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User manual, CellCube FB 200

01 User manual
System documentation
CellCube FB 200

for
Vanadium redox flow energy storage system CellCube

For further information,


please contact your sales representative

Datum: 2013-11-20

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Subject to change ©2013 Cellstrom GmbH
User manual, CellCube FB 200

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Subject to change ©2013 Cellstrom GmbH
User manual, CellCube FB 200

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

2. The vanadium redox flow battery CellCube FB 200 ........................... 8


2.1. Operating principle of the vanadium redox flow battery .......................................................... 8
2.2. System description CellCube FB 200 ..................................................................................... 9
2.3. Intended use ........................................................................................................................ 10
2.3.1. Deep discharge .................................................................................................................... 10
2.3.2. Use as uninterruptivle power supply (UPS) .......................................................................... 11
2.3.3. Use in connection with the grid ............................................................................................. 11

3. Safety instructions .............................................................................. 12


3.1. Symbols on the device ......................................................................................................... 12
3.2. Safety instructions and potential dangers ............................................................................. 14
3.2.1. Safety instructions for electrolyte and leakages .................................................................... 14
3.2.2. Safety instructions for fire ..................................................................................................... 15
3.2.3. Safety instructions for hydrogen formation in the tank, CO- und CO2-formation.................... 15
3.2.4. Safety information for general gas formation (H2, CO und CO2) ........................................... 16
3.2.5. Safety information for electric components ........................................................................... 16
3.2.6. Safety instructions for mechanical components .................................................................... 17
3.2.7. Additional dangers................................................................................................................ 17

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

5. Electrical main connection ................................................................. 21


5.1. Communication interfaces .................................................................................................... 22
5.1.1. External Operations Interfaces (EOI) .................................................................................... 22
5.1.2. Service Access..................................................................................................................... 22
5.1.3. Local Monitoring Display (Local Customer Monitoring) ......................................................... 23

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5.1.4. Additional fire alarm system provided by the customer ......................................................... 23


5.1.5. External hardware Emergency Stop ..................................................................................... 23
5.2. Anschluss an ein öffentliches Elektrizitätsnetz...................................................................... 24

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

7. Maintenance and service.................................................................... 49

8. Malfunctions ........................................................................................ 50
9. Disassembly & Disposal..................................................................... 50

10. Exclusion of liability ........................................................................... 51

11. Warranty .............................................................................................. 52


12. Contact ................................................................................................ 52

13. System documentation FB 200 .......................................................... 53

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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

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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)

1.2. Area of application CellCube


The Cellcube FB 200 system in versions FB 200-400, FB 200-800 and FB 200-
1600 is a stationary energy storage systen and is exclusively intended for storing
electrical energy and supplying reactive power.

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.

Only use Cellstrom-approved products.

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:

See chapter x (chapter of the user manual) or


See section y (section of the system documentation)
The system documentation is located on the switch cabinet door in the power unit.
For technical information about the energy storage system CellCube FB 200, refer
to section 04 of the system documentation (see section 04, "Technical
Specifications, CellCube FB 200")

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1.4. Symbols
Important information in this user manual is especially emphasised. The following
symbols are used for this:

Important warning: Non-compliance can lead to injuries or risk of death or can


cause damage to the energy storage system.

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:

Table 1.: Technical terms and abbreviations


Technical term / abbreviation Explanation
VEL (Vanadium Electrolyte) Liquid energy carrier
IBC (Intermediate Bulk Container) Container for electrolyte transport
FBC (Flow Battery Controller) Control unit of the battery
PLC (Programmable Logic Control unit of the energy storage system
Controller)
IPC (Industrial PC) Industrial PC
GUI (Graphical User Interface) Graphical user interface on touch panel
LM/RM-mode (Local Management / Local and remote management mode
Remote Management mode)
EOI (External Operations Interface) External operations interface for remote
control
DCL (DC link) Bi-directional DC-DC converter
SOC (State of Charge) State of charge of the electrolyte
(chemical)
CL (Charge Level) Charge level of the energy storage
system

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2. The vanadium redox flow battery CellCube FB 200


The CellCube FB 200 energy storage system is available in versions with 400kWh,
800kWh or 1600kWh of energy capacity according to the figures below. Each
storage system consists of a power unit (200) and an energy unit (400, 800 or
1600).

