liquid-cooled piping in the battery compartment.
Page 59 Operation & Maintenance Instruction 5 Common Maintenance Operations Step 5 Remove the drain tube from the injection and drain tooling line storage compartment, insert the quick-connect fitting into the system drain port, and push the snap of the quick-connect fitting into place. Step 6 Open the ball valve V7 of the fluid injection and discharge workpiece discharge pipe.
Page 60: System Refilling
5 Common Maintenance Operations Operation & Maintenance Instruction - - End 5.2.6 System Refilling Step 1 Check the ball valves V1 and V2 of the expansion tank in the liquid-cooled unit to ensure they are in the open position. Step 2 Inspect the ball valves V3 to V6 of the battery clusters to ensure they are fully open. Step 3 Check the automatic exhaust valves to ensure the exhaust valve is in the open position (the valve knob being loose indicates the open state).
Page 61 Operation & Maintenance Instruction 5 Common Maintenance Operations Step 7 Open the valve at the filling port of the liquid-cooled unit and open the ball valve V7 on the filling pipe of the filling and draining tooling. Step 8 Close the drain valve on the filling and draining tooling. Step 9 Disconnect the communication connector of the liquid-cooled unit and connect the external screen (optional) to the corresponding interface of the liquid-cooled unit.
Page 62 5 Common Maintenance Operations Operation & Maintenance Instruction Step 10 Connect the power plug of the filling and draining tooling to the customer's power supply interface. After powering on, the power indicator light of the filling and draining tooling will illuminate.
Page 63 Operation & Maintenance Instruction 5 Common Maintenance Operations Step 18 High-speed operation for 20min, if leakage is found, the system needs to be drained and pipeline inspection or replacement, can not be inserted and removed with pressure pipeline, re-fill operation; if no leakage occurs, high-speed operation leakage check through, the next step.
Page 64: Battery Module Replacement
5 Common Maintenance Operations Operation & Maintenance Instruction Step 25 Push out the snap of the filler tube quick-connect fitting and pinch the quick-connect fitting to pull it out. Step 26 Unplug the power supply from the injection and drainage unit and the computer network cable socket, and store the piping and power cable in the corresponding storage compartments of the unit.
Page 65: Transport Tooling
Operation & Maintenance Instruction 5 Common Maintenance Operations *The figure is for reference only. The actual tooling may be different. The technical data of the maintenance tooling are listed in the table below. table 5-2 Technical Data of Maintenance Tooling Description Description Parameter...
Page 66: Other Tools
5 Common Maintenance Operations Operation & Maintenance Instruction figure 5-8 Transport Tooling *The figure is for reference only. The actual tooling may be different. The height of the PACK must not exceed the height of the ground by 1.5 m to prevent the risk of falling.
Page 67 Operation & Maintenance Instruction 5 Common Maintenance Operations Description Tools • A 5t forklift that runs on oil is recommended; • For dirt and gravel roads that are prone to collapsing, it is recommended that off-road tire forklifts or pre-paved steel plates be used based on an assessment of the strength of the road surface to prevent the tires from sinking into the road surface,...
Page 68 5 Common Maintenance Operations Operation & Maintenance Instruction Description Tools • M8*70 eye bolt（4pcs）; • Included maintenance tooling configuration. Eye bolt Screwdriver An electric M8 socket is recommended (torque adjustable). M8 socket It is recommended to use an allen wrench set. Allen wrench *The figures are for illustration only.
Page 69: Replace Pack
The maintenance work must only be performed by qualified engineers, Please comply with the requirements in “Safety Precautions” in this manual. SUNGROW shall not be held liable for any personal injury or property damage arising from failure to follow the safety instructions.
Page 70: Site Requirements
5 Common Maintenance Operations Operation & Maintenance Instruction 5.3.2.2 Site Requirements • Cables should be pre-buried below the ground surface with cable trench covers with a bearing capacity of not less than 50kN. • The upper surface of the cable trench cover should be at the same height as the ground to ensure ease of passage for forklifts.
Page 71 Operation & Maintenance Instruction 5 Common Maintenance Operations 5.3.2.3.1 System Drainage The system needs to be drained before replacing the PACK, refer to "5.2.5 System Drainage" for the procedure.
Page 72 5 Common Maintenance Operations Operation & Maintenance Instruction 5.3.2.3.2 System Power-off Step 1 Power-down preparations: Stop the system through the software, and disconnect the battery relay (In emergencies, press the emergency stop button on the cabinet). Step 2 Power down the PCS cabinet. Disconnect the DC device power switch Q5(DC POWER).
