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Summary of Contents for DISCOVER AES 210HV
- Page 1 O V E D I S C T E M S Y S R G Y E N E AES 210HV INSTALLATION AND COMMISSIONING MANUAL BATTERY MODEL AES 210HV 805-0092 REV A...
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Page 2: Table Of Contents
AES 210HV Decommisioning Checklist ........ -
Page 3: Guide For Ul9540-Compliant Installations
GUIDE FOR UL9540-COMPLIANT INSTALLATIONS AES 210HV Description Unit Model Number SLL02C2-D1P52S1R8-A01 Maximum capacity per unit 212 kWh Maximum number of battery packs per unit Minimum separation from other ESS (sides) No minimum Minimum separation from other ESS (front 900 mm (35 . 4 3 in) -
Page 4: Introduction
Introduction The AES 210HV is a four-pack battery cabinet with a nominal output of 665 Vdc . It is a liquid-cooled, outdoor energy storage system designed for seamless integration with C&I inverters . Key features include a multi-level BMS, advanced Thermal Management System (TMS), rugged enclosure, fire detection and suppression, explosion control, and thermal runaway mitigation . Paralleling C&I hybrid inverters with AES 210HV energy storage cabinets expands power and energy capacity for both grid-connected and off-grid applications . -
Page 5: Symbols
CAUTION Important information regarding hazardous conditions that may result in personal injury. NOTICE Important information regarding conditions that may damage the equipment but not result in personal injury. NOTE Ad hoc information concerning important procedures and features unrelated to personal injury or equipment damage. 1.3 Symbols Symbol Description Symbol Description Earth Ground Electrical Hazard Explosion Hazard Warning Fire Hazard Refer to the manual 1.4 General Warnings... -
Page 6: Electric Shock Hazard
WARNING ELECTRIC SHOCK AND FIRE HAZARD • The AES 210HV energy storage solution is compatible exclusively with approved inverters . Detailed integration guides are available for supported PCS devices . • Using this product with incompatible inverters may pose safety risks and result in hazardous conditions . -
Page 7: Safe Handling Procedures
1.5 Safe Handling Procedures Before using the battery, thoroughly read all instructions, safety warnings, and cautionary markings on the unit, as well as all relevant sections of this manual . • Preparation Before Use ͬ Read all instructions and cautionary markings . ͬ... -
Page 8: Emergency Procedure
Power Conversion System Compatibility - Review & Approval If an integration guide for the desired Power Conversion System (PCS) is not available, contact Discover Energy Systems to discuss a potential review and approval process . This ensures proper compatibility, safe operation, and reliable system performance . -
Page 9: Lockout Tag-Out Procedures
1.7 Lockout Tag-out Procedures Figure 1. Designated Lockout Points and the Components Disconnected Figure 2. AES 210HV Lock Out and Tag Out 1. Prepare for Shutdown ͬ Notify all affected personnel of the intended shutdown of the battery cabinet . - Page 10 3. Isolate Energy Sources ͬ To fully isolate the battery cabinet from all sources, disconnect or turn off all energy sources, such as AC disconnects (VLD), AC breakers, and DC disconnect switches . Remove the battery pack Manual Service Disconnect (MSD) from each battery pack to completely isolate the batteries .