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".

Figure 1: View of the CellCube FB 200 with different storage capacities

2.1. Operating principle of the vanadium redox flow battery

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

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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

The electrical power is supplied and discharged by means of one bi-directional


DC-DC converter (4) per stack, the so-called DC link1 (DCL). This charging and
discharging controller converts the stack voltage to 650-750V direct-current
voltage. Depending on the voltage applied to the DC bus, these charging
controllers ensure charging and discharging of the energy storage system entirely
independently. At the same time, the DC bus is the interface with the power
electronics, ensuring connection of the energy storage system to the electrical grid
or the user by means of a bi-directional inverter.

2.2. System description CellCube FB 200


The redox flow battery Cellcube FB 200 has a nominal power of 200kVA and,
depending on the used type, a storage capacity of 400kWh, 800kWh or 1600kWh.
The stationary energy storage system provides emission-free energy, regardless
of weather-related or cyclical factors.

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.

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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.

2.3. Intended use


The CellCube is a rechargeable battery for regular and frequent charging and
discharging cycles. As it is an energy storage system with integrated power
electronics, the main application type is parallel operation with the grid. Island grid
or off-grid operation as well as use as uninterruptible power supply is possible, if
the system has been configured accordingly.

As for all electrochemical processes, the capacity of the system is highly


dependent on the state of charge and the temperature of the electrolyte.

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.

2.3.1. Deep discharge


Please notice the following distinction between the two different concepts
regarding to charge-levels

The State of Charge (SOC)


The state of charge represents the ratio of charge carriers in
the electrolyte and is the electrochemically accessible,
measurable factor for determining the charge level.
Usually the term "electrochemical deep discharge" is used for
when the state of charge of a storage system reaches 0%
SOC.

The Charge Level (CL)


The charge level of the system is a measurement for the
storage capacity of the energy storage system during normal
operation. The system can always be operated with a charge
level between 0 % and 100 %. During this operation, the
storage system can be charged and discharged with electrical
energy according to the technical specifications.

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The storage system discharge process is automatically stopped when a bottom


threshold of the state of charge of 5 % (= 0 % charge level) is reached.
In case of a long dwell time without recharging by means of external energy
sources, the battery continues to be discharged due to the energy consumption of
the system components. If the state of charge goes below 4 %, a warning
message is sent to the service centre. The energy storage system now tries to
keep the state of charge in a range of 4-5 % by conservation charging.
If the state of charge decreases below a threshold of 3 %, the energy storage
system automatically disconnects from the grid and is deactivated.
The subsequent start up can only be carried out on-site. Deep discharge does not
damage the electrochemical cells or the electrolyte.

2.3.2. Use as uninterruptivle power supply (UPS)


The standard version of the CellCube FB 200 is incapable of supplying power to a
consumer without interruptions (<15ms). However, a simple extension of this
version makes it possible to additionally supply a sensitive load with up to 200kVA
without interruptions according to IEC 62040-3-111 as long as normal "grid
operation" is maintained.

2.3.3. Use in connection with the grid

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.

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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.

Symbol Position Meaning

Door exteriors, Access is only permitted for persons


power unit authorised by the owner/user or
or maintenance unit persons accompanied by an
authorised person.

Door interiors, This sign shows the direction of the


power unit evacuation route.
and maintenance
unit

Tank surface in the Hazardous to health, toxic (T) - refers


area of the level to the charged electrolyte, specifically
sensor to the vanadium (V) component

Near H2 sensor, gas Danger of explosive atmosphere -


lock and on tank refers to an explosive hydrogenous
surface in the area gas atmosphere in the tank
of the level sensor compartment and the gas exchange
line

Tank container Corrosive/Caustic (C) - refers to the


exterior near steps electrolyte, specifically to the
component sulphuric acid

Door interior, power Danger caused by batteries


unit

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Switch cabinet door Dangerous voltage - refers to


Power unit and 400 VAC or 700 VDC
terminal box

Switch cabinet door, Always read the user manual - refers


Door interiors to all maintenance work.
Power unit and
maintenance unit

Door interiors, Wear protective goggles - refers to the


power and electrolyte
maintenance unit

Door exterior, power No access for persons with pace-


unit and makers
maintenance unit

Door interior, power No eating or drinking


and maintenance
unit

Door exterior, No open flame or other naked light, no


capacity and smoking - refers to the flammable
maintenance unit hydrogen and activation of the smoke
detector.