Page 73 Operation & Maintenance Instruction 5 Common Maintenance Operations 5.3.2.3.3 Open Cabinet Door Step 1 Open the cabinet door. Toggle the protective cover on the handle clockwise to expose the keyhole. Insert the door key and turn it clockwise. Rotate the handle counterclockwise to open the front door. Step 2 Open the door to the full, at an angle of 120°.
Page 74 5 Common Maintenance Operations Operation & Maintenance Instruction 5.3.2.3.4 Pull Out the Liquid Cooling Line Step 1 Pull out the liquid-cooling line of the PACK to be maintained and move the line to the inside of the rail to prevent the PACK from interfering with the push-pull process. figure 5-9 Liquid Cooling Piping Schematic *Pictures are for reference only, please refer to the real thing! - - End...
Page 75 Operation & Maintenance Instruction 5 Common Maintenance Operations 5.3.2.3.5 Remove Cables The locations of the power and communication cables on the PACK are shown below. *Pictures are for reference only, please refer to the real thing! After unplugging the power cables and communication cables, they need to be kept in a safe place for backup.
Page 76 5 Common Maintenance Operations Operation & Maintenance Instruction 5.3.2.3.6 Remove Fuses If the PACK to be maintained is located on layers 3 and 4, the intercluster fuses need to be removed. Intercluster fuse locations are shown below. figure 5-10 Fuse location *Pictures are for reference only, please refer to the real thing! After removing the fuse, it needs to be kept in good condition for spare parts.
Page 77: Tooling Setup
Operation & Maintenance Instruction 5 Common Maintenance Operations 5.3.2.3.7 Remove PACK Fixing Corners Step 1 Use an M8 socket to remove the M8 screws at the PACK corner pieces. figure 5-12 M8 screw position schematic *Pictures are for reference only, please refer to the real thing! Step 2 Remove the PACK retaining corner pieces and keep them for safekeeping.
Page 78: Tooling Adjustment
5 Common Maintenance Operations Operation & Maintenance Instruction Step 1 The platform is lifted and transported to land in front of the hatch. The platform surface is spaced 5~10cm from the container, as shown in the following figure. The platform rails are centered with the container door within 10cm of the bilateral deviation, as shown in the figure below.
Page 79 Operation & Maintenance Instruction 5 Common Maintenance Operations Step 1 Platform leveling adjustment (support feet). The weight of the product is about 500kg and the weight of the battery pack is about 400kg. If the ground is not sufficiently dense (insufficient support), it is necessary to place steel plates/ sleepers and other accessories under the support feet in advance.
Page 80 5 Common Maintenance Operations Operation & Maintenance Instruction ii. The platform surface is high on the left and low on the right, lowering the height of the left 1 foot or raising the height of the right 1 foot. iii. The platform is high in the front and low in the back, lowering the height of Left 1, Right 1 and raising the height of Left 2, Right 2.
Page 81 Operation & Maintenance Instruction 5 Common Maintenance Operations Step 2 The platform is highly elevated. Foot lifting, the platform surface is lower than the battery pack to be replaced by 1~3cm (- recommended), 1cm is suitable. - - End...
Page 82: Pack Mounting
5 Common Maintenance Operations Operation & Maintenance Instruction 5.3.4 PACK Mounting 5.3.4.1 Remove Old PACK Step 1 Pull out the PACK action. Connect the T-bar to the battery pack. Turn the steering wheel to pull out the battery pack. When the battery pack extends out of the container door frame, observe the bottom of the battery pack on the side to see if the relative height of the battery pack to the platform surface is appropriate.
Page 83 Operation & Maintenance Instruction 5 Common Maintenance Operations A status is as follows: need to lower the left 2 feet, right 2 feet height. B state is as follows: need to raise the left 2 feet, right 2 feet height. •...
Page 84: Mount New Pack
5 Common Maintenance Operations Operation & Maintenance Instruction 5.3.4.2 Mount New PACK Step 1 Status Confirmation: After the new PACK is dropped to the platform surface, observe whether the PACK is aligned with the container, which can be confirmed by the guide block at the end of the PACK.
Page 85: Follow-Up Work
Operation & Maintenance Instruction 5 Common Maintenance Operations Step 2 Platform surface adjustment: Platform flatness change and demand when pushing in is opposite to pulling out. The initial state is that the platform surface is higher than the corresponding guide rail by 1cm (recommended), the initial platform surface is recommended as shown in the figure below (lifting the left 1 foot, right 1 foot height).
Page 86 5 Common Maintenance Operations Operation & Maintenance Instruction figure 5-14 Positions of Fuses *The figure is for reference only. Step 1 Fit the M6 screws on the fuse, but do not tighten them now. figure 5-15 Fuse mounting holes Step 2 Insert the plugs that come with the fuse into the PACK bases properly. When the aviation plug is connected in place, you will hear a "click".