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Page 11: Items Shipped In The Box
ITEMS SHIPPED IN THE BOX Upon receiving the shipment, ensure that the following items are included . If any item is missing or damaged, contact customer support immediately . Table 2-1, AES 210HV Accessories Box Contents Description Quantity AC Auxiliary Power Cable Inverter DC+ Power Cable (pre-wired to DC Distributor) 1/0 AWG (50 mm²) -
Page 12: Specifications
SPECIFICATIONS All specifications in this document are published @25ºC / 77ºF. Where appropriate ratings are based on C/4 Charge or Discharge rates . 3.1 Electrical Specifications Table 3-1, AES 210HV Cabinet Electrical Specifications Electrical Specifications AES 210HV Chemistry LiFePO (LFP) Nominal Voltage 665 . 6 V Cabinet Battery Pack Configuration 4 Packs Nominal Energy... -
Page 13: Mechanical Specifications
Table 3-2, AES 210HV Battery Pack Electrical Specifications Electrical Specifications AES 210HV / SLL02C2-D1P52S1R8-A01 Pack model PLL02C2-D1P52S-A01 Cell model GSP71173204F, 3 . 2 V 320Ah Series and parallel 1P2S Nominal capacity (STC) 320 Ah Nominal Energy 53 . 2 5 kWh Nominal Voltage 166 . -
Page 14: Clearance Specifications
Figure 3. AES 210HV Battery Dimensions 3.3 Clearance Specifications Figure 4. AES 210HV Battery Cabinet Clearance NOTE Clearance dimensions are published for airflow and service access only. Consult with the local Authority Having Jurisdiction for accepted spacing and separation or other requirements applicable for the area of installation. -
Page 15: Environmental Specifications
The AES 210HV cabinets may be placed side by side as long as the front and back airflow and service access spacings are adhered to . Consult with the local Authority-Having- Jurisdiction for accepted spacing and separation or other requirements applicable for the area of installation . 3.4 Environmental Specifications Table 3-4, AES 210HV Environmental Specifications Environmental Specifications AES 210HV Environmental Category Outdoor (IP55 / NEMA 3R) Rated Altitude An altitude of up to 2,000 m (6,561 ft) . -
Page 16: Protection Specifications
3.5 Protection Specifications Table 3-5, AES 210HV Protection Specifications Protection AES 210HV Specifications Cell Overvoltage ≥ 3.55 V for 5 s: Charging is derated . Discharging is allowed . Level 1 Consequence: Charging is reduced to avoid overvoltage. ≥ 3.60 V for 5 s: Charging is stopped, Discharging is allowed . - Page 17 Protection AES 210HV Specifications ≥ 189.8 V for 3 s: System shuts down. A manual restart is required. Level 3 Consequence: Total system shutdown to protect against damage from overvoltage-related failure . Battery Pack Undervoltage ≤ 150.8 V for 5 s: Discharging is derated . Charging is allowed . Level 1 Consequence: Discharging is reduced to avoid undervoltage. ≤ 145.6 V for 5 s: Discharging is stopped . Charging is allowed .
- Page 18 Protection AES 210HV Specifications Low Insulation Resistance ≤ 1000 kΩ for 2 s: Charging and discharging are derated . Level 1 Consequence: Charging and discharging are derated to avoid issues from reduced insulation resistance . ≤ 500 kΩ for 2 s: Charging and discharging is stopped .
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Page 19: Thermal Management System Specifications
Level 3 Alarm: This will trigger a system shutdown and maintenance alarm . To restore operation, identify and address the root cause of the alarm, then perform a manual restart . 3.6 Thermal Management System Specifications Table 3-6, AES 210HV TMS Specifications Specifications AES 210HV... -
Page 20: Regulatory
Upon receiving the shipment, inspect the battery cabinet for any damage during transit . Take photos to document a claim . ͬ Report damage claims immediately to the carrier and to Discover Energy Systems . Include the product serial number and carrier details . • Transport Conditions ͬ... -
Page 21: Handling
NOTE CABINET BASE DAMAGE When being moved by a forklift, the AES 210HV must remain on its shipping pallet . The cable raceways at the base of the cabinet are not designed to support forklift handling . Failure to follow these instructions may result in equipment damage. -
Page 22: Overhead Hoisting
Forklift Handling • The cabinet must remain on its shipping pallet for forklift transport . • The battery weighs 2,500 kg (5,511 lb) . Use a heavy-duty forklift with a minimum lifting capacity of 3,000 kg (6,600 lb) and forks at least 1,300 mm (52 in) in length . •... - Page 23 Figure 8. AES 210HV Overhead Hoisting Overhead Hoisting Lifting Preparation • Securely fasten all four lifting lugs into the designated holes at the top of the cabinet . • The diameter of the lifting lug hole is 51 mm (2 in) .