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.

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3.2. Safety instructions and potential dangers


Authorised personnel may enter the power unit as well as the maintenance unit
(top container) with the consent of the owner/operator. However, always wear eye
protection. Suitable eye protection goggles are located on the door interiors.
Do not open the access doors to the fans and air ducts.
Only authorised service personnel may remove the floor covering. If the floor
covering is removed, safe access to the power unit of the CellCube storage is not
guaranteed.

 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.

3.2.1. Safety instructions for electrolyte and leakages


Der Elektrolyt ist eine Lösung von Vanadiumsalzen in Schwefelsäure (siehe
Sicherheitsdatenblatt, Abschnitt 7). Der Elektrolyt ist in jedem Zustand ätzend.
Eine Berührung des Elektrolyten ist daher auf jeden Fall zu vermeiden!
Die Batterie besitzt einen doppelwandigen Tank der eine Kontaminierung
außerhalb der Anlage verhindert. Bei einer Leckage detektieren Sensoren
ausgelaufenen Elektrolyten und die Service-Center wird alarmiert.

Should electrolyte emerge nevertheless, immediately contact the


responsible authorities and Cellstrom GmbH.

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3.2.2. Safety instructions for fire


All electrical components are secured with electrical fuses. Additionally, smoke
sensors monitor any smoke development within the switch cabinet and switch off
the battery if they are triggered.
A fire alarm system may be installed by the customer after consultations with
Cellstrom GmbH.

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.

Do not open the tank!

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.

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Regular maintenance and examination of the hydrogen sensor is necessary.


Qualified service personnel will carry out this work within the scope of the regular
maintenance.

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.

3.2.5. Safety information for electric components


The inverter provides a household level current (400V, 50Hz alternating current for
Europe). In addition, the DC bus has a DC voltage of 700V. Life-threatening
voltages and currents occur within the storage system.
The connection terminals for connection with the electrical energy sources,
consumers and earthing are located in the terminal box on the exterior rear side of
the CellCube.

2
Threshold A defines limit values below the dangerous explosion limit of H 2 or the
hazardous limits of CO and CO2

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There is a danger of an electric shock from the connection terminals!


Ensure that the connection work is exclusively carried out by an authorised
electrical company. (See chapter 5 or section 02, "Site preparation guide")

Adhere to all locally valid standards and directives for electrical installation.

3.2.6. Safety instructions for mechanical components

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)

3.2.7. Additional dangers


For repairs and service work, always use replacement parts and auxiliary materials
approved by Cellstrom!

Using unsuitable replacement parts or incorrect auxiliary materials (oils,


greases, lubricants, cleaning agents, etc.) is dangerous and can lead to the
destruction of the storage system. The qualified service personnel is trained
in the use of suitable materials.

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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.

4.1. Requirements for the installation site


4.1.1. Minimum dimensions foundation plate
Install the foundation according to the "Site preparation guide"; see section 02 of
the system documentation documentation or section 04, "Technical specifications".

Table 2.: Minimum dimensions, foundation plate


Fundament FB 200-400 FB 200-800 FB 200-1600
Minimum Length 6.25m 12.5m 12.5
dimensions for 20 ½ ft 41ft 41ft
foundation plate Width 3.0m 3.0m 5.5m
10ft 10ft 18ft

Include a service space in your plans, as enough space for maintenance work has
to be provided around the battery.

Ensure that the foundation (concrete slab thickness and reinforcement) is


always laid by an expert in accordance with the results of the current
geological survey. Always take the local ground characteristics into account.
It is the customer's responsibility to have a geological survey carried out.

4.1.2. Accessibility and access roads


Ensure that there are access roads and shunting areas for lorries (articulated
lorries), at least within crane range. The containers are unloaded by means of a
crane designed for a load of at least 20,000kg (44,100lbs) across the respective
lifting distance to be covered.

