20C1200K Service Manual V2.0

1. Overview

This manual focuses on Commissioning, Routine Onsite Survey, Troubleshooting, and Spare Parts Replacement instructions for the PowerCombo-20C2H1200K of energy storage systems.

1.1. Symbols

The following symbols may appear in this article, and their meanings are as follows:

DANGER: Indicates a hazardous situation that, if not avoided, will result in death or severe injury

WARNING: Indicates a dangerous situation that, if not avoided, will result in death or severe injury

CAUTION: Indicates a dangerous situation that, if not avoided, may result in minor or moderate injury

NOTICE: Indicates that if property damage may result from improper use.

NOTE: Please note important information best practices and recommendations.

NOTE is used to address information that is not related to personal injury, equipment damage, and environmental degradation.

1.2. Revision record Document version A01

⚫ First official release

The contents of this manual are subject to periodic updates or revisions due to product development without prior notice.

1.3. Symbol Description

2. Safety Precautions

2.1 Important safety instructions

Safety warning

When operating and maintaining the BESS, please read this manual carefully and follow the identification on the BESS and all safety precautions in the manual.

Authorised Engineer

• Commissioning and maintenance of the BESS must be carried out by an engineer appointed by the manufacturer or its distributor.

• Unauthorised operation may endanger personal safety and lead to malfunction or damage to the BESS.

• Damage caused by non-compliance is not covered under warranty.

Compliance

• Installation, operation and maintenance of the BESS must comply with local laws, regulations and codes.

• The safety precautions in this manual are in addition to, and not a substitute for, local laws, regulations and codes.

Important Safety Guidelines

• This manual contains important safety guidelines for the 20C1200K BESS that should be strictly followed during installation and maintenance.

DANGER

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

Don't touch any terminal and conductor connected with the loop of the utility grid.

Pay attention to any instruction and safety documents about power on grid.

WARNING

There might be an electric shock risk inside the BESS!

Any operation related to this device will be conducted by professionals.

Pay attention to the safety precautions listed in safety instructions and installation documents.

WARNING

Don't touch electric parts within 15 minutes after the power outage!

There is dangerous energy in capacitance storage. Don't touch device terminal, contactor and cooper bar, and other electric parts within 15 minutes after disconnecting all device power supplies.

NOTICE

All maintenance and preservation inside the BESS require using tools and shall be conducted by the trained person. All internal equipment that needs to be opened with tools must be maintained by a professional. Please read this service manual before operation.

2.2. Attention

2.2.1. Personnel requirements

Site engineers must prepare the following tools:

2.2.2. Application scope

The Energy storage products are only permitted to use for commercial or industrial purposes and must not be used in any environment or application related to life support equipment.

2.2.3. Electrical safety marking

The marking contains important information about the security operation of the system and is strictly prohibited from tearing or damaging. Make sure the logo is clear and readable, and replace it as soon as damage or blur occurs.

2.2.4. Explain

For easier reading of this manual, images are provided. The images are used only for illustration purposes, and if there is any inconsistency between the image and the actual product, the actual product shall govern.

2.3 Storage Attention

2.3.1. Environmental requirement

• Storage Temperature:

  1. Short-term Storage (up to 1 month): -20°C to +55°C  

  2. Long-term Storage (up to 1 year): 0°C to +35°C  

  3. After 12 months at the recommended temperatures, irreversible capacity loss may range from 3% to 10%.

• Relative Humidity:

Should not exceed 95%, non-condensing.

• Safety Precautions:

No explosive materials should be present in the storage area.

• Pollution Control:

Avoid strong acids, alkalis, and other highly contaminating substances that could adhere to or be inhaled by the equipment.

• Storage Surface:

The ground must be flat, with a height variation of less than 3mm between the ground and the box.

• Storage and Transportation Duration:

Total storage and transportation time must not exceed 6 months from the date of shipment. After 6 months, battery charging and State of Charge (SOC) calibration are required, with at least 60% SOC to be restored. Failure to recharge as required may impact battery performance and lifespan.

• Inspection Requirement:

If the storage period exceeds 3 months, the battery must be inspected and tested by professionals before use.