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Page 24: System Overview
6. SYSTEM OVERVIEW Figure 9. AES 210HV System, Front Doors Open Figure 10. AES 210HV, Doors Closed Name Description Audible and Visual In the event of a fire hazard, the battery cabinet activates Fire Alarms the thermal suppression device and sounds an alarm . For more information, see 6 . 4 Thermal Suppression System . - Page 25 Name Description Passive Deflagration Explosion control vents relieve pressure during thermal Vent events by venting gases, which helps minimize the risk of explosion . Thermal The TMS manages heating and cooling for the battery Management System cabinet . For information, see Section 6 .
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Page 26: Cabinet Indicator Lights
6.1 Cabinet Indicator Lights Indicator Light Status Description Green Light (Blinking) Standby (UPS Active / This indicates that the UPS is active or that Receiving AC Power) the cabinet is receiving AC input power . The battery cabinet is in standby mode . There is no output power (contactors are open) . -
Page 27: High Voltage Box (Hvb)
6.2 High Voltage Box (HVB) Figure 11. AES 210HV - High Voltage Box Name Description Battery Pack Negative (-) Input Battery Pack Positive (+) Input AC Auxiliary Supply to Thermal Management Unit Thermal Management Communication Port Inter-battery Communication Port for the First Battery... -
Page 28: Uninterruptible Power Supply (Ups)
The internal UPS battery provides a 24 V supply to the sensors and control system . The AES 210HV system’s Uninterruptible Power Supply (UPS) is designed for Black Start scenarios and redundant control without AC input . The UPS provides power to critical components when no AC auxiliary input is available . -
Page 29: Battery Pack
6.3 Battery Pack Figure 13. AES 210HV Battery Pack Name Description Battery Pack Coolant Connects the battery pack to the Thermal Management Inlet/Outlet System, facilitating the flow of coolant for temperature regulation . Battery Pack Pressure If a thermal event occurs inside the battery pack, the Relief Valve valve indicator will pop forward and release the internal aerogel to suppress a thermal runaway event . -
Page 30: Thermal Management System
6.4 Thermal Management System Figure 14. AES 210HV Thermal Management System Name Description Inlet / Outlet Connects to the cooling system for circulation of liquid coolant through the TMS system . Air Intake Facilitates air intake for the cooling mechanism of the TMS . Debug/Service Port Used for diagnostics, testing, and software updates . -
Page 31: Cooling Mode
6.4.1 Cooling Mode Figure 15. Cooling Power Consumption When battery temperatures exceed the preset threshold, the Thermal Management System (TMS) initiates the cooling cycle. Liquid coolant flows through the battery pack’s cooling plates, absorbing excess heat before being directed to an evaporator . There, heat is transferred to a refrigerant, rapidly cooling the fluid before it recirculates through the system. Three high-efficiency fans at the rear of the TMS expel the extracted heat from the cabinet, ensuring effective thermal regulation and preventing overheating . Cooling activates when the system-wide temperature reaches ≥ 30°C (86°F) or any battery pack exceeds 32°C (89 . -
Page 32: Ess Protection - Mitigation, Detection, Suppression, Control
Heating activates during discharge if the system-wide temperature is ≤ -5°C (23°F) or any battery pack is ≤ -10°C (14°F), and during charging if the system-wide temperature is ≤ 10°C (14°F) or any pack is ≤ 5°C (41°F). Heating turns off when the system-wide temperature is ≥ 25°C (77°F) and all individual packs are at least 20°C (68°F), ensuring uniform thermal conditions . The TMS controls PTC heaters, maintaining a target coolant temperature of 30°C (86°F), and limits charging/discharging until safe operating temperatures are restored . 6.5 ESS Protection - Mitigation, Detection, Suppression, Control Figure 17. Fire Protection System Components The AES 210HV battery cabinet is equipped with a comprehensive thermal runaway mitigation and fire protection system. This includes aerogel cell separation to limit thermal propagation, a dual-redundant aerosol-based fire suppression system for rapid... - Page 33 6.5.1 ESS Protection Components • Thermal Runaway Mitigation. Implemented through multiple safety mechanisms . The BMU (Battery Management Unit) and BCU (Battery Control Unit) continuously monitor system parameters, ensuring controlled charging and discharging for safe operation . The TMS (Thermal Management System) actively regulates cell temperatures within safe operating ranges .