Ensure that the installation site is accessible through an access road/path


with a load-bearing capacity of at least 2,000kg/m² (410lbs/ft²)for service
work. If there is a risk of collision with a vehicle, ensure adequate collision

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protection by means of constructional measures according to the valid local


legal regulations.

4.1.3. Indoor installation


Energy storage systems of the type CellCube FB 200-400, FB 200-800, FB 200-
1600 are perfectly adapted for outdoor installation due to their weather-proof
housing as well as their integrated temperature and climate management system.
Indoor installation is technically possible, but only after special consultations with
Cellstrom.

4.1.4. Exterior cladding and modification of the housing


An additional optional exterior cladding for display and promotion purposes can be
installed by Cellstrom. For this purpose, a substructure is used to place a graphics
film in the corresponding graphics frame. The exterior cladding is designed for a
wind speed of 116 km/h (wind zone 2, inland, according to DIN 1055).

Figure 4: Photography of a CellCube FB 200-400 in customer's installation site. The


exterior cladding carries graphic designs for marketing purposes

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.

Cellstrom does not assume liability in case of unauthorised modifications of


the housing.

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4.2. Earthing and lightning protection


4.2.1. Earthing

The customer must provide a standardised earthing connection in the immediate


vicinity of the terminal box. The earthing is connected according to the local safety
regulations. Ensure that this is carried out by an authorised electrical engineer.
Earthing points are located in the customer terminal box and at least on the
container corners of the storage tank container;
Equip the foundation with a foundation earthing connection. (See section 02 "Site
preparation guide" of the system documentation)

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.

4.2.2. Lightning protection

The CellCube is equipped with an internal lightning protection device in form of


grid-bound lightning arresters. Exterior lightning protection mainly consists of the
flat, earthed container walls, which conduct lightning towards the ground.

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.

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5. Electrical main connection


The electrical interface for the grid connection 200kVA AC, 400V / 50Hz, (TN-S)
configuration is located on the rear of the energy storage system below the power
unit. The exterior switch cabinet is the connection point of the energy storage
system with the owner/user / customer grid. It is equipped with an NH fused circuit
breaker for all-pole disconnection of the storage system.

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

However, it is the customer's responsibility to install suitable disconnection and


fuse triggering mechanisms on the grid connection point (for example with medium
voltage)

Ensure that a standardised connection is established and the electro-


technical acceptance is carried out by an authorised electrical company.

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5.1. Communication interfaces


For control and maintenance purposes, the CellCube FB 200 is equipped with
several, physically separated interfaces. This measure is intended to fulfil the
customer's safety requirements as well as possible. There is a distinction
between the following communication interfaces:

Table 3.: Overview of the communication interfaces


Designation Purpose Protocol Connection
External Operations Remote control of Modbus TCP/IP Optical fibre
Interface the CellCube

Service access Remote TeamViewer Optical fibre with


maintenance Tunneling DSL modem
GILDEMEISTER protocols (UMTS optional)
Local monitoring Local parameter Modbus TCP/IP Optical fibre /
display display Ethernet

5.1.1. External Operations Interfaces (EOI)

Connection: Optical fibre

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.

5.1.2. Service Access

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.

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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.

5.1.3. Local Monitoring Display (Local Customer Monitoring)

Connection: Optical fibre or Ethernet network cable

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 connect the "Local Customer Monitoring" the customer has to establish a


connection of the terminal box (power connection) to the monitor.

The monitor is to be set up on the very edge of the foundation, however, at a


maximum distance of 10 m, unless otherwise specified by the customer.
Furthermore, the customer has to provide a supply (230VAC) constructed and
secured according to the respective standards and regulations for connecting the
monitor. (Nominal power approx. 2.5 kW for heated 46 inch monitor in housing
IP65)

5.1.4. Additional fire alarm system provided by the customer

As an option, it is possible to install a customer-provided fire alarm system in the


energy storage system in addition to the other protective measures after
consultations with Cellstrom. All connections must be provided by the customer.

5.1.5. External hardware Emergency Stop

Optionally an externally triggered, hardware-guided "Emergency Stop" option can


be installed after consultation with Cellstrom. With this option, Emergency Stop
terminals in the terminal box can be used to stop the system, similarly to the
Emergency Stop button on site.

To confirm the Emergency Stop, press the "Goto Standby" button on the Graphical
User Interface on the touch screen.

