01 User manual
System documentation
CellCube FB 200
for
Vanadium redox flow energy storage system CellCube
Datum: 2013-11-20
Contents
1. General information .............................................................................. 6
1.1. Scope of validity ..................................................................................................................... 6
1.2. Area of application CellCube .................................................................................................. 6
1.3. References ............................................................................................................................. 6
1.4. Symbols ................................................................................................................................. 7
1.5. Terms ..................................................................................................................................... 7
4. Installation ........................................................................................... 18
4.1. Requirements for the installation site .................................................................................... 18
4.1.1. Minimum dimensions foundation plate.................................................................................. 18
4.1.2. Accessibility and access roads ............................................................................................. 18
4.1.3. Indoor installation ................................................................................................................. 19
4.1.4. Exterior cladding and modification of the housing ................................................................. 19
4.2. Earthing and lightning protection .......................................................................................... 20
4.2.1. Earthing................................................................................................................................ 20
4.2.2. Lightning protection .............................................................................................................. 20
6. Operation ............................................................................................. 25
6.1. Definition of energy flow and metering scheme .................................................................... 25
6.2. Fundamental information concerning operation .................................................................... 26
6.2.1. Overview of switch cabinet panel. ........................................................................................ 26
6.2.2. State-Machine ...................................................................................................................... 27
6.2.3. Control and monitoring screen of the graphical user interface (GUI) .................................... 28
6.2.4. Control screen oft he Graphical User Interface (GUI) ........................................................... 30
6.2.5. „Element - P“: Charge Level ................................................................................................. 32
6.2.6. „Element - L,M,N“: input window for power ........................................................................... 33
6.2.7. „Element – G“: Local/Remote Management mode ................................................................ 34
6.2.8. Operating statuses „ON“ and „OFF“ for remote control ......................................................... 35
6.3. Manually switching on the storage system ........................................................................... 35
6.3.1. Switching the system to „standby“ state ............................................................................... 36
6.3.2. Switching the system to „grid connected“ state..................................................................... 36
6.3.3. Switching the system to „running“ state ................................................................................ 37
6.3.4. Standby mode ...................................................................................................................... 39
6.3.5. Eco Mode ............................................................................................................................. 39
6.4. Switching off the storage system .......................................................................................... 40
6.4.1. Manual shutdown via the local touch panel .......................................................................... 40
6.4.2. Controlled shutdown via the External Operations Interface (EOI) ......................................... 41
6.5. „Emergency Stop“ function principle ..................................................................................... 41
6.6. Operating the storage system via the local GUI.................................................................... 43
6.6.1. Manual operation ................................................................................................................. 43
6.6.2. Testin schedule .................................................................................................................... 44
6.7. Operating the External Operations Interface (EOI) ............................................................... 47
8. Malfunctions ........................................................................................ 50
9. Disassembly & Disposal..................................................................... 50
List of figures
Figure 1: View of the CellCube FB 200 with different storage
capacities ........................................................................................................ 8
Figure 2: View of a cell with positive and negative semi-cells as well
as an ion-conducting membrane and the
corresponding chemical reactions ................................................................... 8
Figure 3: Operating principle and overview of the vanadium redox
technology and the arrangement of the components,
using the example of a FB 200-400 ................................................................. 9
Figure 4: Photography of a CellCube FB 200-400 in customer's
installation site. The exterior cladding carries graphic
designs for marketing purposes ..................................................................... 19
Figure 5: Rear of the energy storage system. Power unit and energy
unit The main connection with an NH fused circuit
breaker and overvoltage protection is located on the
rear of the energy unit.................................................................................... 21
Figure 6: energy flow metering scheme and phase-angle definition .................................... 25
Figure 7: Four-Sector-Operation within consumer metering scheme .................................... 26
Figure 8: Overview of switch cabinet front ............................................................................ 26
Figure 9: State machine with the status display and the respective
transitions between the statuses .................................................................... 27
Figure 10: Main window for control system a) and monitoring b). All
important operating and display elements are
designated by letters...................................................................................... 29
Figure 11: Control screen of the GUI for controlling the storage
system. All important operating and information
elements are designated by letters ................................................................ 30
Figure 12: Maximum apparent power subject to active and reactive
power. Within the 200kVA power line all
corresponding values for active and reactive power
can be set. The figure shows only one of four
possible quadrants ........................................................................................ 34
Figure 13: Main page of the GUI for controlling the storage system.