Page 87: Connect Cables
Operation & Maintenance Instruction 5 Common Maintenance Operations 5.3.5.3 Connect Cables Step 1 Connect the power cables between the PACKs. *Pictures are for reference only, please refer to the real thing! When the aviation plug is connected in place, you will hear a "click". Please make sure the connection is secure.
Page 88: System Power-On
5 Common Maintenance Operations Operation & Maintenance Instruction Step 2 Insert liquid-cooled line quick-connect fittings. figure 5-16 Liquid Cooling Lines Schematic *Pictures are for reference only, please refer to the real thing! - - End 5.3.5.5 System Power-on After the PACK replacement operation is complete, perform a system power-up. Preparation: Before powering up, it is necessary to carry out a comprehensive and detailed inspection of the equipment to ensure that all indicators are in line with the requirements before powering up.
Page 89 Operation & Maintenance Instruction 5 Common Maintenance Operations Step 2 Remove the P+/P- AC cable plug from the switch gear panel. figure 5-17 AC cable schematic *The above pictures are for reference only, please refer to the actual object received! Step 3 Remove the DC cable airline plug from the switch gear panel.
Page 90 5 Common Maintenance Operations Operation & Maintenance Instruction Step 5 Remove the network cables from the network port. figure 5-20 Network port schematic *The above pictures are for reference only, please refer to the actual object received! Step 6 Remove the CONN1~CONN3 terminal wiring from the front of the distribution box panel. figure 5-21 CONN1~CONN3 terminal schematic *The above pictures are for reference only, please refer to the actual object received! Step 7 Remove the fixing corners at both ends of the switch gear.
Page 91: Replace Liquid-Cooled Unit
Operation & Maintenance Instruction 5 Common Maintenance Operations Step 11 Push the switch gear into place by lifting the end of the switch gear and resting on the switch gear rail. Step 12 Install the screws for fixing the corner pieces at both ends of the switch gear with a torque of 7.5±0.5N·m.
Page 92: Bmu Replacement
5 Common Maintenance Operations Operation & Maintenance Instruction Step 11 Restore all wiring to the liquid-cooled unit. - - End BMU Replacement Step 1 Removing the front cover of the PACK: Remove the 8 bolts from the front cover using the special tools and store the removed cover and bolts properly.
Page 93: Fuse Replacement
Operation & Maintenance Instruction 5 Common Maintenance Operations Fuse Replacement Step 1 Removing the connection plugs: unlock the plugs and remove the plugs from the ends of the fuse that are connected to the pack. Step 2 Remove the two fixing bolts from the fuse. Step 3 After replacing the faulty fuse, reinstall the fuse in the reverse order of the above and plug in the connection to the battery pack tightly.
Page 94: Troubleshooting
Troubleshooting Overview When an abnormal change occurs in the ESS, it is recommended that preliminary troubleshooting be performed first through the troubleshooting. If problems cannot be resolved according to this manual, please contact us. We need the following information in order to provide you with better assistance. •...
Page 95 Operation & Maintenance Instruction 6 Troubleshooting Fault Fault condition Treatment Caveat name Generally the machine will re- connect to the grid after the DC voltage returns to normal, if Bus voltage less The DC voltage is 5V the fault recurs: than the set value or less than the peak above the DC...
Page 96 SUNGROW. The machine will HVRT off, the grid normally be re- voltage is higher than connected to the grid • Grid voltage the first ~ fifth level of...
Page 97 SUNGROW. the same as that of grid-connected. The machines are usually reconnected to the grid when the grid frequency returns to normal. The grid frequency is Observe •...
Page 98 SUNGROW. Wait for the PCS to Follow the steps of AC Wait 3 minutes to force return to normal, if the side relay self-test to recovery. Maximum of...
Page 99 LVRT. fault persists, contact SUNGROW. Check to see if the battery pack is in Static leakage rainy, current greater weather; if it is, than the set value (- there is no need default 300mA) and for concern.
Page 100 Wait 3 minutes to force treatment, if the fault overcurre- 1.5 times rated for recovery. occurs repeatedly, 200ms. please contact SUNGROW. Usually it will recover Inverter unit phase automatically without current peaks exceeding Wait 3 minutes to force treatment, if the fault overcurre- 1.6 times rated current...
Page 101 Confirm that the cause is not one of the above and that fault persists, contact SUNGROW. Usually it will recover Hardware overcurrent (- automatically without including AC, DC, and Wait 3 minutes to force Hardware treatment, if the fault overcurrent) and DC recovery.
Page 102 Confirm that it is above reasons and the fault still exists, please contact SUNGROW. Check lightning arrester loose After protection, if the damaged, if it is AC lightning protector AC surge damaged, replace feedback IO level is...