• Storage State Definition:

If the battery has not undergone charging and discharging cycles for 3 consecutive days, it is considered to be in a storage state.

2.3.2. Charging Guidelines Before Storage:

• For Storage Periods Less Than 10 Days:

Charge the battery to ensure the minimum voltage of each string is ≥ 3.30V. The "Ready" indicator light on the "Status" interface should be green.

• For Storage Periods of 10 Days or More:

  1. Charge the battery to ensure the minimum voltage of each string is ≥ 3.36V.  

  2. Check the minimum voltage of the cells on the "BMS Status" interface, ensuring it is ≥ 3.36V. The "Ready" indicator light must be green. If voltage is inadequate, set the BESS to charging mode until the minimum voltage is achieved.

• Loss of External Power Supply:

Disconnect all breakers and isolation switches of the system. When power is restored, close all breakers and isolation switches and perform maintenance on the system.

NOTICE

In the storage state, lithium cells experience a self-discharge rate of approximately 0.1% per day. Without proper maintenance over an extended period, the State of Charge (SOC) may become inaccurate. If the cell voltage drops too low, it can lead to over-discharge, potentially causing damage to the cells!

It is important to note that any faults arising from inadequate maintenance under these conditions are not considered quality issues and will not be covered under warranty terms. Regular monitoring and maintenance are essential to prevent such issues and ensure the longevity and reliability of the battery system!

3. System Introduction

3.1 Introduction to the System

The PowerCombo-20C2H1200K utilizes a 20-foot standard shipping container, featuring integrated AC and DC systems that are 100% pre-installed and FAT for ease of transportation and quick on-site installation.

Specifications

Rated Power: 1,200 kW Energy Capacity: 2,256 kWh

Components:

As illustrated in Figure 3-1, the PowerCombo-20C2H1200K energy storage system includes:

• Energy storage batteries

• GPC control box

• Air conditioning unit

• Fire suppression system

• Auxiliary device

(Note: The transformer is supplied by the customer.)

Figure 3-1 Schematic diagram of energy storage system

Primary Circuit Diagram

Figure 3-2 is a primary circuit diagram of the 20C2H1200K. After the battery energy is converted by PCS , it supplies power to users through transformer.

Figure 3-2 Primary Circuit Diagram

3.2 Technical Data

4. System Components

4.1 System Layout

The system is divided into three areas: Battery room, PCS room and Electrical room.

Figure 4-1 System layout

4.2 Power Conversion System

The conversion system can realize the bi-directional energy conversion between the battery and the AC power supply of the grid. Its core part is an inverter composed of power electronic components and embedded control software.

Figure 4-2 EH-0200-HA-M

Figure 4-3 PCS schematic diagram

Table 4-1 LED indicator status description

4.3 GPC Controller Box

The GPC serves as the control and data acquisition center for the Battery Energy Storage System (BESS). It collects and integrates data from various components, including:

• - Power Conversion System (PCS)

• - Battery Management System (BMS)

• - Fire Suppression System (FSS)

• - Air Conditioning (HVAC)

By aggregating this data, the GPC enables comprehensive scheduling and management of system operations. This ensures optimal performance and enhances the overall efficiency and reliability of the energy storage system, allowing for seamless integration and coordination among all subsystems.

Figure 4-4 GPC controller box

4.4 Power Distribution Box

Figure 4-5 Distribution Box

Table 4-2 Distribution box layout and description

4.5 Battery

• Integrate BMU modules through copper bars and cable series;

• The positive and negative copper bar can withstand the current intensity of more than 250A;

• Battery pack: No external exposed live metal parts;

• Battery Pack: The overall calendar life is more than 10 years; cycle life is not less than 5000 times. (The end of life is the battery capacity degradation to EOL with 80% retention)

Figure 4-6 Battery PACK

Table 4-3 Battery Datasheet

4.6 Battery String

The battery string is a smart and user-friendly energy storage product. It consists of 24 standard battery packs (P15), the BMU in the battery pack can effectively monitor and manage the each battery pack, and improve the safety performance and cycle life of the DC system during the entire operating life.

Figure 4-7 Battery String

Table 4-4 Battery String Configuration Table

4.7 HVU

Figure 4-8 HVU

The HVU is equipped with advanced features to ensure the safe and efficient operation of the battery system:

High-Voltage Disconnection Capability:

The HVU can safely disconnect the high-voltage unit.

