Documents

site plan 29 pages

Also attached to this agenda item: Amended Site Plan Application Redacted Auto Park PB Resolution 10.11.11 Auto Park PB Resolution 11.12.02 CROTON AUTO PARK 9-30-24 Material Safety Datasheet eSpire 280 SP Sprocket Special Permit Stat-x UL 1741 SB CRD certificate eSpire 280 eSpire 280 Battery User Manual eSpire 280 Datasheet 2.28.23

1 | P a g e ESPIRE 280 SYSTEM INSTALLATION MANUAL 2 | P a g e Contents 1. IntroducƟon .......................................................................................................................................... 3 2. Product Models & Layout ..................................................................................................................... 4 2.1 eSpire 125 KW / 280 KWH ............................................................................................................ 4 2.2 eSpire 125 KW / 560 KWH ............................................................................................................ 5 3. Overview of Site Components ............................................................................................................. 6 3.1 Batery System .............................................................................................................................. 6 3.2 Keystone Micro Grid Control Panel .............................................................................................. 9 3.3 Power CondiƟoning System (PCS) .............................................................................................. 11 4. InstallaƟon .......................................................................................................................................... 14 4.1 Mechanical.................................................................................................................................. 14 4.1.1 ForkliŌ TransportaƟon ....................................................................................................... 15 4.1.2 Pre-InstallaƟon Requirements ........................................................................................... 16 4.1.3 FoundaƟon ConstrucƟon Method ..................................................................................... 17 Electrical ................................................................................................................................................. 18 SchemaƟc Diagram and Wire RouƟng ............................................................................................... 20 Recommended CT’s Placement .......................................................................................................... 24 Recommended installaƟon steps for eSpire System ......................................................................... 24 ConnecƟons ........................................................................................................................................ 25 3 | P a g e 1. IntroducƟon This document provides the necessary details to design a site for eSpire 280 system. The eSpire 280 system is modular, fully integrated, AC coupled Energy Storage System (ESS) This document should be used for the design, installaƟon, and maintenance of the system. Only qualified personnel can install, maintain, and troubleshoot the eSpire System. Unauthorized persons should not operate the procession and should be away from the eSpire system to avoid potential hazards. This document applies to the following configuraƟons: I. eSpire 125 KW / 280 KWH II. eSpire 125 KW / 560 KWH III. eSPire 125 KW / 840 KWH The installaƟon consists of five major components: o Keystone Micro Grid Control Panel o Power CondiƟoning System (PCS) o Liquid Cooling Lithium Batery Cabinet o System Islanding and Feeder ProtecƟon System o Energy Meters 4 | P a g e 2. Product Models & Layout 2.1 eSpire 125 KW / 280 KWH Figure 1. Front view layout of eSpire 125KW/280KWH Figure 2. Spacing Layout of eSpire 125KW/280KWh 5 | P a g e 2.2 eSpire 125 KW / 560 KWH Figure 3. Front view layout of eSpire 125KW/560KWH Figure 4. Spacing Layout of eSpire 125KW/560KWh 6 | P a g e 3. Overview of Site Components 3.1 Batery System The batery serves as a fundamental and essenƟal unit within an energy storage system, playing a pivotal role in the storage and management of electricity. Comprising bateries, a Batery Management System (BMS), and relevant structural installaƟon devices, the batery cabinet acts as the central hub for energy storage, ensuring a reliable and efficient operaƟon of the enƟre system. SpecificaƟons Battery Specification Fortress Power Battery Module eSpire 280 Chemistry Lithium Iron Phosphate Cell Type Prismatic Configuration 1P6S Number of Modules Nominal Capacity 280 Ah Nominal Energy 279.5 kWh Nominal Voltage 998.4 Vdc Operating Voltage Range 873.7 – 1123.2 VDC Maximum Continuous Charging / Discharging