6 Electrical connection

6.1. Needed tools

6.2. Preparing for Connection

Cable inlet holes are reserved for system containers. The AC outlet and communications share one cable inlet hole (aperture size :800 x 150mm). The cable inlet hole is located at the bottom of the primary distribution box.

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

Step 1: Remove the fixing screws on the right side of the distribution box door and open the distribution box door

Figure 6-2 Open the distribution box door instructions

Step 2: Remove the acrylic plate

Figure 6-3 Remove the Argley plate instructions

Step 3: Remove the inlet hole baffle

Figure 6-4 The inlet hole baffle is removed

6.3. Connecting Cables to the Power 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 six PCS modules converge on the busbar through the circuit breaker. The outgoing mode of the system is threephase three wire, as shown in Figure 6-6 system AC outgoing busbar. The internal equipment of the system has been grounded, and the grounding can be repeated if necessary.

WARNING

When the AC cable is connected to the system, please confirm that the PCS AC circuit breakers QF21 ~ QF26 in the distribution box are disconnected.

WARNING

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 inburning or fatal electric shock.The following operations need to cut off the powersupply of PCS to a void electric shock during operation

.

WARNING

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~QF26).

Figure 6-5 Switch positions of the PCS AC circuit breakers

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

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.

Figure 6-6 Ac outlet bus size

Figure 6-7 Design of the connection with one one-hole terminal lug

Table 6-2 Terminal structure composition

Figure 6-8 AC bus outgoing cable

The diameter of the busbar cable is 13mm, and 8 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 two 240mm2 cables connect to the two holes on the right side of the grounding bar, as shown in the Figure 6-8.

Table 6-3 AC cable specification recommendation

20C2H1200K40N.m M12

PE ground cable ≥2*120mm²/

1*240mm² copper core cables

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 6-9 OT/DT terminal description

Table 6-4 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 6-10 Crimping OT terminal steps

Figure 6-11 Crimping DT terminal steps

Table 6-5 Description of crimping OT/DT terminal equipment

6.3.2. Dry Contact Signal Connection

On the 0D terminal block of the power distribution 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 6-12 0D terminal strip position

NOTE

QF1 circuit breaker of grid connection cabinet is the label of incoming switch of system grid connection cabinet

Figure 6-13 Reserved function signal terminal

6.4. Optional EMS gateway

Connection to any EMS platform is possible via a Modbus-MQTT gateway. The CMU and RTU transmit the data from the energy storage system to the gateway via Modbus TCP, the gateway determines whether the data has changed (transposition), and if it has changed the gateway uploads the data to the cloud platform via MQTT, which provides real-time monitoring, operational analysis, fault alarms, diagnostics and fault location, etc. based on these data.

This gateway is normally provided by the EMS platform provider and installed in the third-party control box (see next section). Paneco can provide an EMS platform for customers at no cost.

Figure 6-14 Screenshot of cloud platform

6.5. Connecting Cables to GPC Box

6.5.1. Cable Routing Instructions for GPC Box

The third party control box (CCB) and distribution box (DB) and control box (GPC) are located below the PCS. Below the GPC box is the control transformer (T), and the distribution of the distribution room is shown in Figure 6-15 Distribution room layout. (See section 2.7.2 for specific layout of electrical room)

Figure 6-15 Distribution room layout

The path between the network cable and the GPC box is indicated by the red arrow, as shown in Figure 616 Wiring path of GPC box.

Figure 6-16 Wiring path of GPC box

6.5.2. Control Box for Third Party EMS Controller

The third party control box is mounted behind electrical compartment door.

Figure 6-17 The location of the third-party control box

The size of the third-party control box is 400(W)*170(D)*250(H) mm, as shown in Figure 6-18 below. The box contains an MCB and a 120W power supply module which provides a 24Vdc power supply. The 220Vac power supply can be taken from the lower port of the MCB. The customer is free to install their equipment on the right-hand side of the box.

Figure 6-18 Three-dimensional drawing of the third-party control box

6.5.3. The Third-Party EMS communication access

The 20C2H1200K provides an RJ45 network port for easy access.

This port is located in the GPC box, the network cable enters the power 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 The third-party EMS communication access port 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.

The third-party EMS communication access port

Figure 6-19 The third-party EMS communication access port

RJ45 production sequence description

Figure 6-20 RJ45 Port sequence Description

Table 6-6 RJ45 Port sequence definition

6.6. 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: With shielded twisted pair (cross-sectional area > 0.82mm ² , Recommended cable model: UL2464-1*2*18AWG)

6.6.1. Synchronous signal wire location

Synchronous signal terminal on the GPC’s X1 board, J40 is signal input terminal, J39 is signal output terminal, the synchronous signal terminal location as follow:

6.6.2. Connection method of synchronous signal wire

Here are some connection cases:

1#container2#container3#container

6.7. 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: Acrylic plate mounting

Figure 6-21 Acrylic plate installation instructions

Step 2: Secure the PDC door

Figure 6-22 Open and close the distribution box door instructions

6.8. Fire Fighting system and Hose Connection

In front of the container, there are two water firefighting protection boxes.

Figure 6-23 In front of the container

The water fire protection pipe interface is located on the side of the container, with the top being the inlet and the bottom being the outlet, claw pitch size 81. When there is a fire inside the system, the container can be cooled down through the water interface. Attention should be paid to the external sealing of the water fire pipe interface to maintain the temperature of the battery room.

       KA --------81mm

H --------95mm

D --------65mm

Model: STORZ 65

Figure 6-24Water Firefighting interface

The fire fighting system is designed according to the specification and size of the 20ft container. The fire extinguishing agent is transported from the fire extinguishing agent cylinder group through the main pipe and branch pipe to the nozzle of the container battery room to achieve the fire extinguishing function.

The system includes gas cylinder, fire extinguishing agent, solenoid valve, pressure feedback device, firefighting control system, etc.

The fire control system is mainly composed of fire detector (temperature and smoke), audible and visual alarm device, emergency start and stop button, air release indicator, fire controller, etc.

The combustible gas detector is separately configured to detect the concentration of hydrogen and carbon monoxide in the battery room, and the signal is transmitted to BESS. At the same time, the container is equipped with pressure relief device, air inlet and exhaust fan.

Figure 6-25 Fire fighting system action logic

This system has two control modes: automatic and electrical manual. There are two independent detection circuits in each protection area. When the first fire signal is given, an alarm will be issued, indicating the location of the fire and reminding the staff to pay attention. When the first 2 detector also signal fire, automatic fire extinguishing controller began to delay phase (0 to 30 s adjustable), after a time delay, open the solenoid valve, solenoid valve needle start bottle storage cylinder head valve, the fire area firefighting operations, at the same time receive the feedback signal from the pressure switch alarm controller, control panel discharge indicator; When the alarm controller is in the manual state, the alarm controller only sends out alarm signals and does not output action signals. After the on-duty personnel confirm the fire alarm, press the emergency start button on the alarm control panel or the emergency start and stop button at the entrance of the protection area to start the system and spray fire extinguishing agent