LH image a) storage system is in "Emergency" mode
after start-up. Confirm with the "Standby" button to
reach the "Standby" mode. ............................................................................ 36
Figure 14: Operating modes "Grid Connected" c), and "HV ready" e)
with the status change "build up HV" d) as well as the
status "AC-link connected, Battery Off" f)....................................................... 37
Figure 15: Operating status change from "AC link connected, battery
off" to "running", inset g) and "running" status, inset h).
The max. Target Power in this figure has already been
set to 200 kW. ............................................................................................... 38
1. General information
1.1. Scope of validity
This user manual is intended for owners/users of the Cellcube FB 200. It describes
and explains the functional principle and the correct use of the CellCube energy
storage system in daily operation.
Assembly and commissioning/start-up of the energy storage system as well as
malfunction rectification and maintenance can exclusively be carried out by
Cellstrom GmbH or its authorised partners. Technical descriptions or instructions
for installation and malfunction rectification are not included in this user manual.
These instructions are valid for the CellCube storage systems FB 200-400, FB
200-800 and FB 200-1600 for the serial-no. range 1xx05xxxxx (eg. 1800500113)
Other uses not intended by the manufacturer are not permitted. Only operate this
product within the specified limits.
The Cellcube FB 200 energy storage system was developed according to the
current state of the art and complies with the requirements of the EC guidelines. Its
conformity is confirmed by the CE mark. The process for obtaining the CE
conformity declaration was supervised by the technical control board TÜV-Süd,
Germany.
1.3. References
The „User manual“ is part of the system documentation listed in chapter 13,
"Sytem documentation". Some sections of this document make reference to other
sections, i.e. other documents included in the system documentation. The
following phrasing is used for this:
1.4. Symbols
Important information in this user manual is especially emphasised. The following
symbols are used for this:
This symbol marks a note. Non-compliance might complicate use of this energy
storage system or otherwise affect the proper use of the storage system.
1.5. Terms
Several technical terms and abbreviations are used in this user manual; refer to
the following table for an explanation:
The first figure represents the nominal apparent power in kVA (e.g. 200kVA) and
the second figure, separated by a hyphen, represents the storage capacity in kWh
(e.g. 800kWh).
The storage system of the FB 200-1600 version is additionally equipped with a so-
called "maintenance unit".
The vanadium redox flow battery is an electrochemical flow reactor equipped with
serially connected electrochemical cells. Each individual cell is divided into two
semi-cells with one electrode each by means of a membrane.
Figure 2: View of a cell with positive and negative semi-cells as well as an ion-
conducting membrane and the corresponding chemical reactions
A liquid, the energy carrier - also called electrolyte - flows through these semi-cells
in a parallel manner. During the charging process the semi-cells are charged with
electrical energy by means of the electrodes and due to this, the chemical energy
of the liquids is altered in a redox process. During the discharging process the
chemical energy of the liquids is returned to its original state due to a reversal of
the redox process and removal of electrical energy. During operation, the liquid
energy sources is cycles between the electrochemical stacks (1) and the storage
tanks (2) for positive and negative electrolyte which is maintained by fluid pumps
(3). Also refer to figure 3.
Figure 3: Operating principle and overview of the vanadium redox technology and
the arrangement of the components, using the example of a FB 200-400
1
As the link between the chemical cells/stacks and the DC voltage circuit of the inverter,
the DC link is a crucial component of the storage system. The DC link ensures that the
stack is protected from overcharging, allows the DC bus system to have a reaction time of t
< 4 ms and facilitates quick deactivation and switch-off of the DC voltage circuit.
The Cellcube consists of two system components: The energy unit (bottom storage
tank container) and the power unit (top container). The two containers are stacked
above each other and may partially be inserted in the ground in a concrete tub. In
this case, the top container can be accessed through an access door and in case
of above-ground installation by means of steps with a landing platform. It is
possible to enter/access the storage tank in the energy unit below through the
bottom of the top container.
In case of normal, regular use, the battery system is automatically kept within its
ideal operating range. If the ambient conditions are outside of the defined range
(see chapter 13), the nominal capacity indicators (power and energy) cannot be
reached. In this case, the availability of the storage system is limited.
Parallel operation on the public grid is subject to local legal regulations. For this
reason, always obtain the required permits and consult the responsible authorities
and / or the local grid providers about technical requirements.
3. Safety instructions
3.1. Symbols on the device
The following symbolic warning notes (or the valid equivalents in the country of
installation) must be attached to the FB 200 in clearly visible positions:
If the "maintenance unit" is specified as the intended position, this only applies to
FB 200-1600.
Ensure that the warning symbols are clean, legible and complete. If they are
damaged or become illegible, renew them. The Cellstrom service centre will
provide you with warning labels.
