6 Connection

6.1 Electrical tools

6.2 Prepare the connection

Cable inlet holes are reserved for system containers. The AC power input hole

(aperture size:680x295mm) and AC Auxiliary power,Communication input hole (aperture size: 110 x 260mm), which is located at the bottom of the primary distribution box.

Figure 6-1 Diagram of cable inlet holes at the bottom of a container

6.2.1 Remove the AC power inlet hole baffle in the primary distribution box.

Figure 6-2 The location of AC power inlet hole in primary distribution box(CB)

Step1:  Open the door of primary distribution box

Figure 6-3 The door of primary distribution box(Left view from back of the container)

Figure 6-4 The door of primary distribution box opened

Step2:  Remove the inlet hole baffle

Figure 6-5 The inlet hole baffle is removed

6.2.2 Remove the AC Auxiliary power, Communication input hole.

Figure 6-6 The location of AC Auxiliary power, Communication input hole in distribution box(DB)

Step1:  Open the door of distribution box(DB),remove the baffle.

Remove the baffle Step2:  Remove the inlet hole baffle

Figure 6-7 The inlet hole baffle is removed

6.3 Connecting Cables to the Primary Distribution Box

6.3.1 Power cable connection

The outgoing terminal of the system is located in the distribution box, and the AC outputs of 8 PCS modules converge on the busbar through the circuit breaker. The outgoing mode of the system is three-phase three wire, as shown in Figure 6-9 system AC outgoing busbar. The internal equipment of the system has been grounded, and the grounding can be repeated if necessary.

When the AC cable is connected to the system, please confirm that the PCS AC circuit breakers QF21 ~ QF28 in the distribution box are disconnected.

WARNING

When the AC cable is connected to the system, please confirm that the PCS AC circuit breakers QF21 ~ QF28 in the distribution box are disconnected.

Hazardous Voltage Circuits

Any contact with the copper bars, contactors,or terminals inside the device or connected with the loop of the utility grid might result in burning or fatal electric shock.

The following operations need to cut off the power supply of PCS to avoid electric shock during operation.

To reduce the risk of injury please read this entire manual and pay attention to all safety placards.

The AC circuit breakers disconnects the Modular Energy Storage Conversion(PCS ) from the Grid(QF21~QF28).

Figure 6-8 Switch positions of the PCS AC circuit breakers

Table 6-1 PCS AC circuit breaker switch position status description

Before connecting to the power grid, check the line voltage and voltage phase sequence using the phase sequence table to ensure that the system meets the grid connection conditions

DANGER

Before connecting to the power grid, check the line voltage and voltage phase sequence using the phase sequence table to ensure that the system meets the grid connection conditions

NOTICE

AC outgoing busbars are U phase (brown), V phase (orange), and W phase (yellow) from top to bottom.

Primary distribution box power cable connection

Figure 6-9 Primary distribution box Ac outlet bus size

Figure 6-10 Design of the connection with one one-hole terminal lug

Table 6-2 Terminal structure composition

The diameter of the busbar cable is 13mm, and 6 AC connection holes are reserved for each phase. For the specifications selection and recommended tightening torque of grid-connected AC cables, see Table 6-3 AC cable specification recommendation.

The PE grounding wire uses four 120mm² cables connect to the two holes on the right side of the grounding bar, as shown in the Figure 6-9.

Table 6-3 AC cable specification recommendation:

Distribution box power cable connection

Figure 6-11 Distribution box Ac outlet bus size

Figure 6-12 Design of the connection with one one-hole terminal lug

Table 6-4 Terminal structure composition

The diameter of the busbar cable is 10mm, and 1 AC connection hole are reserved for each phase. For the specifications selection and recommended tightening torque of grid-connected AC cables, see Table 6-5 Auxiliary Power AC cable specification recommendation.

Table 6-5 Auxiliary Power AC cable specification recommendation

NOTE

The current carrying capacity of the above cables only supports the connection within 5m. If the length exceeds 5M, the cables with greater current carrying capacity shall be used or the number of cables shall be increased.