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5.2. Anschluss an ein öffentliches Elektrizitätsnetz

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.

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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.

6.1. Definition of energy flow and metering scheme


Generation units connected to an electrical grid, underly technical guidlines such
as the German guidlinie „Technische Richtlinie: Erzeugungsanlagen am
Mittelspannungsnetz“ (bdew 06/2008)“. Regarding to this guidline, generation units
are considered within the generator energy flow metering scheme displayed below.
This consideration should also underly the CellCube energy storage system which
means that for active power consumption from the grid both, current and active
power are measured positive. Therefore a positive power displayed in the GUI
always denotes „charging“, whereas the display of a negative active power means
„discharging“ of the storage.

Figure 6: energy flow metering scheme and phase-angle definition

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).

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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).

Figure 7: Four-Sector-Operation within consumer metering scheme

6.2. Fundamental information concerning operation


6.2.1. Overview of switch cabinet panel.
The switch cabinet with the local touch panel and the key switch for starting up the
storage system is located on the interior rear wall of the power unit. Always use the
key switch to activate the CellCube storage.

Figure 8: Overview of switch cabinet front

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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

Emergency and Stop


The statuses "Emergency" and "Stop" can be accessed from any operating status.
1
corresponds to the OFF status in the "Remote Management" mode
2 corresponds to the ON status in the "Remote Management" mode

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Table 4.: Operating statuses of the system


State Description
“Deactivated” The storage system is switched off; the PLC is switched
off; communication is not established;
“Emergency” The storage system is in Emergency Stop mode; always
confirm this status on the touch panel; all communication
systems are active.
“Standby” In this state, the system is not connected with the grid.
The communication and BMS can only be maintained for
a limited time.
“Grid Connected” The storage system is connected to the grid (the auxiliary
systems are supplied with voltage); The main switch is
closed; in this state the "management mode" can be
changed; this operating mode corresponds to remote-
OFF;
“HV ready” The 700 V DC bus is active; the 200kVA inverter is
operational
“AC-link connected, The transformer is pre-magnetised, the main contactor
battery off” K3 is closed; reactive power can be set; the fluid pumps
are initialised; the DC links are not initialised
“Battery on, AC- The DC links are initialised, the main contactor has not
link disconnected” been closed yet.
“Running” The storage system is operational; in this state the
"management mode" can be changed; this operating
mode corresponds to remote-ON;
“STOP” The shutdown sequence is initiated and cannot be
stopped. The storage system is completely deactivated.
The storage system can only be activated by means of
the key switch

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.

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Figure 10: Main window for control system a) and monitoring b). All important
operating and display elements are designated by letters.

A: Change-over to different display


Button for switching between the control screen and the monitoring screen

B: Minimising the GUI


Press this button to minimise the GUI and display the desktop surface of Windows

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.

Icon on the Windows user interface of the IPC…………………………

D: "Active Target Power" display


Display of the set-point value of the required active power (-) discharging, (+)
charging

E: "Reactive Target Power" display


Display of the set-point value of the required reactive power (-) capacitive, (+)
inductive

F: Power measurement, "Active Target Power"


Active power measured on the grid connection point

G: Power measurement, "Reactive Target Power"


Reactive power measured on the grid connection point

H: Statuses of the state machine


Displayed in grey: Operating modes of the state machine which cannot be reached
through a direct switching action.

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J: Statuses of the state machine


Displayed in dark grey: Current operating status of the state machine.

K: Statuses of the state machine


Displayed in light grey: Operating statuses of the state machine which can be
reached through a switching action.
L: Display of "max. Target Power"
Display of the maximum value of available active power

M: Display of "Electrolyte temperature"


Display of the electrolyte temperature in the storage tank

N: Display of "DC bus voltage"


Voltage measurement on the DC bus between 650VDC and 750VDC

P: Display of "Charge Level"


Range between 0% and 100% Shows the charge level of the energy storage
system.

6.2.4. Control screen oft he Graphical User Interface (GUI)

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

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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)

G: Activation of Remote/Local Control


Flag for activating/deactivating the External Operations Interface (EOI)

H: Data log window


Opens the "Data log" window. This menu can be used for daily download of all
operating data from the PLC to the IPC.