Do not use fire or naked light in the container or directly in the entrance
area.
Eating and drinking in the container as well as bringing food and drinks into
the container is prohibited.
No access to the power unit for persons with pace-makers.
Always wear eye protection.
When entering the power-unit, always switch on the lighting. The light
switch is located in the entrance area on the RH interior.
Do not adjust or cover ventilation boxes.
Avoid soiling the floor elements in the entrance area.
Illuminated signs, which show the escape routes for emergencies in case of a
power failure, are located above the entrance doors in the power unit and the
maintenance unit.
Eye rinsing bottles are located on the interior of the power unit and the
maintenance unit for quick First Aid in case electrolyte makes contact with a
person's eyes.
If fire or smoke are noticed from the outside, immediately contact the
appropriate authorities, the fire brigade and Cellstrom GmbH. Never try to
extinguish the fire yourself. Keep a safe distance.
3.2.3. Safety instructions for hydrogen formation in the tank, CO- und CO2-
formation
As is the case for any other battery with water-based electrolyte, the vanadium
redox flow battery can form hydrogen. Compared to other battery types (e.g. lead-
acid batteries) the amount is very small.
The gas is discharged from the tanks to the outside through a gas line. A flame
arrester is located on the end of the degasification line to prevent accidental or
deliberate ignition of the gas.
The tank compartment itself is separated from the ambient air by means of a gas
lock. As a consequence, the gas atmosphere in the tank room will only pass
through the gas lock as of a certain excess pressure. This causes a higher
concentration of hydrogen in the tank compartment.
Ensure that the manual valve of the gas lock is always in the "CLOSED" position.
Ensure that the manual valve is only opened by service personnel.
The filling level designations "min" and "max" on the gas lock only apply in case of
an open manual valve.
If the flame arrester on the exterior freezes or is blocked, the excess pressure from
the gas lock is released into the interior of the power unit. Possibly emerging
hydrogen is detected by a hydrogen sensor.
3.2.4. Safety information for general gas formation (H2, CO und CO2)
An integrated gas warning system emits a warning signal if hydrogen (H2), carbon
monoxide (CO) or carbon dioxide (CO2) is accumulated within the power unit oft he
storage system. If the first warning level has been reached (threshold A),2 the
ventilators are automatically started to convey the gas from the container.
However, if the gas concentration keeps rising, a second warning level is reached.
The respective alarm messages are automatically transmitted to the service
centre. The battery is automatically switched off when the second warning level is
reached. In addition, an acoustic and optical warning signal is given in the centre
of the power unit.
In this case, immediately exit and lock the power unit and contact the Cellstrom
service centre.
The gas warning system for H2, CO, CO2 is automatically supplied with electrical
power during operation of the CellCube. If the storage system is turned off or there
is no voltage due to deep discharge and a disconnected grid, the gas warning
system can be supplied by the integrated auxiliary accumulators by means of a
manual toggle switch (this switch is located in the entrance area of the power unit
and the maintenance unit).
To do so, manually switch on the manual switch for emergency power supply
(switch position 2). When leaving the power unit, starting-up or re-starting, set the
manual switch to "on-board supply" (switch position 1) again.
2
Threshold A defines limit values below the dangerous explosion limit of H 2 or the
hazardous limits of CO and CO2
Adhere to all locally valid standards and directives for electrical installation.
There are no automatically moving parts posing a safety risk. The access paths to
the ventilators are located behind the cover plates. Do not block or cover them.
The CellCube is equipped with a weather-proof housing and separated from the
environment by means of insulation panels. The storage system is protected
against splashing water on all sides (protection class IP 54)
4. Installation
The installation and commissioning/start-up is exclusively carried out by qualified
personnel of Cellstrom GmbH or trained partner companies. However, for a
successful installation, the customer has to take precautionary measures. For a
detailed overview, refer to the "Site preparation guide", see section 02 of the
system documentation.
Include a service space in your plans, as enough space for maintenance work has
to be provided around the battery.
Drilling, riveting, sawing and screwing unauthorised by Cellstrom can damage the
housing of the CellCube energy storage system, which may cause operating
malfunctions and/or risks.
Disassembling or installing additional ventilation boxes may also cause operating
malfunctions.
Connect the storage tank containers with the foundation earthing connection, at
least on the four corners.
The Cellstrom service technician establishes a proper earthing connection
between the power unit and the energy unit.
Local electrical companies will provide information about local conditions and
regulations.
A lightning strike may impact the CellCube because of the temperature and climate
management system installed on the roof of the power unit and the control and
connection lines routed on the exterior.