Power Circuit Protection:

The power circuit integrates contactor, fuses, and breaker, providing reliable protection for the battery string against faults.

Integrated Cell Management Unit (CMU):

The CMU functions as a secondary Battery Management System (BMS), collecting data from each Cell Management Unit (BMU). This allows for realtime current monitoring and protection of the entire battery string, ensuring timely communication and responsiveness to any issues.

5. BESS Commissioning

5.1 Pre-power-up checks and precautions

5.1.1. Precautions

Before commissioning the Battery Energy Storage System (BESS), it is crucial to ensure the following:

• Qualified Personnel:

Confirm that all commissioning personnel possess the necessary qualifications and have completed safety training.

• Safe Environment:

Ensure that the area surrounding the BESS is clear of fire hazards, explosive materials, and other dangerous elements.

• Personal Protective Equipment (PPE):

Provide essential PPE, including insulated gloves, goggles, and other protective gear to safeguard personnel.

• Equipment Compliance:

Verify that the model, specifications, and parameters of the equipment meet project requirements, particularly for critical parameters such as voltage, current, and power.

• Wiring Verification:  

Inspect the wiring connections of the energy storage equipment to the grid, load, and transformer to ensure correctness.

• Secure Cable Connections:

Check that all cable joints are tight and free from looseness or poor contact to prevent failures.

• Environmental Conditions:

Confirm that the temperature, humidity, and ventilation in the area where the energy storage equipment is located comply with operational requirements.

5.1.2. Container appearance inspection

The Battery Energy Storage System (BESS) has an IP54 protection rating, making it suitable for outdoor installation. To ensure safe and efficient operation before commissioning, please verify the following:

• Container Condition:

  1. Check that the container is in normal condition with no peeling paint, corrosion, cracks, scratches, or obvious deformations.  

  2. Ensure that all doors can open and close properly.

• Interior Dryness:

Inspect the inside of the container to confirm it is dry, without any ponding or water stains.

• Cabinet Stability:

Ensure that all cabinets are securely installed and will not shift or fall due to vibrations.

• Assembly and Wiring Integrity:

  1. Verify that all internal assemblies and wiring are complete and standard.  

  2. Confirm that cables and conductors are reliably connected, with no damage or disconnections.  

  3. Ensure that screws are tightened, cables are not exposed, and the system is properly grounded.

• Labeling and Signage:

  1. Check that labels, silk screen prints, signboards, and nameplates are complete and clearly visible.  

  2. Ensure that any dangerous electrified components have appropriate safety protection or warning signs.

• Cable Management:

Ensure that cables are tied evenly, with no sharp corners left at the cutting points of cable ties.

5.1.3. Grounding inspection

BESS must be securely grounded to ensure personal safety. The BESS shell provides two ground points. The ground points are arranged diagonally at the bottom of the container, as shown in Figure 5-1. After the container is secured to the base, weld the external ground flat steel to the ground point of the container shell, and take anti-corrosion measures according to the electrical standards.

Figure 5-1 Container ground point

5.1.4. Power cable connection

NOTE

The battery string cable has been removed during transportation. Install it again after the device arrives at the installation site.

All cables are stored in a carton under battery cluster 2# (2BC) in the battery room.

Take out the battery cluster cables in the carton

Figure 5-2 Location of cable and spare parts

Figure 5-3 Fixed end of DC cable

NOTICE

When the joint is inserted tightly, there will be breaking sound, if the joint is not inserted tightly, there will be equipment damage!

5.1.5. Battery insulation inspection

Insulation testing is a crucial step in ensuring the safe operation of Energy storage products. The high or low insulation resistance directly affects the insulation performance of Energy storage products, which in turn affects the service life and safety performance of the BESS. Through insulation testing,the insulation performance of electrical equipment can be evaluated to ensure its safety and reliability under normal operating conditions.

Figure 5-4 Insulation resistance tester

Operation Steps:

Step 1:

Disconnect DC Connection: Remove the positive or negative connection on the DC side of the High Voltage Unit (HVU).