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Page 34: Lynk Ii Gateway - Connecting To Inverters And The Cloud
6.7 Fused DC Distribution Figure 20. Location of fused DC distribution The Fused DC Distributor is a critical component inside the AES 210HV cabinet . It provides a centralized connection point for high-current DC wiring and safely distributes power between the battery and connected devices, such as inverters . -
Page 35: Installation
(alternative fuses available from 35 to 150 A) each for fault protection during operation . • High Voltage Capability. Designed to handle the AES 210HV’s high voltage with robust interrupt capacity to support high-power applications . • Convenient Access. Equipped with a removable protective shield for safety, installation and maintenance . -
Page 36: Tools
The AES 210HV must be installed in compliance with all applicable local and national electrical and building codes, including the National Electric Code (NEC) in the USA and the Canadian Electric Code (CEC) in Canada. Additional requirements may be imposed by the Authority Having Jurisdiction (AHJ) based on site-specific conditions. Key considerations include, but are not limited to: • Upstream Protection. Properly rated input disconnects and overcurrent protection as required by code. -
Page 37: Outdoor Installation Requirements
460 (18 420 (16 FRONT Figure 21. AES 210HV Dimensions For stability and performance, the AES 210HV battery system must be installed on a properly constructed concrete foundation . Follow these steps to construct the pad and secure the cabinet . - Page 38 Proper wire trench design, inlet positioning, and sealing are critical to ensuring a secure and reliable battery cabinet installation . Figure 22. AES 210HV Foundation Inlets Power and Communication Line Inlets • DC Power Inlet/Outlet. The cabinet includes two inlet openings, each with a 50 mm (1 .
- Page 39 Remove the DC Distribution Panel - Access the Connections Compartment Figure 23. Remove DC Distribution Panel • Ensure the workspace is safe and clear . • Open the left battery cabinet door to access the internal connections area . • Ensure the battery is off, the DC disconnect is off, and all MSD are removed before removing any connections or panels .
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Page 40: Cabinet Grounding
7.3.3 Cabinet Grounding Figure 25. AES 210HV Grounding Options Grounding Points The AES 210HV battery system includes two designated grounding points to ensure proper electrical bonding and system safety . • Exterior Ground Terminal. Located on the front-bottom-left of the enclosure, this terminal is used for external system grounding, providing a secure, low-resistance connection to the cabinet’s exterior . - Page 41 • Align the Battery. Overhead lift and position the battery cabinet onto the pad . Align the cabinet precisely over the conduit . 2. Installing Anchors Figure 26. AES 210HV Anchor Points • Drill Anchor Holes With the battery cabinet positioned, use a hammer drill to create anchor holes at the designated mounting points on the cabinet’s base .
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Page 42: Electrical Wiring
Once the epoxy has fully cured (consult the Epoxy Manufactures’ Instructions for cure time guidelines based on temperature conditions), attach flat washers, lock washers, and hex nuts to each threaded rod. Torque the nuts to the epoxy manufacturer’s specification to fasten the battery cabinet to the concrete pad. 7.4 Electrical Wiring Figure 27. AES 210HV Electrical Wiring WARNING ELECTRIC SHOCK HAZARD • Always ensure the system is de-energized following lockout/tagout (LOTO) procedures and MSDs are removed for full isolation . - Page 43 DO NOT PARALLEL AES 210HV BATTERY CABINETS ON THE DC BUS Do not parallel AES 210HV battery cabinets on the DC bus . Attempting to connect multiple cabinets in parallel on the DC bus may result in unbalanced currents, system instability, or potential damage to the equipment.