Lightning rods and lightning lines (ropes or wires) are always used as exterior
lightning arresters. The lightning arresters of a lightning protection system serve to
determine the possible strike points and avoid uncontrolled strikes into wirings and
cables.
Ensure that the lightning protection complies with the locally valid regulations. The
lightning protection is the responsibility of the owner/user.
Figure 5: Rear of the energy storage system. Power unit and energy unit The main
connection with an NH fused circuit breaker and overvoltage protection is located
on the rear of the energy unit
If this is included in the scope of delivery, the energy storage system can be
controlled by means of an "External Operations Interface". The connection for this
purpose is established by means of optical fibres. For a detailed list of all signals
and parameters as well as the description of the interface, refer to the system
documentation, see section 03, "Remote interface guide", of the system
documentation.
The EOI is accessed by a Modbus TCP/IP protocol. As the respective port allows
for direct access to battery management, the customer should ensure that the data
line is secured accordingly and that the battery management is accessed from a
"stand alone" PC or control system, if possible. EOI data is not encrypted.
Connection: Optical fibre with DSL modem and internet access (optional UMTS
access)
The "service access" uses a floating optical fibre line and the service router. This
router serves to provide GILDEMEISTER with service access to the internal
network of the battery management system in order to carry out firmware updates,
service and maintenance work remotely.
For this purpose, it is necessary for this interface to be able to freely connect to the
internet. The energy storage system uses this interface to autonomously send
messages and status information to the service centre via e-mail.
Furthermore, the IPC connects with the internet via the "Teamviewer" software or a
VPN tunnel. This provides the service centre with "remote service access". Access
via the service interface is only intended for the service centre.
For this reason, ensure that the Gildemeister service centre has access via the
service interface at all times.
If this is included in the scope of delivery, parameters and operating modes of the
energy storage systems can be displayed by means of a local, external monitor
"Local Customer Monitoring". The connection for this purpose is established via
Ethernet and an RJ45 contact or optical fibres.
To confirm the Emergency Stop, press the "Goto Standby" button on the Graphical
User Interface on the touch screen.
Ensure that prior to the installation of the storage system the basic legal
conditions for mains parallel operation are clarified in each country and
that the required safety devices are available.
6. Operation
Commissioning/start-up is carried out by a qualified employee of Cellstrom GmbH
or a qualified service partner.
During commissioning/start-up the commissioning/start-up report is created and
handed over to the customer during the final acceptance procedure; see chapter
13 or section 09 "Transfer and acceptance documentation" of the system
documentation.
After commissioning/start-up the storage system can run independently, for
example by means of the programmable testing schedule on the Graphical User
Interface (GUI) or via the External Operations Interface (EOI).
Cellstrom GmbH advises that only qualified expert personnel operate the storage
system by means of the local touch panel after having received training on the
CellCube system.
Important warning: Improper operation can damage the energy storage system
and impact proper use.
In the same manner, four sectors for simultaneous acquisition and disposal of
active power and the allocation of reactive power can be defined (see figure 7).
Therefore positive values for reactive power displayed in the GUI oft he storage
denotes inductive or under-excited operation of the storage. In this operation
mode, the phase angle is always positiv (0-180°). Negative values for reactive
power denotes the capacitive or over-excited operation mode with negative phase
angles (0,-180).
6.2.2. State-Machine
The state machine is the mechanism of the battery management system which
handles switch-over between different machine states. After using the key switch
to activate the storage, set the storage to its initial state ("grid connected") by
means of the touch panel. Controlling the system by means of the External
Operations Interface is only possible after the above step has been completed.
Figure 9: State machine with the status display and the respective
transitions between the statuses
6.2.3. Control and monitoring screen of the graphical user interface (GUI)
The Graphical User Interface (GUI) serves to control the storage system locally.
It provides information about a variety of parameters and characteristics. The
GUI has two main windows.
When starting the storage with the key switch, the GUI opens automatically and
the control screen appears. Use button A to switch between the control screen a)
and the monitoring screen b). The monitoring screen can be used to read off
values and the status of the state machine, but not to manipulate them.
Figure 10: Main window for control system a) and monitoring b). All important
operating and display elements are designated by letters.
C: Exit GUI
Use this button to end the GUI after a user confirmation prompt. This does not
affect operation of the energy storage system. If the storage system is in remote
management mode (RM-mode), operation of the storage can continue. When re-
opening the GUI by double-clicking the Windows symbol, the GUI is displayed with
all operating parameters again.
The control screen is the display shown immedaitely after the GUI is started.
