1. Tools
Maintenance personnel must wear the required personal protective equipment (PPE) according to safety standards before starting any maintenance work. Proper PPE is essential to prevent injuries caused by electrical hazards or accidental incidents during maintenance.
Helmet |
Insulated boots |
Insulating gloves |
Multimeter |
3mm flat-head screwdriver |
Torque wrench (19mm) |
Hexagon wrench (5mm) |
Diagonal cutting pliers |
2. BESS Shutdown
Power Disconnection
Before carrying out any maintenance on BESS, ensure that both the AC and DC sides are completely disconnected from the power supply. A minimum waiting time of 15 minutes must be observed to allow any residual energy in the BESS to be completely discharged.
Qualifications of Maintenance Personnel
Maintenance personnel must hold valid electrical operator certifications and be familiar with local electrical safety standards and operating procedures. They should have sufficient experience and have received specific training in the maintenance of energy storage systems.
Weather Condition Restrictions
Maintenance should never be carried out in adverse weather conditions such as high winds, high humidity, typhoons, rain or lightning. Any damage caused by carrying out maintenance in such conditions will not be covered by the warranty.
After-Maintenance Inspection
On completion of maintenance, ensure that the BESS door is fully closed. Also check that the weather strip around the door is intact and not curled or damaged. This will ensure that the system is sealed and watertight.
3. Maintenance Instructions
Corrective Maintenance:
Remote monitoring: Real-time monitoring of the operating status of the energy storage BESS via the EMS or Cube platform, including output power, temperature, humidity and other data to ensure the BESS is operating in a normal operating environment.
Fault diagnosis: Using the platform's big data analysis function to analyse the historical data of the energy storage system, detect potential problems, perform timely fault warning and diagnosis, quickly and accurately locate the faults and ensure power generation.
Quarterly Maintenance (3-6 month):
Powered Inspection: Under the condition that the BESS is operated with power, a visual inspection is performed to observe whether there are any abnormalities in the appearance of the BESS, such as breakage, deformation, liquid leakage, etc., and to check whether the Pack, connection wiring, cooling system, safety devices and other components are functioning normally.
Record data: Record protection data, including battery voltage, current, temperature and other parameters to ensure that these parameters are within the normal range.
Environmental check: Check the operating environment of the energy storage system, including temperature, humidity, ventilation, etc., to ensure that the BESS is operating in a suitable environment and to avoid the influence of high temperature and humid environment on the performance of the BESS.
Annual maintenance:
Shutdown inspection: Carry out a comprehensive inspection and maintenance with the BESS completely de-energised. Check the internal structure to ensure that connections are secure and free from looseness and corrosion.
Cleaning: Use cleaning tools to thoroughly clean the inside of the container, including the surfaces of the BESS, such as the battery racks and PCS, and the container floor and walls, to remove accumulated dust, dirt and rust.
Calibration and adjustment: Calibrate the SOC and SOH of the BESS to ensure the accuracy of the measurement data. At the same time, adjust and optimise the parameters and performance of the BESS according to the operation and test results of the BESS.
Quarterly Maintenance
1. Container and environment inspection
Inspection Content | Check |
A. The outer fences of the container are in good, not broken and not rusted (if any); | |
B. No debris, weeds or construction(10ft) around the container; | |
C. No flammable, explosive or other hazardous materials in the vicinity of the container; | |
D. No other operations around the container that could affect safe operation; | |
E. Container foundations are free from sinking, tilting, breaking, cracking, shifting, etc; | |
F. Safety markings and labels on the surface of the container are not damaged or missing; | |
G. The container has no corrosion, good sealing of adhesive strips, no breakage of shutters and dust nets and no deformation of the container door; | |
H. No abnormal water leakage from the container and no leakage or water damage at the PCS AC inlet; | |
I. No visible accumulation of dust inside or outside the container; | |
J. Container grounding is not loose or rusty and grounding markings are intact; | |
K. Container fireproofing mud has not been removed (if any) | |
Comment: | |
2. Electrical inspection
Inspection Content | Check |
A. PCS protective netting is well secured, has no breaks and is cleared of any visible leaves or shading. | |
B. PCS safety labels are clear, not broken or peeling; | |
C. The PCS operates normally, the fan works properly and there are no strange noises or odours; | |
D. The PCS indicator is normal, the communication is normal, there is no abnormal alarm. | |