Current 140 Amps Communication Modbus TCP, CAN, Modbus RTU Cycle Life @ 25C @ 70% Retention 8000 Cycles DC-DC Round Trip Efficiency 92% @ 0.5C, 25°C, 1 Cycle Per Day Operating Temperature Range Charging: 0-55°C & Discharging -20-55°C Thermal Management System Integrated Liquid Cooling System (HVAC) Fire Suppression System Fire Detector, Smoke Detector & Fire Extinguisher IP Class Type IP66, NEMA 3R Battery Bank Scalability Up to 10 (2.8 MWH) Weight 3005 kgs / 6625 lbs Dimensions 92.13 x 51.18 x 51.18 in (2340 x 1300 x 1300 mm) 7 | P a g e Figure 7. Batery Cabinet Dimensions and layout Figure 8. Batery internal components 8 | P a g e CommunicaƟon and Electrical Interface Panel The interface panel below allows for a plug-and-play connecƟon between Batery, PCS, and the Fortress Control panel. Below are the usable terminals of the interface panel. Figure 9. CommunicaƟon and Electrical Interface Panel HVAC/Chiller SpecificaƟons No Parts Description Operating Specification Auxiliary Power 1Ph 187 -253 VAC 50/60Hz Compressor rated power 3.5KW Compressor rated speed 4500 RPM Compressor RLA 15.8Amp Total Load 25A Maximum over current protection device 40A Figure 10. Batery chiller schemaƟc diagram Tag # Terminal Description DS Disconnect Switch JX3 Fire Alarm Signal JX2 Terminal Resistor JX1 N/A JHX1 HVAC and Power Supply Signal HV + & HV- High Voltage DC Positive Terminal & High Voltage DC Negative Terminal 9 | P a g e 3.2 Keystone Micro Grid Control Panel The Control Panel serves as the main control unit for the energy storage system, providing monitoring, control functionalities, and Feeder Protection Relay. The panel houses a collection of electronics and communications devices for monitoring and controlling the energy storage system, including the battery cabinet, PCS, and other controllable Distributed Energy Resources. The Keystone Microgrid Control Panel also includes an SEL device for protection. It is a user interface between the customer, energy storage system, and cloud-based monitoring system, and it’s equipped with the following buttons in front of the panel: I. ON/OFF Push Button II. Emergency Stop Button III. Status Indicators such as Low voltage LV, High voltage HV & Alarm indicator (Warning). Customers can initiate start-up or shutdown commands to the energy storage system through the push buttons/activate the emergency stop button. All the components in the panel and external islanding panel are backed up through online UPS, allowing the control system and Islanding logic to remain online during grid failure. Specification ITEM UNIT SPECIFICATION Input Voltage VAC 180-260 Input Frequency HZ 60Hz DC Control Voltage VDC Integrated Microgrid Controller - Cloud Based Controller Support Protocol - Modbus TCP/RTU High Voltage DC Sensing VDC 750-1000 Enclosure RaƟng - NEMA 3R / IP54 AlƟtude m ≤ 3000 Humidity % 0 ~ 95%, no condensation OperaƟng Temperature C / F 0 – 40 / 32 - 104 Weight kg / lbs 313 / 690 Dimension (H x W x D) mm/inch 1990 x 900 x 916 / 78.34 x 35.43 x 36.00 10 | P a g e Figure 11. Dimensions and layout of Control Panel Figure 12. Components of Keystone Microgrid Control Panel No Description UPS SEL 851 (Optional) IMM MBMU Ethernet Switch HVAC 1 Circuit Breaker QF1 ETH Modem HVAC 1 Circuit Breaker QF2 15KVA Transformer (1Ph 480/240 V) 11 | P a g e 3.3 Power CondiƟoning System (PCS) The eSpire 233 system facilitates power conversion in both direcƟons, converƟng AC to DC and DC to AC. It uƟlizes this bi-direcƟonal power conversion capability to charge the liquid cooling lithium phosphate batery from the available power source (Grid) and discharge it to the grid or the load as determined by the keystone control strategy. The modular design of the eSpire system allows for scalability, meaning the system capacity can be adjusted or expanded to accommodate different power requirements. The turnkey soluƟon works can be used in both grid Ɵe and off grid applicaƟons. • For grid-Ɵe applicaƟons, up to 10 PCS can be connected in parallel configuraƟon. • For off grid applicaƟon, up to 5 PCS can be connected in a parallel configuraƟon. Specifications Description eSpire 125kw Rated Grid Voltage 3 Phase 480VAC Grid Voltage Range 423 to 528VAC (-12% +10%) Rated Grid Frequency 60Hz Frequency Range 59.3 to 60.5Hz, adjustable Rated AC Power 125kva Rated AC Current 151A Maximum Continuous AC Current 167Arms Current THD IEEE 1547 Compliant, < 5% at rated power DC Voltage Range 750 to 1350VDC Rated DC Voltage 900VDC Rated Discharge Power 128kW Rated Charge Power 122 kW Max Discharge DC Current 157A Max Charge DC Current 151A Rated Output Voltage 480VAC (3P3W / 3P3W) Rated Output Power 125KVA/125KW with Linear Load 100KVA with RCD load (Ipk≦240A) Rated Output Current 151A Rated Output Frequency 60Hz ±1% Power Factor >0.99 (-1 leading to 1 lagging, adjustable) Output Voltage Accuracy 1% Output Voltage THD <3% @ linear load