Step 2:

Set Up Insulation Tester: Connect the positive terminal of the insulation resistance tester to the positive/negative connector of the HVU. Ground the negative terminal of the insulation resistance tester.

Step 3:

Perform the Test: Use a DC voltage of 1500V or above for the test, and maintain the testing duration for 1 minute.

Step 4:

Record Results: Check and record the test results. The insulation resistance value should be ≥ 10 MΩ to ensure acceptable insulation performance.

NOTICE

The DC side cable can only be removed from the positive or negative terminal during insulation testing to prevent positive and negative short circuits!

5.2. Power-up operation

WARNING

People with electrical operation qualifications can operate Energy storage products, and others may not operate without authorization!

Operation Steps:

Figure 5-5 Start-up operation step

AC side switch location：

Table 5-1 Distribution box breaker

Table 5-2 GPC breaker

Control Mode：

The energy storage system has two operating modes: Constant AC power mode and Stop mode.

Figure 5-6 Operation mode setting interface

Table 5-3 Description of system operation modes

5.3. Inspection after power-up

5.3.1. Switch signals and data check

DC Breaker Check Step:

Step 1:

Close HVU Breakers 1# ~ 6# (QF61 to QF66).

Step 2:

Verify whether the switch on the (HMI) is illuminated.

Contactors Check Step:

Step 1:

Close Contactors 1# ~ 6# (QF61 to QF66).

Step 2:

Verify whether the switch on the (HMI) is illuminated.

Figure 5-7 Switch check

Battery Status Check Step:

Step 1:

Check the battery voltage and temperature in the BMS interface, record the data.

Figure 5-8 BMS data check

NOTICE

The BESS should be recharged as soon as possible after the voltage below 3V!

Charging and discharging temperature should be >15 degrees！

5.3.2. HVAC inspection (cooling, heating)

Check Step:

Step 1:

Verify that communication is normal after powering on the air conditioning unit.

Step 2:

Set the ECS interface to manual mode. Adjust the cooling/heating temperature logic values to simulate high/low temperature conditions and check if the air conditioning unit activates cooling/heating.

Step 3:

When the air conditioning unit operates normally in cooling/heating mode, revert the temperature logic values to their normal state and switch back to automatic mode.

Step 4:

Confirm that the air conditioning unit has turned off the cooling/heating function.

NOTICE

Due to site conditions it is usually only possible to check the cooling/heating function!

5.3.3. Fire Suppression system inspection

Method 1: Tool Trigger

Figure 5-9 Trigger tools

Step 1:

Remove the fire gas solenoid valve and check whether the solenoid valve thimble is popped up.

Step 2:

Use a smoke spray to trigger the smoke sensor in the battery room, ensuring that the secondary alarm is activated and the second-level alarm indicator light on the fire host illuminates.

Step 3:

Use a portable temperature gun to trigger the temperature sensor, ensuring that the first-level alarm is activated. Both the first and secondlevel alarm indicator lights on the fire host should illuminate, followed by a 30-second countdown before releasing the fire suppression gas.

Step 4:

Confirm that the external alarm and indicator lights are activated, and the solenoid valve thimble pops up (indicated by red), confirming that the fire system is triggered correctly.

Step 5:

After completing the tests, press the reset button to restore the fire suppression system, and use the appropriate tool to reset the solenoid valve.

Method 2: Manual Trigger Step 1:

When testing tools are not available on-site, manually press the fire alarm button to trigger the fire suppression alarm.

Figure 5-10 Outdoor button Figure 5-11 Indoor button

Step 2:

Once the alarm is triggered manually, the fire suppression alarm should activate immediately, and the fire host will begin a 30-second countdown.

Step 3:

After the countdown ends, the solenoid valve thimble for the fire gas cylinder will pop up.

Step 4:

After completing the test, click the reset button to restore the fire system and use the appropriate tool to reset the solenoid valve.

NOTICE

The thimble must be unpopped when installing the fire gas cylinder solenoid valve after commissioning!

5.3.4. EPO Test

Step 1:

After verifying that the BESS is functioning normally, press the emergency stop button located on the outside of the container.