Figure 11: Control screen of the GUI for controlling the storage system. All
important operating and information elements are designated by letters
A: Type designation
e.g. FB 200-400, FB 200-800 or FB 200-1600
B: CellCube Symbol
Functionless button
C: Event log
Last entry from the event log
D: Version Number
GUI and PLC software version
E: Tab Display
Marks active, opened window
F: Tab bar
With the windows: Ctrl (controls), G-A, G-B, G-C, G-D (detailed values of the A-D
groups), UPS (Parameters for the DC startup controls), AC (Parameter display of
the PLC), PAC (display of power values for auxiliary systems), FBC (Parameters of
the FBC board), SET (setting values), LOG (Log entries of input values)
J: Schedule window
Opens the "Schedule" window for setting the programmable schedule. Once the
schedule is activated, the font on the operating button is displayed in red.
P: Charge Level
Charge level of the storage system (0-100 %)
S: Parameters DC bus
HV-I (DC bus current in Ampere), HV-U (DC bus power in Volt), HV-P (DC bus
active power in kW = HV-I x HV-U), LV-I (total current of stack in Ampere), LV-U
(medium stack power in Volt), HV-P (total electrical power of stacks in kW = LV-I x
LV-U).
The content of all other GUI tabs is described separately. Usually instructions are
given in the course of user training at the end of commissioning/start-up. These
"tabs" are not directly relevant for operating the storage system.
The OCV cell is a measuring unit in the energy storage system which ensures that
the state of charge of the electrolyte is available as a parameter in the battery
management system in "real time". The state of charge is calculated from the
measured off-load voltage on the measuring cell with the electrolyte temperature
taken into account.
For this reason, the determined "state of charge" value as a ratio of vanadium ions
in the electrolyte shows the chemical state of charge of the energy storage system.
[ ]
[ ]
and takes into account that the battery management system operates the storage
at a SOC of 5 % to 85 %. This precautionary measure prevents the storage system
from being "overcharged" and ensures that a residual capacity is available to
enable the system to be parked in "standby mode" at zero charge level for a longer
time.
Active target power ("Target Power"): Set-point value specification for the energy
storage system - AC charging or discharging power. A positive value (>0)
corresponding to a positive consumer reference arrow system signifies "charging",
a negative value (<0) signifies discharging the storage system. The values are
displayed as "integral number Z" in the unit kW.
Values in a range of -200...0...+200 are possible.
Maximum Active Target Power ("max. TargetPower"): Ensure that the maximum
active target power is equal or higher than the active target power; otherwise the
energy storage system is not released for charging or discharging.
The "maximum target power" value allows the storage system operator to
determine a maximum foreseeable power set-point value jump. This serves for
regulating an optimised self-consumption, see also chapter "Eco Mode" (pump
management)
The value is entered as absolute value without a mathematical sign 0...200
Always enter the maximum active target power before setting the active target
power.
Delayed supply when changing the "target power" = "active target power"
If the "target power" is changed, power can be supplied within t<2 seconds.
If the "maximum target power" is increased, the delayed supply of active power
changes subject to the pump management (as pump circuits might have to be
activated). Decreasing the "maximum target power" does not change the delayed
supply of t=2 seconds.
A setting of Q=0 on the grid connection point is not possible, as all local capacitive
and inductive assembly elements such as filters, throttles and transformers
influence the phase angle cos(phi) on the grid connection point.
Set the reactive power according to the active power to adjust the phase angle on
the grid connection point.
Figure 12: Maximum apparent power subject to active and reactive power. Within
the 200kVA power line all corresponding values for active and reactive power can
be set. The figure shows only one of four possible quadrants
Active and reactive power may only be set if the owner/user of the machine
line is authorised to supply the public grid with power.
The External Operations Interface permits toggling between the operating statuses
"ON" and "OFF" on the CellCube. These are physically defined as follows:
"OFF“:
The main switch on the CellCube remains closed.
all 400VAC systems can be supplied by the grid ("grid connected")
24V DC control voltage circuits are established
Battery Management (PLC) is active
Communication via the EOI is established
The 200 kW circuit breaker is not closed
The DC bus is not maintained
The DC links are not active
The internal status is "Grid Connected = Cold Standby"
"ON“:
The 200 kW circuit breaker is closed
The DC bus voltage is 650-750VDC
The bi-directional DC links are active
The energy storage system is ready for charging/discharging
The storage system is at idle speed as long as no power is required
The internal status is: "Running"
Only start the energy storage system, if it is in perfect condition and fully
functional and all safety measures are adhered to.