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.

K: Buttons for operating modes


Buttons for changing the operating mode

L: Input window for maximum active power


For entering the active power to be held available Refer to chapter 6.1.6

M: Input window for active power


Currently required active power (+) = charging, (-) = discharging

N: Input window for reactive power


For entering the reactive power between -160 an +160 [kVAr]. The adjustable
cos(phi) on the grid connection point depends on the actual connection point.

O: Status display of main control system


Feedback about the state of the DC link groups and the DC startup circuit

P: Charge Level
Charge level of the storage system (0-100 %)

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Q: Display of operating status


Display of operating status and status changes

R: DC link collected status


S, E, A: Status, Error, Alarm: Summary of all 80 DC links

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.

6.2.5. „Element - P“: Charge Level

The State of Charge

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.

Der Ladegrad (Charge Level)

The Charge Level is the value relevant for operation. It is calculated

[ ]
[ ]

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.

Therefore, a Charge Level (CL) of 100 % corresponds to a SOC of 85% - 5% =


80%. This range provides the full power range of the energy storage system
according to the "Technical Specifications"; refer to section 04 of the system
documentation.

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6.2.6. „Element - L,M,N“: input window for power

"Max. Target power“ and "Target power“


The "active target power" and the "maximum active target power" can be specified
for both, operation via the local interface (touch screen) and operation via the
"External Operations Interface".

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.

Reactive power ("TargetRepower")


This input window is used to set the reactive power value (Q). Values between (-)
160 and 160 kVAr can be entered. This corresponds to capacitive or inductive
reactive power on the grid connection point.

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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.

6.2.7. „Element – G“: Local/Remote Management mode

The switch-over from "Local Management mode" (LM mode) to "Remote


Management mode" (RM mode) can only be carried out on the touch panel of the
storage system.

Transition from RM mode to LM mode:


The current settings on the Modbus interface of the External Operations
Interface (EOI) are taken over by the storage system and the input fields for
power in manual operating mode on the control screen are unlocked.

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Transition from LM mode to RM mode:


Regardless of the current power specifications in manual or scheduled
operation the transfer to the "External Operations Interface" is made with the
storage system at idle speed (i.e. with "max. target power"=0 and "target
power"=0)

Toggling between LM and RM mode:


It is only possible to toggle between LM and RM mode in the operating
modes "Running" and "Grid-Connected". (These correspond to the ON and
OFF statuses in the External Operations Interface)

6.2.8. Operating statuses „ON“ and „OFF“ for remote control

Explanation of the "ON" and "OFF" operating statuses:

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"

6.3. Manually switching on the storage system

Only start the energy storage system, if it is in perfect condition and fully
functional and all safety measures are adhered to.

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6.3.1. Switching the system to „standby“ state

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.

6.3.2. Switching the system to „grid connected“ state

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.

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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)

6.3.3. Switching the system to „running“ state


Press the "Goto running" button (figure 12, inset c) to make the energy storage
system switch over to "Running" mode autonomously. During this process, the
"build up HV" command is first carried out independently.

Manual switch-over to Running


If it is not necessary to use the manual mode for commissioning/start-up purposes,
we recommend using the autonomous switch-over procedure to switch the storage
system over to "running" mode.

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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.

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6.3.4. Standby mode

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.

6.3.5. Eco Mode

In this operating mode, the pump management is active and an especially


efficient operation is guaranteed.

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".

Behaviour when changing the "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".

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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.

 The AC link is active (supplying reactive power is possible)


 All pumps and DC links are switched off (low self-consumption)
 Activating the DC links and switching over to "Hot Standby" mode is
possible within 2-3 minutes, if the "max. Target Power" is increased from 0
to a value between 1 ... 200.

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.

6.4. Switching off the storage system


This switching action corresponds to a controlled "Shutdown" of the storage
system. In this state, no communication to the outside of the system is possible via
the interfaces. The storage system must be switched on manually and locally.

6.4.1. Manual shutdown via the local touch panel


In order to make a controlled storage system shutdown possible, ensure that the
capacity specifications "max. Target Power", "Target Power" and "TargetRePower"
are first set to "0" and the storage system is at idle speed.
This is possible via the GUI or the External Operations Interface (EOI).
The storage system can be shut down step by step or directly by pressing the
"Stop" button.