Step 2:

Once the emergency stop button is pressed, the following components should trip:

• System breakers: QF2K and QF3K

• AC breakers: QF21 to QF26

• DC breakers: QF61 to QF66

5.4. Charge-discharge cycle test

5.4.1. Charge/discharge cycle test

Step 1:

Follow the BESS power-up steps to close all system switches. Check the BESS status interface to ensure that the system ready indicator light is continuously illuminated.

Step 2:

Access the Energy Storage interface following the steps shown in the figure.

Step 3:

Perform a charging test using a power of 0.5C, maintaining this for 5 minutes while monitoring the system for any abnormal alarms.

Step 4:

Conduct a discharging test using a power of 0.5C, also for 5 minutes, and observe the system for any abnormal alarms.

Step 5:

After the charging and discharging tests are completed, confirm whether the system needs to be stored for more than 10 days. If storage is required, disconnect the system switches according to the storage precautions.

6. Routine Onsite Survey

6.1. Maintenance Instructions and Tools Introduction

6.1.1. Maintenance Instructions

⚫ Power Disconnection

Before performing 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 for the full discharge of any residual energy in the BESS.

⚫ Qualifications of Maintenance Personnel

Maintenance personnel must possess valid electrical operation certifications and be familiar with local electrical safety standards and operating procedures. They should have sufficient experience and have received specialized training for maintaining energy storage systems. ⚫ Personal Protective Equipment (PPE) Requirements

Maintenance personnel must wear the required personal protective equipment (PPE) according to safety standards before starting any maintenance work. This includes, but is not limited to: insulated gloves, insulated footwear, protective work clothing, helmets, and safety goggles. Proper PPE is essential to prevent injuries caused by electrical hazards or accidental incidents during maintenance.

⚫ Weather Condition Restrictions

Maintenance work should never be carried out under adverse weather conditions, such as strong winds, high humidity, typhoons, rain, or lightning. Any damage caused by performing maintenance under such conditions will not be covered under quality protection warranties.

⚫ After-Maintenance Inspection

After maintenance is completed, ensure that the BESS door is fully closed. Additionally, verify that the weatherproof sealing strip around the door is intact and not curled or damaged. This ensures the sealing and waterproofing of the system.

6.1.2. Tools Instructions

6.2. Maintenance Items

Maintain a list of items:

6.3. Container and Environmental Inspections

The inspection process for the BESS container involves a comprehensive visual and functional assessment of both its exterior and interior components. This includes checking for structural integrity, safety features, grounding, and potential hazards in the surrounding environment.

6.4. PCS Room Inspection

WARNING

• Only professional personnel are allowed to maintain the converter. Others cannot maintain it without authorization!  

• In order to ensure the safety of maintenance personnel, it is prohibited to touch any live parts of the converter when the converter is running, and always check whether the ground point of the converter is reliably connected.  

• After the converter is completely powered off, there are still dangerous voltage hazards in the converter! Wait for 15 minutes before operating the converter!  

• When the converter is working, it is prohibited to plug or unplug the toolless female connector!  

• Please use qualified spare parts provided by Sineng only. Sineng shall not assume any liability for the equipment damage due to the use of nonSineng spare parts.

The inspection of the electrical and power converter focuses on ensuring both the physical condition and operational functionality of key components. This includes verifying the cleanliness and safety of the electrical room, checking the integrity of cables, terminals, and grounding connections, and ensuring that all power systems are operating efficiently.

Date Record:

6.5. Battery Room Inspection

The inspection of the battery room and its components focuses on maintaining optimal environmental conditions and ensuring the integrity of the battery system. This involves checking room temperature and humidity, ensuring they are within safe operating limits, and performing a thorough inspection of the battery packs for any damage or operational issues.

Date Record:

6.6 Fire Suppression System Inspection

The fire safety inspection ensures the proper functioning of fire suppression systems within the energy storage facility. This includes verifying the operation of the fire extinguishing and alarms, as well as conducting simulation tests to check the responsiveness of smoke and temperature sensors.

Figure 6-1 Fire logic

6.7. Air Conditioning Inspection

The air conditioning inspection ensures that both the physical condition and functionality of the system are optimal. This includes checking for cleanliness, damage, and secure installation, as well as confirming that ventilation openings are clear. Simulation tests are performed to verify the heating and cooling functions, while cables and terminals are inspected for integrity.