For the selection of AC input and output copper core cables of the system, please refer to the cable ampacity recommended in the table above, and select upward according to the installation environment.

OT/DT Terminal requirements

NOTICE

When using copper core cables, please use copper terminals.

When using copper-clad aluminum cables, please use copper terminals.

When using aluminum alloy cables, please use copper aluminum transition terminals, or aluminum terminals with copper aluminum transition gaskets.

NOTICE

It is strictly forbidden to connect the aluminum terminal directly to the terminal strip, otherwise it will cause electrochemical corrosion and affect the reliability of cable connection.

When copper aluminum transition terminal is used, or aluminum terminal is matched with copper aluminum transition gasket, it shall meet the requirements of IEC61238-1.

When using copper aluminum transition gaskets, please pay attention to the front and back sides to ensure that the aluminum surface of the gasket contacts the aluminum terminal and the copper surface contacts the terminal strip.

Figure 6-13 OT/DT terminal description

Table 6-6 OT/DT terminal description

Crimp OT/DT terminal

NOTICE

Do not scratch the wire core when peeling off the protective layer.

The cavity formed by the conductor crimping piece of OT/DT terminal after crimping shall completely cover the wire core, and the wire core shall be closely combined with OT/DT terminal without looseness.

The crimping gap can be covered with heat shrinkable sleeve or insulating tape. Take the heat shrinkable casing as an example.

When using the hot-air gun, please pay attention to protection to prevent the equipment from being burnt.

Figure 6-14 Crimping OT terminal steps

Figure 6-15 Crimping DT terminal steps

Table 6-7 Description of crimping OT/DT terminal equipment

6.3.2 Dry Contact Signal Connection

On the 0D terminal block of the control box, a system function signal input / output port is reserved, including analog input signal, 485 communication, passive dry contact output and 24V active dry contact input signal. Users can choose whether to use it according to their needs.

Figure 6-16 0D terminal strip position

Figure 6-17 Reserved function signal terminal

6.4 Connecting Cables to the control Box

6.4.1 Cable Routing Instructions for the Control Box

The distribution box (DB) and control box (GPC) are located below the PCS, the distribution of the distribution room is shown in Figure 6-18 Distribution room layout

Figure 6-18 Distribution room layout

The path between the network cable and the GPC control box is indicated by the yellow arrow, as shown in Figure 6-19 Wiring path of control box.

Figure 6-19 Wiring path of control box

6.4.2 EMS communication access

The 20C1600K provides an RJ45 network port for easy access.

This port is located in the GPC control box, the network cable enters the distribution box through the cable inlet hole on the container, and enters the control box through the cable hole on the top of the distribution box. Figure 6-19 Wiring path of control box shows how to connect cables to the control box.

Connect the network cable to the WAN port of the router (TP) in the GPC controller enclosure.

Figure 6-20 EMS communication access port

RJ45 production sequence description

Figure 6-21 RJ45 Port sequence Description

Table 6-8 RJ45 Port sequence definition

6.5 Synchronous signal wire

If only one system is connected to a copper bar of the transformer, there is no need to install a synchronous signal wire. If two or three systems are connected to the same copper bar of the transformer, synchronous signal wires need to be installed.

Cable requirement: Shielded twisted pair cables(cross-sectional area > 0.82mm2, Recommended cable model: UL2464-1*2*18AWG)

6.5.1 Synchronous signal wire install location of the container

Synchronous signal terminal on the GPCʼs X1 board, J40 is signal input terminal,

J39 is signal output terminal, the synchronous signal terminal location as follow:

6.5.2 Connection method of synchronous signal wire

Here are some connection cases:

Note: The wire length between containers canʼt longer than 10m.

6.6 Work after connection

Step 1: Cut the bottom inlet hole baffle

Cut the inlet hole baffle according to the inlet cable.

Step 2: Install the inlet hole baffle

Install and fix the cut inlet hole baffle

Step 3: Use flexible flame retardant materials to seal the gaps

Use flexible flame-retardant materials to plug the gaps between cables

Step 4: Iron plate mounting

Install the baffle

Figure 6-22 Install the baffle,close the door of distribution box(DB),