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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.

6.4.2. Controlled shutdown via the External Operations Interface (EOI)

„DEACTIVATE“:

If the energy storage system is to be deactivated completely by means of the


External Operations Interface, a controlled shutdown can be initiated via the
Modbus Protocol (register address 2). However, this process is irreversible and,
like the shutdown of a PC, can no longer be reversed once it has been initiated.
Initiation via the Modbus protocol is equivalent to pressing the "Stop" button.
However, no user confirmation prompt appears in this case.

The energy storage system can now only be switched on by means of the key
switch on site.

6.5. „Emergency Stop“ function principle


Two "Emergency Stop" buttons are located in the power unit, one in the entrance
area on the LH side, the other on the door of the switch cabinet.

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Triggering of "Emergency Stop":

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.

"Emergency Stop" via remote triggering:

Optionally, four contact terminals (protected by overvoltage arresters) are located


in the terminal box, so that the customer can connect a two-circuit external
Emergency Stop switch.
If the external "Emergency Stop" circuit is triggered, a certified relay in the
Cellcube is activated, which, in turn, affects the local "Emergency Stop" circuit.
This allows for the initiation of a hardware-based "Remote Emergency Stop"
function similar to an on-site initiation of the "Emergency Stop" button. For details
about all interfaces, refer to section 03 of the system documentation ("Remote
interface guide").

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Measures in case of an Emergency Stop:


 The electrolyte pumps are switched off
 The main frequency converter is switched off
 The 700VDC bus voltage is switched off
 The grid connection 400VAC is disconnected
 The integrated battery systems are switched off
Not affected by an Emergency Stop:
 Bachmann control system of the battery management system
 Grid monitoring relay
 Insulation monitoring

The energy storage system is no longer operational after the Emergency Stop button
has been pushed and no longer supplies power.

Unlocking the "Emergency Stop" button:


Once the dangerous situation has been rectified, the "Emergency Stop" button can
be unlocked. Afterwards, use the "goto standby" button to switch the system over
to its standby mode.

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.

6.6. Operating the storage system via the local GUI


The storage system can be locally controlled on site by means of the control
screen of the GUI. A simple schedule for testing purposes can also be
programmed and stored. To do this, ensure that the CellCube is in "Local
Management" mode. Activate and deactivate this mode in the "Grid Connected" or
"Running" states. (Flag in the top lefthand corner).

6.6.1. Manual operation


In this operating mode, a current target active power (Target Power) and a
maximum target active power (max. Target Power) can be specified for charging or
discharging the energy storage system. To do this, ensure the storage system is in
RUNNING mode. In addition, a reactive power (TargetRePower) can be entered
(this is also possible if "Running" is deactivated, but "AC link connected / battery
off" is active, as the DC links do not have to be active to set a reactive power.)

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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.

Limiting to 200 kVA


Regardless of whether "TargetRePower" or "Target Power" is entered first, the
respective other value is always calculated from a Pythagorean triangle with the
sum of 200kVA.

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.

Example 2: The maximum reactive power of 160kVAr is first set as "Target


Repower". Then a value of 140kW is entered as "Target Power". This value is
immediately corrected by the control system, as a maximum apparent power of
200kVA only allows for 120kW. For an overview, compare with fig. 10

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.

6.6.2. Testin schedule


In "LM mode" a schedule for autonomous operation of the storage system can be
programmed. First and foremost, this schedule serves for test and demonstration
purposes and only permits static programming of "reactive power" subject to "time"
or "SOC".

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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.

 Save Saving the schedule


 Load Loading a saved schedule
 Activate Activating the currently selected schedule
 Deactivate Deactivating the currently running schedule

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.

Note that the schedule is programmed via SOC = State of Charge.

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.

 wait=1 keeping the current value, e.g. for 1 minute


 SOC>=8500 Charging until SOC value 85 % is reached
 SOC<=500 Discharging until SOC value 5 % is reached

Only integral numbers can be entered. The power settings in kW are


predetermined values for the "target power" parameter. After activating the
schedule, the "maximum target power" parameter is always the highest available
power value of the absolute value. We recommend only entering SOC values in
increments of "10".