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Page 44: Recommended Cable Specifications
7.4.1 Recommended Cable Specifications These specifications are a general guide, actual wire sizes and ratings should be verified based on use, load calculations, and local electrical codes . Description Terminal ID Cable Type Notes Ground Bare or Insulated Connected to a ground rod Copper or Ufer ground-in pad for low-resistance grounding . Communication LYNK II Standard CAT6 or Run two separate cables,... - Page 45 Figure 28. Example Step-Down Transformer (480 Vac to 240 Vac) NOTE Installation Instructions (for reference) . The transformer’s installation manual is the primary resource for installation guidance . Figure 29. Example Transformer Wiring NOTE Operational Consideration For continuous off-gird operation wire the AC input to provide continuous power to auxiliary components, such as the TMS, even when grid or generator power is unavailable .
- Page 46 NOTE AC System Compatibility For installations using a 120/208 V three-phase or a single-phase 120/240 V setup, a transformer may not be required. The TMS and UPS can operate within an AC input range of 200 to 276 Vac . Therefore, it can use a single-phase input of either 208 V or 240 V . NOTE Operational Consideration A single larger transformer can support multiple battery cabinets at the same site .
- Page 47 Connecting Communications to LYNK II Gateway Plug the LYNK II communication cable into either the J3 or J4 port on the HVB . Route and connect the communication cable (RJ45) to the LYNK Port on the LYNK II Communication Gateway . NOTICE COMMUNICATION NETWORK DAMAGE •...
- Page 48 Figure 32. DC Distribution Connection to HV Box High-Current Conductors to DC Distribution Panel Plug the corresponding ends of the high-current positive and negative conductors into their respective ports on the High-Voltage Box (P+ & P-) . Red/Orange to P+ and black to P- .
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Page 49: Ac Surge Protection
Terminate Inverter DC Conductors Route DC Conductors. Run the inverter’s DC conductors to the fuse terminals . Crimp & Secure. Attach an appropriate ring terminal to each conductor and securely fasten them to the fuse. Leaving sufficient slack to prevent strain. Polarity Check. Verify that all connections from the HVB (High-Voltage Battery) to the DC Distribution Panel and from the DC Distribution Panel to the Inverter are properly terminated with the correct polarity . -
Page 50: Manual Service Disconnect (Msd) Installation
7.5 Manual Service Disconnect (MSD) Installation Figure 34. MSD Locations WARNING ELECTRIC SHOCK HAZARD • DO NOT insert or remove the MSD (Manual Service Disconnect) while the system is under load or powered on . • Before handling the MSD, the system must be completely shut down . •... - Page 51 3 . Locate the MSD Slots: The MSD slot is located on the of front each battery pack . Repeat for each MSD a . Insert the MSD. Insert the MSD into the battery pack’s MSD receptacle slot with the handle in the unlocked upright position, as shown in the figure below.