6.8. Battery Protection Settings Check

7. Guidance on spare parts replacement

7.1. List of common spare parts

NOTICE

The table above lists the list of spare parts that are given away.

Depending on the project requirements, you may contact the manufacture for more detailed spare parts.

7.2. Battery System

7.2.1. BMU

NOTICE

• Confirm that no live voltage remains at any point in the system before proceeding with any maintenance or replacement of parts

• Ensure that all maintenance personnel are wearing the required PPE, including insulated gloves, safety glasses, protective footwear, in accordance with safety standards and local regulations.  

• PPE should be checked for integrity before use to ensure it provides adequate protection against electrical hazards.

Step 1: Disconnect HVU power

Disconnect the faulty BMU corresponding to the battery string HVU DC contactor;

Figure 7-1 Contactors switch

Disconnect the AC 220V HVU power switch (QFHV) in the distribution box.

Figure 7-2 QFHV Switch

Disconnect the DC breaker of the HVU of the corresponding battery string of the faulty BMU.

Figure 7-3 HVU DC Switch

Step 2: According to the fault information of the BMS_Tools, find the Pack of the BMU corresponding to the fault.

Figure 7-4 PACK

Step 3: Remove Pack power cable and communication COM terminals

WARNING

The two cable connector must be completely unplugged, it is forbidden to have a situation where only one end of the cable is removed; it is forbidden to have a situation where the positive and negative ends of the target PACK are unplugged and the cable is hanging in the air!!!!

Step 4: Remove the PACK panel

Remove the panel screws.

Figure 7-9 PACK panel

Unplug the terminals on the adapter board and completely remove the panel.

Figure 7-10 BMU Power Cable

Step 5: Replacement of BMU

Unplug BMU Sampling Terminal.

Figure 7-11 BMU Sampling Terminal

NOTICE

Insulated gloves must be worn for plugging and unplugging operations!

Use a Phillips screwdriver to remove the screws at the corners of the BMU plate and take out the BMU plate.

Figure 7-12 BMU

Replace the new BMU and install the screws at the corners to complete the fixing, the DIP position of the new BMU should be the same as the old BMU replaced.

Figure 7-13 DIP Code

Step 6: Reset Panel and Cables

Step 7: HVU Power-Up

Close HVU DC breaker

Close HVU AC 220V MCB on distribution box

Close contactor on HMI

Step 8: Decode using BMS_Tools,IO Unlock >> BMU dialling code unlocked >> reboot >> BMU locked dialling code

Figure 7-14 BMS_Tools

Step 9: After completing the BMU replacement, use HMI or BMS_Tools to check if the fault is eliminated.Check that the BMU software version are always the same as the other PACK.

7.2.2. PACK Fan

Step 1: Remove the panel screws.

Figure 7-15 PACK panel

Step 2: Unplug the power cable from the defective fan and remove the fastening screws.

Figure 7-16 PACK Fan

Step 3: Replace the fan with the same model and tighten the screws.

7.3. HVU（High voltage unit）

7.3.1. CMU

Step 1: Disconnect HVU power

Disconnect the faulty BMU corresponding to the battery string HVU DC contactor;

Figure 7-17 Contactors switch

Disconnect the AC 220V HVU power switch (QFHV) in the distribution box.

Figure 7-18 QFHV Switch

Disconnect the DC breaker of the HVU of the corresponding battery string of the faulty BMU and disconnect power cables.

Figure 7-19 HVU DC Switch

Step 2: Use a 5mm Phillips screwdriver to remove the nine screws from the cover, lift off the cover and confirm locate of CMU.

Figure 7-20 HVU Cover Figure 7-21 CMU

NOTICE

Screwdrivers operate vertically to prevent screws from slipping!

Step 3: Remove CMU

Clean the fixing adhesive on the CMU terminal block and pull out the terminals in order.

Figure 7-22 CMU

Step 4: Replacement CMU

Before installing a new CMU, use a portable hoover to suck out the debris of the adhesive inside the HVU.

Replacement CMU and restore HVU

Step 5: After completing the CMU replacement, use HMI or BMS_Tools to check if the fault is eliminated. Check that the CMU protection value and software version are always the same as the other strings.