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SOC-controlled schedules:
Fill in the LH and RH column of each line

Table 5.: Example of a SOC-controlled schedule


wait=1 100
SOC>=8000 0
wait=504 -150
SOC<=2050 30
wait=921 0

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

Table 6.: Example of a time-controlled schedule


wait=2 -200
wait=60 20
wait=240 40
wait=600 0
wait=720 -15

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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.

6.7. Operating the External Operations Interface (EOI)


Implementation of the "External Operations Interface" is optional.

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

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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.

Online schedule (via External Operations Interface)


For operation via an online schedule, i.e. via a power setting through the External
Operations Interface, refer to section 3 of the system documentation ("Remote
Interface Guide").

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7. Maintenance and service


To ensure a long operating life without malfunctions, we recommend carrying out a
yearly maintenance. Apart from that, it is, of course, possible to cover repairs and
maintenance work through a maintenance contract. For details, please contact
Cellstrom.
Outdoor work, for example removal of vegetation, can be carried out by the
customer.
The following work is carried out during the annual inspection by Cellstrom or a
qualified partner company:

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

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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.

In the scope of a maintenance contract these malfunction messages are analysed


by the Cellstrom service centre or the responsible service partner and appropriate
correction measures are taken. Malfunctions can only be rectified by trained
personnel.

9. Disassembly & Disposal


Ensure that disassembly and disposal are only carried out by qualified personnel.
The discharged electrolyte is pumped into IBC containers and can then by
recycled or chemically disposed of. Discharge is achieved by mixing positive and
negative electrolyte.
The tanks and the fluid system still contain electrolyte residue after being drained.
For this reason, they have to be chemically disposed of in a proper manner. The
safety data sheets for the chemicals can be found in the customer documentation.
The electrical and electronic components are regarded as waste
electronic equipment. For this reason, dispose of them according to
the nationally valid regulations. Likewise two small lead-acid
batteries are located in the electronic components. Dispose of these
batteries separately as spent batteries.

The steel frame can be recycled as scrap metal.

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10. Exclusion of liability


The adherence to all operating conditions listed in this user manual cannot be
monitored by the manufacturer. For this reason the manufacturer accepts no
liability or responsibility for damage and losses resulting from improper operation
of the system.
The manufacturer also accepts no liability for violations of the patent law or other
violations of the rights of third persons resulting from use of this device.
It is the responsibility of the owner/user to protect the system against access by
third persons and/or - depending on the installation location - take additional
measures.

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.

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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

Tel +43 2236 379000-10


Fax +43 2236 379000-9
www.cellstrom.com

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13. System documentation FB 200


Some sections of this user manual make reference to other sections in the system
documentation. The system documentation contains the following sections, each
of which is an individual document.

Table 9.: Overview system documentation


Abs. Dokumentenname (Deutsch) (English)
00 Übersichtsliste erweiterte Overview of extended list of
Anlagendokumentation documents
01 Benutzerhandbuch FB 200 User manual
02 Anleitung für Vorbereitung Aufstellungsort Site preparation guide
03 Anleitung für Fernsteuer-Schnittstellen Remote interface guide
04 Technische Spezifikation Technical specification
05 Kuppelschalter Coupling device
06 Netzverhalten und Oberschwingungen Grid-performance and harmonics
07 Schalungs- und Ausführungsplanung Casing and armoring planning for
Fundamentplatte foundation baseplate
08 Fundament Spezifikation Foundation specification
09 Inbetriebnahme Dokumentation: Commissioning documentation
 091 Prüfprotokoll Auslieferung  Inspection protocol
 092 Inbetriebnahme Bericht  Commissioning report
 093 Übergabe und Abnahme Protokoll  Handover & Approval
 094 Endabnahme-Nachweis  Final Approval certificate
 095 CE-Konformitätserklärung  CE-conformity
 096 Statik-Nachweis Treppe  Structural Analysis landing
10 Sicherheitsdatenblatt VEL Safety data sheet electrolyte
11 Sicherheitsdatenblatt Kühlmittel Safety data sheet coolant
12 Sicherheitsdatenblatt Grundöl Safety data sheet base oil
1x Eventuelle Erweiterung laut 00 Possible extension as in 00

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