E. The primary inlet holes of the distribution box are well sealed and free of animal marks. | |
F. Primary circuit cable connection terminals and insulation are not loose, damaged or corroded, and fixing marks are not displaced; | |
Comment: |
Record:
PCS A phase voltage | PCS B phase voltage | PCS C phase voltage | PCS frequency |
|---|---|---|---|
PCS DC Volt 1# | PCS DC Volt 2# | PCS DC Volt 3# | PCS DC Volt 4# |
PCS DC Volt 5# | PCS DC Volt 6# | ||
3. Battery room inspection
Inspection Content | Check |
A. Normal temperature (<45°C) and humidity (<85%) in the battery room. | |
B. There are no water leaks in the battery room and the battery cluster looks good with no corrosion or deformation; | |
C. Pack safety markings are clear, not detached and not broken; | |
D. Pack power cable and secondary cable are connected tightly without abnormality; | |
E. Clusters are tightly grounded and copper rows are free of corrosion; | |
F. Lighting is on properly; | |
G. Pack fans operate normally with no noise; | |
H. Each cluster of high-voltage box terminals and network cable is well connected, normal communication; | |
I. The BMS is operating normally with no alarms. Protection limit are normal and not modified; | |
J. Good cell consistency (Cluster each cell voltage difference <300mV); | |
Comment: | |
Record:
Cell Highest Volt: | Cell Lowest Volt: | Cell Highest Temp: | Cell Lowest Temp: |
|---|---|---|---|
Version: CMU BMU | HMI RTU |
4. Fire inspection
Inspection Content | Check |
A. The fire control indicator shows normal, the standby power supply is normal and the battery voltage is measured and recorded; | |
B. Fire labels are clear and intact; | |
C. Fire gas cylinders are intact and the air pressure is within the correct range (22-26 bar); | |
D. Smoke and temperature sensors are detected normally and alarms can be triggered normally; | |
E. Audible and visual alarms and sirens can be activated normally; | |
F. The solenoid valve is firmly installed and the pin can be ejected normally after the fire has been touched; | |
Comment: |
NOTICE
Before test: Make sure that the solenoid is disconnected.
After the test: the solenoid must be reset.
Spraying problems caused by misuse are not covered by the warranty, so please operate strictly!
Record:
Cylinder pressure:
5. HVAC Inspection
Inspection Content | Check |
A. The air conditioner operates normally and there is no abnormal noise from the internal or external fans; | |
B. The air conditioner is well mounted, with no condensation on the internal unit and no obstruction of the external cooling vents; | |
C. Power and communication cables are not loose or broken; | |
D. There is no abnormality in the sampling of the internal temperature sensor of the air conditioning system; | |
Comment: | |
6. Other inspection
Inspection Content | Check |
A. Detection of combustible gases (hydrogen and carbon monoxide) is normal; | |
B. Pressure device installed properly | |
C. Fire water connections no change (if any); | |
Comment: | |
Annual maintenance
1. Electric Room
Inspection Content | Check |
A. Cleaning of PCS protection nets; | |
B. Check the cable (PCS, AC) for looseness, the connection terminals and the earthing for discolouration or detachment, and replace any damaged or corroded connection terminals. | |
Comment: | |
2. Container
Inspection Content | Check |
A. Cleaning/replacement of BESS filters | |
B. Check for signs of leakage around the tank, check for rust; | |
C. Complete cleaning of the battery room. | |
D. Check and tighten the connection bolts of each part. | |
E. Check the voltage consistency of the cells and carry out balance maintenance | |
F. Use BMS_tools to check the BMS, read and save the data and update the software (if needed). | |
G. Checking network/CAN cable connections | |
H. Cleaning the air-conditioning filter. | |
I. Do an insulation resistance test of the total positive/negative clusters to ground. | |
Comment: | |
Record ≥1.5MΩ:
Positive | Negative |
NOTICE
It is recommended to increase the cleaning frequency according to the actual situation on site to ensure that the nets or filter is not clogged!
Recommended cleaning season: summer
Recommended tools: high-pressure washer
3. CO/H2
Inspection Content | Check |
A. Check CO/H2 detection concentration (8000). | |
B. Trigger CO/H2 alarm and view exhaust fan linkage | |
Comment: |
4. SOH Cablibration
In fact, the SOH of a battery continues to decline as the battery system operates. Because the capacity used to calculate SOC is based on the default capacity of a new battery, and the actual battery capacity declines in tandem with the decline in SOH, once a year we need to calibrate the SOH.
SOH cablibration logic
Operation:
EMS SOH calibration switch-on command via point 49536
After calibration start, EMS charge/discharge control command is invalidated, and EMS needs to exit charge/discharge control after reading RTU calibration start status;
When calibration is finished or calibration is not turned on, EMS can control charging and discharging normally;
Calibration status reading point: 49626 bit6, bit7
NOTICE
SOH calibration time is expected to be 6-8 hours, and calibration will fail and need to be recalibrated if you start charging and discharging during the calibration process!