7.3.2. Fuse

Step 1: Disconnect HVU power

Disconnect the faulty BMU corresponding to the battery string HVU DC contactor;

Figure 7-24 Contactors switch

Disconnect the AC 220V HVU power switch (QFHV) in the distribution box.

Figure 7-25 QFHV Switch

Disconnect the DC breaker of the HVU of the corresponding battery string of the faulty BMU and disconnect power cables.

Figure 7-26 HVU DC Switch

Step 2: Use a 5mm Phillips screwdriver to remove the nine screws from the cover, lift off the cover.

Figure 7-27 HVU Cover

NOTICE

Screwdrivers operate vertically to prevent screws from slipping!

Step 3: Remove Fuse

Use spanner (13mm) to loosen and remove screws.

Figure 7-28 Fuse

Remove fuse

Figure 7-29 Remove Fuse

Step 4: Replacement Fuse

To install a new fuse, pre-fix the screws at both ends of the fuse first, without tightening the screws.

Use 14mm open-end spanner to hold the screws of positive and negative copper rows of circuit breaker output, use torque spanner with 13mm on the opposite side, adjust the torque value according to the torque requirement, and fasten the M8 flange nut, the torque is 14kgf.cm.

Figure 7-30 Install Fuse

Step 5: After completing the fuse replacement, use HMI or BMS_Tools to check if the fault is eliminated.

8. Troubleshooting

8.1. Information

In the event of an abnormal failure of an BESS that cannot be repaired with the help of the service manual, please contact a the manufacturer’s engineer and send for the following information:

1. BESS model;

2. Container number;

3. Gateway number;

4. Fault information (pictures, videos, logs);

8.2. Battery system

Troubleshooting of the battery system can be carried out via the HMI and

BMS_Tools (see the BMS user manual for details on how to use BMS_Tools).

8.3. PCS

Troubleshooting of fault messages can be carried out through the HMI PCS status interface (see the BESS user manual for details on the use of the HMI).

WARNING:

8.4. Fire Suppression System

8.5 HVAC

9. Gateway and Update

9.1. Gateway online

Method 1:

Step 1:

Prepare a medium-sized local SIM card with a stable network connection.

Step 2:

Insert the SIM card into the gateway, then restart the gateway (disconnect the power and reconnect it).

Step 3:

Consult with a manufacturer’s engineer to confirm whether the gateway is online.

Method 2:

Step 1:

Prepare an Ethernet cable that provides a stable network connection (ensure the network is WAN and that the firewall is configured to allow the gateway to connect).

Step 2:

Connect the Ethernet cable to the ETH1 port on the gateway.

Step 3:

Consult with a manufacturer’s engineer to confirm whether the gateway is onlin

9.2. Site Update

NOTICE

Remote update are available once the site meets the required network conditions. On site update are only offered when a network connection is unavailable!

9.2.1. RTU update

Operation Step:

Step 1:

Prepare SD card with a maximum storage capacity of 32GB, formatted as FAT32. (A blank SD card is pre-installed in the RTU at the factory )

Step 2:

Extract the package to access two folders.

Step 3:

Disconnect the power supply to the RTU, insert the SD card into the RTU, then reconnect the power supply. The SD indicator on the RTU will blink. After a few seconds, the Error indicator blink, indicating that the upgrade is complete.

Step 4:

Disconnect the power to the RTU, remove the SD card to clear the internal files, then reinstall the SD card and reconnect the power. Once the update is complete and there are no errors, the Error indicator will turn off and the Run indicator will turn on.

NOTICE

The SD card must be formatted after the update is complete!

9.2.2. HMI update

Operation Step:

Step 1:

Remove the USB flash drive from the back of the HMI (ensure the USB flash drive is formatted as FAT32).

Step 2:

Extract the update package and copy it to the USB flash drive.

Step 3:

Insert the USB flash drive back into the HMI. On the screen, click "Download" and enter the password “111111”. (Make sure the HMI remains powered on during this process.)

Step 4:

Select the corresponding folder for the update. Wait for a short period until the download file indicator appears.

Step 5:

Check the HMI version on the system interface to confirm whether the update was successful.