Output Voltage Regulation <10% at dynamin, Recovering within tolerance in 100ms Weight (kg/lbs) 230 / 506 Dimension (H x W x D) (mm / inch) 2000 x 600 x 500 / 78.74 x 23.62 x 19.68 12 | P a g e Figure 13. SchemaƟc layout of PCS with Batery Figure 14. Dimensions of PCS 13 | P a g e Figure 15. Terminals for DC and AC ConnecƟons Figure 16. Cable glands for AC. DC, and CommunicaƟon wiring 14 | P a g e 4. InstallaƟon 4.1 Mechanical WARNING: Adhere to all national, state, and local codes required to install the energy storage system (eSpire system). Transportation Transporting the eSpire system is possible, and provision should be made for the system to be moved on a low-bed truck or truck. Ensuring that the forklift used to transport the eSpire system has a sufficient load capacity is essential. After a freight forwarding company delivers the eSpire system to the site, the plant staff will transport the eSpire system to the designated location on site. It is important to note that the plant staff should have the necessary knowledge and experience to transport the equipment safely. Transporting the eSpire system piece by piece is also an option. However, it is necessary to ensure that each piece of equipment is appropriately packaged and labeled for transport. This will help to prevent any damage that may occur during transportation. In either case, taking necessary precautions during transportation is crucial to avoid damaging the equipment. Proper handling, packaging, and labeling of the equipment are essential to ensure it arrives at the installation site in optimal condition. WARNING: Follow all local and national electric codes during loading & unloading of the eSpire system. Observe safety instructions as required by law. • All the accessories required for transportation should be maintained beforehand. • The eSpire system must be transported by qualified personnel. Qualified means the operators must have relevant training experience, especially those related safety. NOTICE: Always keep in mind the dimensions and weight of battery • Battery H x W x D: 2340 x 1300 x 1300 • Weight: approx. 3005 kg 15 | P a g e NOTICE: Always keep in mind the dimensions and weight of control panel • Keystone Microgrid Control panel H x W x D: 1990 x 900 x 916 mm • Weight: approx. 313 kg Ensure that the following requirements are met: • All the doors are locked. • Choose the appropriate crane or hoist or forklift to transport each piece of equipment. • The forklift or crane or hoist must be sufficient to bear the weight of each piece of equipment. • Battery should be only transported after its being discharged to <25% SOC. • Anything that may hinder transportation, like trees, cables (or similar), should be removed. • If possible, choose fine weather days to transport the eSpire system. • Warning signs or barriers must be posted near the transport areas to avoid accidental injuries. Additionally, the following should be met when the eSpire system is placed on the ground: • Place each piece of equipment carefully and gently. • Do not pull or push each panel on any surface. The ground should be firm and flat with a good drainage system and have no obstacles or outshoots. Each piece of equipment should be placed and supported by four feet. 4.1.1 ForkliŌ TransportaƟon When using a forkliŌ to transport each piece of equipment (Batery Cabinet, PCS, and Fortress Control panel), it is important to ensure the following: • The forkliŌ has a sufficient carrying capacity. (At least a minimum of tons) • That the box’s center of gravity falls between the two forks of the forkliŌ during transportaƟon. • That the forkliŌ prong is at least 1500mm long and inserted into the pockets at the botom of the container. • Handle the eSpire system slowly and steadily and perform trial handling first to ensure safe transportaƟon. • The place where the forkliŌ will operate should be firm and flat, with good drainage and no obstacles or humps. • During the transportaƟon process, it is important to observe the safety operaƟon rules of forkliŌs strictly. • The large batery cabinet may block the driver's view, it is recommended to coordinate with auxiliary personnel to ensure safe transportaƟon. 16 | P a g e 4.1.2 Pre-InstallaƟon Requirements 4.1.2.1 LocaƟon ConsideraƟon Item Description Proximity Proximity to the structure and convenient proximity to the AC power disconnect will be major factors in locating the system. Clearance It is recommended that the system be located a minimum of 5 feet from any doors or windows. Ensure that there is sufficient clearance for any maintenance required. Do not locate the system where bushes, trees, or other vegetation may grow up and obstruct access. Do not locate the system under any decks or other structures. Ensure there is adequate overhead clearance from any structure, overhang, or projections from the wall. Ensure the concrete pad will not interfere with any easements or any underground services such as phone, water, sewage, fuel, or irrigation. Drainage and Flooding Do not locate the system where excessive water may accumulate or in locations subject to flooding. Ensure that gutter downspouts, roof runoff, landscape irrigation, water sprinklers, or sump pump. Security It is recommended that the system be located such that it will not be easily accessible to unauthorized individuals. 