The internal switch cabinet containing the important components of the Battery and
Energy Management System is located in the top accessible power container.
The main switch (key switch) of the storage system is located on the front of the
switch cabinet.
Insert the key and turn it clockwise to automatically start the storage system and
display the main menu of the storage system control system on the touch screen.
Press the "Standby" button to switch the energy storage system over to "standby
mode" (see figure)
Actuate the key switch (the storage system starts up - wait until the GUI is
displayed)
Press the "Standby" button
Once standby is activated, the following line of text is displayed beneath
the operating status: "wait until main switch is ready"
Figure 13: Main page of the GUI for controlling the storage system. LH image a)
storage system is in "Emergency" mode after start-up. Confirm with the "Standby"
button to reach the "Standby" mode.
If the "Connect to Grid" button is no longer displayed with a grey background, the
storage system can be switched over to this status.
Press the "Connect to grid" button to close the main switch. Now the main
connection 400VAC is connected to the CellCube and voltage is applied to all
auxiliary systems (400VAC). It is now possible to activate the temperature and
climate management system as well as all ventilators and fans.
In this state, all auxiliary batteries as well as the 24V DC-USV are supplied by the
grid. Therefore, this is the safe state in which the storage system can be operated
permanently.
For this reason, this state is also the "OFF" status in the Remote Mode for the
External Operations Interface.
The "Grid connected" status (figure 12, inset c), is the starting point for passing
through all other statuses up to the "Running" status by means of the auto-forward
command "Goto Running".
Figure 14: Operating modes "Grid Connected" c), and "HV ready" e) with the
status change "build up HV" d) as well as the status "AC-link connected, Battery
Off" f)
As an alternative, this can be carried out manually. In this case, the DC bus is
activated (duration approx. 1 min.) so that the inverter is operational. This figure,
inset d), shows this status change at a given moment. The DC link 81, which is
responsible for building up the DC bus voltage, is currently in "Startup" mode.
Once the DC bus voltage has been built up, two options are made available by the
state machine.
"Switch on battery" - only use this option if no grid is available, but the DC
links are to be activated nevertheless.
"Connect AC link" - use this option to first close the main contactor K3;
subsequently the battery can be activated by means of "switch on battery".
The fluid pumps start automatically after "AC link connected" has been reached.
Once the "AC link" is closed and the DC links have been initialised (switch
on battery), the status display "ready" appears.
It is possible to set the "REMOTE" flag, even in this status. This corresponds to the
"ON" status in the External Operations Interface.
Figure 15: Operating status change from "AC link connected, battery off" to
"running", inset g) and "running" status, inset h). The max. Target Power in this
figure has already been set to 200 kW.
In the above figure, inset g), the 3 active groups A,B,D are being initialised. Group
C is deactivated. Once the initialisation process is completed and all DC links have
been detected, the status 20/20 C D appears for every group. This means that the
individual groups are released for charging [C] and discharging [D] and are now
operational.
Cold Standby:
This mode is equivalent to the "Standby" mode. It cannot be accessed in Remote
Mode (RM mode) (as "Grid Connected" = "OFF" is the lowest status in this case).
In this cold standby, communication is established and the storage system can be
operated locally. The storage system is not connected to the grid. For the self-
consumption of the storage system, refer to the technical data, chapter 13, or the
document "Technical Specifications" (see section 04 of the system
documentation).
Hot Standby:
This mode is the equivalent of the "Running" status, but the storage system is at
idle speed, which means that the active target power "Target Power" and the
reactive target power "TargetRePower" are set to 0.
In this state, immediate power discharge or intake is possible within only a few
seconds.
Ensure that the storage system does not remain in Cold Standby or the "Standby"
operating mode for longer than a few hours, as this leads to deep discharge and
can cause damage to the back-up batteries.
Pump management:
The 200kVA power unit consists of four separate pump circuits with 2 pumps, 20
stacks and 20 DC links each. Each of this 50 kW groups can be switched on and
off separately. If the full nominal power is not required in the foreseeable future,
this offers a method of saving energy and operating the storage system more
efficiently.
The pump management system autonomously decides how many fluid circuits are
required depending on the charge level, the electrolyte temperature, but above all
the entered available "max. Target Power".
The "max. Target Power" can be adjusted in a range from 0 to 200 and is indicated
in [kW]. The "max. Target Power" value limits the "Target Power", meaning that a
value higher than 0 is required to even be able to set a "Target Power".