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Page 52: Inverter Closed-Loop Communications
PCS/Inverter . Once set up, the LYNK II: • Transmits real-time battery parameters, including voltage, current, temperature, and state of charge (SOC), to the inverter . • Relay charge/discharge voltage and current limits from the AES 210HV to the inverter for optimized battery management . -
Page 53: Rapid Shutdown Integration
7.7 Rapid Shutdown Integration Figure 39. Rapid Shutdown Control NOTE Installation of Rapid Shutdown may not be required unless local regulations or project design specify . This feature supplements the preinstalled emergency shutdown button located on the front of the cabinet. This heartbeat feature is configurable and can be disabled where undesired . • Integrate the inverter’s Rapid Shutdown function with the designated Rapid Shutdown initiation device . •... -
Page 54: Automatic Recovery
Automatic Recovery • The system will automatically resume operation when communication is restored, or the Rapid Shutdown is deactivated . • If the Rapid Shutdown (heartbeat) feature is not required for the application, it can be deactivated in the LYNK Access system settings . ͬ This may be applicable during commissioning, troubleshooting, off-grid setups, or highly redundant installations . -
Page 55: Normal Start-Up Procedure
8.2 Normal Start-Up Procedure Procedure Check Confirm the Emergency Stop. Verify the Emergency Stop is not activated . Turn ON the AC Auxiliary Breaker. Switch on the AC auxiliary breaker to activate external AC power into the HVB . Make sure power is turned on at the source and at the breaker on the HVB. Verify the AC voltage is within the specified range . -
Page 56: Normal Shutdown Procedure
8.4 Normal Shutdown Procedure Procedure Check Set the System to Standby Mode. Verify the system is not actively charging or discharging before proceeding with shutdown . Press the Emergency Stop Button. Engage the Emergency Stop to disengage the integrated contacts in the HVB . This cuts the power to DC Power circuits . Turn off UPS. -
Page 57: State Of Charge (Soc) Algorithm
8.6 State of Charge (SOC) Algorithm The AES 210HV battery system uses a multi-method SOC algorithm to ensure high accuracy and reliability in determining the State of Charge (SOC) . SOC Calculation Methods 1. Coulomb Counting (Method #1) ͬ Active when the battery is charging or discharging (current ≠ 0). - Page 58 Maintenance Alarm Cause Troubleshooting/Resolution BMU Communication Fault BMU communication is Check BMU and pack connections inconsistent or unresponsive . (internal/external), inspect for bent or (System Shutdown) corroded pins, and replace BMU or connectors if needed . BMU Temperature Sensor Fault BMU temperature detection Inspect internal BMU connections, failure .
- Page 59 Maintenance Alarm Cause Troubleshooting/Resolution Abnormally High Temperature Temperature exceeds safe Inspect TMS operation, check airflow limits (>60°C) . Possible TMS and vents, ensure proper coolant or battery pack issue . circulation . Disconnect charger or load, and monitor system behavior . Replace TMS or battery pack if necessary .
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Page 60: Storage Guidelines
10. STORAGE GUIDELINES NOTICE DAMAGE DUE TO IMPROPER STORAGE • Do not store the battery cabinet at a low or full State of Charge (SOC) for extended periods . • If the SOC reaches a low level, immediately recharge the battery to prevent damage . •... -
Page 61: Glossary Of Terms, Abbreviations, And Acronyms
11. GLOSSARY OF TERMS, ABBREVIATIONS, AND ACRONYMS Arc Flash Protection Boundary Authority Having Jurisdiction Battery Control Unit Battery Management System C&I Battery Monitoring Unit Commercial and Industrial Coefficient of Performance Energy Management System LOTO High Voltage Box Lock Out Tag Out OCPD Manual Service Disconnect Overcurrent Protection Device Power Conversion System... -
Page 62: Appendix
APPENDIX A.1 AES 210HV COMMISSIONING CHECKLIST This checklist is specific to the AES 210HV cabinet and should be used to confirm the correct installation and function of the cabinet during the commissioning of a complete energy storage system . Additional system-level test must be completed after the full battery energy storage system is integrated . - Page 63 Battery Operation Verification Procedure Check Result Confirm all DC disconnect and Verify correct installation and rating overcurrent protection of overcurrent protection and DC disconnect devices . Ensure the battery cabinet is powered Confirm that the battery cabinets are on, and the status LED indicates normal operation (solid green) . Verify each battery cabinet status Check for any fault indicators on the battery cabinets (amber or red LEDs)
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Page 64: Aes 210Hv Decommisioning Checklist
A.2 AES 210HV DECOMMISIONING CHECKLIST This checklist is used to ensure the proper decommissioning and disassembly of the AES 210HV battery energy storage system . Additional system-level decommissioning procedures may be required for interconnected equipment. Disconnection and Safety Procedures Procedure Check Result Open all disconnects Ensure there is no electrical connection to any externally connected Hybrid Inverter System .
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