Page 103 Operation & Maintenance Instruction 6 Troubleshooting Fault Fault condition Treatment Caveat name please contact SUNGROW. Restart the PCS. The bias value of the Check for loose channel sample internal exceeds Cannot be cleared connections theoretical reference current sensor automatically, need to Analog value by 15%.
Page 104 Bus voltage the fault persists, voltage and the Bus failure is greater than 40V for contact SUNGROW. voltage is less than 120s before closing the 30V. DC contactor. Generally the machine will re- connect to the grid...
Page 105 If currently in high, delay 10s to above other state, and clear the fault. fault persists, battery voltage contact greater SUNGROW. than 200V, protect after another 5min delay. Check to see if the actual ambient temperature is too high.
Page 106 SUNGROW. This is an alarm to check if the setup parameters satisfied. In PQ operation mode, Check whether The DC voltage is less the actual battery the DC voltage is greater...
Page 107: Battery Fault Diagnosis
Confirm that it is voltage. above reason alarm still exists, please contact SUNGROW. Check the fan. Please turn off the machine, Running mode fan drive disconnect the power pulse duty cycle is abnormal- supply to eliminate Fan speed is not zero.
Page 108 6 Troubleshooting Operation & Maintenance Instruction Trigger Handling Method Fault Name 1. Check whether the BSC parameters The total voltage of are set correctly. Total over PACK continuously 2. Check the cell voltage for exception. voltage fault exceeds the set fault 3.
Page 109 Operation & Maintenance Instruction 6 Troubleshooting Trigger Handling Method Fault Name 1. Check whether the BSC parameters The current continuously are set correctly. Over current fault exceeds the set fault 2. Check whether the power cable of the threshold. system is properly connected. 1.
Page 110 6 Troubleshooting Operation & Maintenance Instruction Trigger Handling Method Fault Name The difference between the cumulative total 1. Troubleshoot other system faults such voltage and the sample as communication fault and voltage total voltage exceeds the Total voltage sampling fault. set fault threshold, or difference fault there is an exception in...
Page 111 The difference between 2. Check for cell imbalance (refer to the max cell voltage and Sungrow Maintenance Manual for Cell voltage the min cell voltage imbalance). difference alarm collected from the RACK continuously exceeds the 3.
Page 112 6 Troubleshooting Operation & Maintenance Instruction Trigger Handling Method Fault Name The difference between 1. Check the PACK cells for over- the highest PACK discharge and over-charge. Pack voltage voltage and the lowest difference alarm PACK voltage 2. Check BMU for exception (replace it if continuously exceeds the so).
Page 113: Bsc Troubleshooting
*If the fault persists after the above operations, contact Sungrow. BSC Troubleshooting Login LC Web, click “Operation Information→BSC Information” to view Fault Status or...
Page 114 6 Troubleshooting Operation & Maintenance Instruction Troubleshooting advice Name Reason The node input signal is • Check for loose node feedback signal different from the default Node 1-Node wires. configuration signal (- 16 failure • Check whether the node feedback configuration item).
Page 115: Lc Troubleshooting
• Check for missing refrigerant under manufacturer's guidance. *If the above does not solve the problem, please contact SUNGROW. LC Troubleshooting Login LC Web, click on the interface to view the fault alarm information.
Page 116 6 Troubleshooting Operation & Maintenance Instruction Troubleshooting advice Name Reason • Is Q2 disconnected in the PCS cabinet. UPS utility • Whether the battery compartment Q2 is UPS power loss disconnected, if Q2 is not disconnected disconnect power normal, check whether the UPS failure.
Page 117 Operation & Maintenance Instruction 6 Troubleshooting Troubleshooting advice Name Reason • Immediately shut down the faulty system and disconnect its external power supply. Status node 1# Surge • Check for failure of AC lightning disconnected or device protector failure protector FL1. failed •...
Page 118 High differential system and disconnect its external High battery differential pressure failure power supply. pressure in CMU branch • View the system voltage through the circuit CMU information screen. *If the above does not solve the problem, please contact SUNGROW.
Page 119: Appendix
State Of Charge Switch Gear Quality Assurance When product faults occur during the warranty period, SUNGROW will provide free service or replace the product with a new one. Evidence During the warranty period, the customer shall provide the product purchase invoice and date.
Page 120: Contact Information
7 Appendix Operation & Maintenance Instruction Exclusion of Liability In the following circumstances, SUNGROW has the right to refuse to honor the quality guarantee: • The free warranty period for the whole machine/components has expired. • The device is damaged during transport.
Page 121 Sungrow Power Supply Co., Ltd. www.sungrowpower.com...

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Powerstack-st570kwh-250kw-2h