If the "max. Target Power" is increased significantly or beyond a limit value and
activating new fluid groups becomes necessary, take an output delay of 2-3
minutes into account. (In this case, 30 seconds are used for starting up the pumps
and the remaining time is required for initialising the DC links)
If the "max. Target Power" is decreased, this happens only after 5 minutes have
elapsed. Within this time, increasing the "max. Target Power" is possible without
affecting the current power output or intake.
If the "max. Target Power" is decreased to 0, all fluid groups are immediately
deactivated, but the switch-off procedure can take up to 30 seconds.
Eco Mode:
Decreasing the "max. Target Power" to 0 constitutes the Eco Mode. The storage
system is in "Running" mode, but the DC links are not active (charging and
discharging is only possible if they are active) and therefore have a very low self-
consumption.
Above all, this mode is useful for Remote Management setting, as the self-
consumption is low, but the storage system is not in "OFF" mode and the DC bus
remains active.
If the Eco Mode is maintained over a longer duration (6 hours or more), changing
over to "Hot Standby" mode can take up to 5 minutes. If a quick modification
(within seconds) of the "Target Power" in a range from -200 and 200 is to be
possible, set the "max. Target Power" to 200.
Step-by-step shutdown:
Initiate this process by pressing the "switch off battery" button. Then press the
"goto standby" button. The energy loss in the power contactor is clearly audible. In
"Standby mode" only the "Stop" button can be pressed.
Direct shutdown:
Initiate this mode by pressing the "Stop" button.
In both cases, a user confirmation prompt appears after the "Stop" button is
pressed. Answer this prompt with "yes" to initiate the shutdown sequence.
The operating window is closed and the IPC is shut down. After approx. 2 minutes,
all control systems of the storage system are turned off. (the power decrease of
the relay in the switch cabinet is clearly audible)
The system can now be restarted by means of the key switch.
„DEACTIVATE“:
The energy storage system can now only be switched on by means of the key
switch on site.
Activating the "Emergency Stop" button on site in the storage system or a self-
activation in case of a malfunction (e.g. smoke in the switch cabinet, a leak in the
collecting vat) deactivates a certified relay via a malfunction circuit.
The electrolyte pumps are immediately stopped. (Attention: The fluid area remains
under pressure.) Furthermore, triggering the Emergency Stop function causes the
inverter to be switched off, the 200kW contactor to be opened, the DC bus to be
switched off and the main switch to be opened. This means that the supply of the
400VAC systems as well as the switch cabinet ventilator, DC link ventilator and
electrolyte cooling system is deactivated.
Attention: Even after the "Emergency Stop" button has been triggered, electrical
components may still carry capacitive voltage.
If the storage system is in "Emergency Stop" mode, only the lighting and the 230V
socket on the switch cabinet are supplied with power. The 24V control voltage for
the battery management system also remains active and is supplied by two back-
up batteries.
Confirming the error via the External Operations Interface to exit the "Emergency
Stop" mode is not possible. First, it is necessary to unlock the Emergency Stop
button on site (if active), or to acknowledge the malfunction manually on the GUI or
via a "remote access" tool.
Do not use the "Emergency Stop" button to shut down the storage system in place
of the controlled shutdown.
Ensure that the storage system does not remain in "Emergency" mode for more
than a few hours, as this can lead to deep discharge and cause damage to the
back-up batteries.
The energy storage system is no longer operational after the Emergency Stop button
has been pushed and no longer supplies power.
Once the Emergency Stop button has been pushed and the DC bus system is shut
down, a dangerous voltage is applied to the DC Bus system for another 10
minutes.
Power specification
The maximum reactive power (TargetRePower) which can be set is (+/-)
160kVAr
The maximum active power (Target Power) which can be set is (+/-) 200kW
To be able to enter an active power, first ensure that the maximum target active
power (max. Target Power) is set to a value equal or higher than the desired
(Target Power).
The limit of the maximum target active power (max. Target Power) which
can be set is 200kW. This value is entered as an absolute value without a
mathematical sign.
Example 1.: A "Target Power" of 150kW is set first. Afterwards a value of 140kVAr
is entered as "Target RePower". This value is immediately corrected by the control
system as a maximum apparent power of 200kVA only allows for 132kVAr.
The storage system always tries to regulate its power to the specified active power
"target power". The specified reactive power is not regulated, it only serves for
"setting" or "turning" the cos(phi) on the grid connection point.
To do so, press the "Schedule" button in the top LH corner of the main screen.
Four options are available on the bottom edge of the window for continuing this
process.
Either an example schedule can be loaded and used as template for creating a
new schedule or a new schedule can be programmed in the lines of the window.
The control options in the schedule are predetermined times and set-point powers
on the one hand and charge level conditions on the other hand.
To program the schedule, five (!) lines in the display window can be used. If a
longer schedule is programmed, the entries after the first five lines are ignored.
However, it is possible to use the "loop" setting to set up a constantly repeating
schedule.
The "syntax" to be entered is explained below. The integral numbers are examples
of figures.
SOC-controlled schedules:
Fill in the LH and RH column of each line
Explanation:
After the "activate" button is pressed, the current local power settings are
maintained for 1 more minute. Afterwards, the energy storage system is charged
with 100kW AC until a State of Charge (SOC) of 80% is reached. Afterwards the
set-point specification for "target power" is set to 0 for a time of 504 minutes. This
means that the energy storage system is "idling". After the 504 minutes have
elapsed, the energy storage system is discharged with 150kW AC until a state of
charge (SOC) of 20.5 % is reached. Now the energy storage system is charged
with 30 kW for 921 minutes and then changes over to idling speed (set-point power
"Target Power"=0) again.
If the "loop" button were active, the energy storage system would start charging
with a power of 100kW after a waiting time of 1 minute again until the SOC=80% is
reached.
If SOC values below 500 (5%) or higher than 8500 (85%) are entered, these
values are not taken over. When the limit values are reached, the charging or
discharging release is not active.
Time-controlled schedules:
Fill in the LH and RH column of each line
Explanation:
After the "activate" button has been pushed, the current local power settings are
maintained for 2 minutes. Afterwards the energy storage system is discharged with
200kW AC for 60 min.
Then the storage system is charged with 20 kW for 240 minutes and subsequently
with 40 kW AC for another 600 minutes.
Now the storage system switches to idle speed ("target power" = 0) and is
discharged with 15kW for 2 minutes after 720 min have elapsed.
If the "loop" button were active, a 2-minute discharging time at 15kW would elapse
and then the energy storage system would be discharged with 200kW for another
60 min.
If one of the SOC limits (5 % or 85 %) is reached during the schedule and the
charging or discharging release is consequently deleted, the system remains in
this state until e.g. the self-discharge in "idle speed" or changes in the schedule
result in the limit values no longer being reached.
A "wait value"=0 is not recommended.
Use the "time" display in the bottom area of the screen window to determine where
the current operating status can be placed in the schedule time, i.e. what part of
the schedule the system is currently in.
To use the schedule in a reasonable manner, take the charging and discharging
behaviour into account, as the achieved SOC cannot be exactly determined
beforehand.
If the schedule cannot be activated and the windows/lines are displayed with a red
background, there is either a syntax error or more than five lines were filled.
Malfunction rectification: Deactivate and change the schedule.
The "target power" value can be manually changed in the input window, even while
a schedule is active. This value is taken over by the control system until the
schedule determines a new value.
Toggling between Local/Remote can only be carried out manually in the battery.
This only influences the predetermined power and the switching of the state
machine. In any case, the battery status can be displayed in both systems
(Local/Remote).
A switch-over to Remote is only possible if the battery is in "Grid connected" or
"Running" mode.
If an error causes the battery to fall back to a different mode, it automatically enters
"Local Management mode" again.
External:
Cleaning the ventilation openings + replacing the filter
Inspection of the flame arrester
Inspection of the storage system for corrosion
Inspection of the state of the radio antenna (optional)
Inspection of the state of the main terminal box external wiring
(closing, leak-tightness, dirt, insulation, corrosion)
Removal of vegetation
Internal:
Inspection of the seals for water ingress
Removal of dirt
Inspection of the fluid system for leaks
Inspection of the pumps (leaks, running noises, pressure), pipes
and hoses
Inspection of the gas lock (leaks, oil containers, base oil filling
level) and the hydrogen sensor
Inspection of the ventilators
Inspection of the cooling circuit with the heat exchanger (if
installed)
Inspection of the function of the EMERGENCY STOP button
Inspection of the sensors
Inspection the DC contact rail, high voltage contacts
Inspection of the power unit
8. Malfunctions
The battery monitors itself and triggers alarm messages in case of a malfunction.
In case of an unexpected malfunction, a malfunction message may cause the
storage system to be shut down.
The manufacturer reserves the right to change the technical data of the energy
storage system or this user manual without prior notice or announcement, as long
as the changes are not relevant for the safety regulations or the CE conformity.
11. Warranty
For the warranty provisions, refer to the contractual agreements.
12. Contact
Cellstrom GmbH
Industriezentrum NÖ-Süd
Straße 3, Objekt M36
2355 Wiener Neudorf
Austria