4.1.2.2 Concrete Pad PreparaƟon Improper foundation construction may affect an operator’s ability to open and close the door of the eSpire system. Therefore, the foundation must be designed and constructed according to related standards. The dimensions, weight of the eSpire system, cable routes, and maintenance access should always be considered. The following conditions must be fulfilled according to the local and naƟonal codes. • The bottom of the foundation should be firm enough. • The foundation should be at least 300mm/11.8 inches higher than the ground level on the site to avoid rain or flood from entering inside the eSpire system. • Sufficient cross-sectional area and depth of the foundation should be maintained. The depth is designed according to local site conditions. • Cable routes through electric conduit should be considered. • The ground pit with proper grounding conductors should be designed early and finished with foundation construction. 17 | P a g e 4.1.3 FoundaƟon ConstrucƟon Method This section describes a method for the construction of the foundation. For specific on-site design, please refer to each piece of equipment manual. • If each piece of equipment will be installed side by side, design the concrete pad with the following (Length ×Width): 11.4 Ō x 8.6 ft for 1 PCS, 1 batery cabinet and 1 keystone microgrid control panel. *Note: Refer the recommended spacing layout in the Product Models and layout secƟon in this manual. • Provision must be made for electrical conduits to connect the system to the disconnect AC panel. • Provision must be made for electrical conduit interconnect wiring between each piece of Equipment (PCS, batery cabinet & control panel). • The concrete pad or other installaƟon such as skid installaƟon on exisƟng pad shall have a minimum strength of 4000 psi and a minimum slab thickness of 8”. The reinforcement for the concrete pad shall be in accordance with all local building codes and regulaƟons. • According to the position and size of the cable, inlets/outlets at the bottom of the eSpire system, cables must thread through the bottom of each piece of equipment. Reserve the trough for AC/DC cables and electric conduit during the concrete pad construction. • A licensed electrician or engineer should determine the size and quanƟty of electrical conduits aŌer reviewing the Scope of Supply. • The foundaƟon and anchoring design must be performed by a civil or structural engineer registered in the state where the system is being installed in accordance with local building codes. Consult the site geotechnical report for the geotechnical design requirements. • The concrete pad or base shall slop a minimum of 1% and a maximum of 2% to allow posiƟve drainage from the pad/ base or toward a drain or catch pit. • Catch pits should be designed at the bottom of the foundation, and drainpipes should be provided. • The two ends of all-electrical conduit pipes must be sealed temporarily to prevent entry of foreign objects to facilitate future wire implementation. • After making electrical connections, cable outlet/inlet and gaps in between should be sealed with fireproof mud to prevent entry of rodents. • Concrete finishing or other mounƟng equipment is required to produce smooth, even surfaces of uniform texture and appearance, free from bulges, depressions, and other imperfecƟons that would impact equipment anchorage or foundaƟon/ base drainage. 18 | P a g e 4.2 Electrical DANGER: High voltage! Electrical hazard • Do not touch the live components of the device. • Make sure the AC and DC sides are voltage-free before installation. • Never put flammable materials in the vicinity of the eSpire system. DANGER: Electrical hazard! • If a ground fault occurs, some parts that were voltage-free before may contain lethal voltage. • Accidental touch may cause serious damage. Make sure there is no system ground fault before operation and take proper protection measures. WARNING:  Observe all the country-specific national, state & local standards and regulations.  Connect the PCS to public grid only after receiving authorization from the local network operator. WARNING: Only professional or licensed electricians can perform electrical connections. • Follow all wiring instructions in accordance with NEC when performing electrical action. • Fortress Power LLC will not be held liable for any personal injury or property loss due to negligence of the safety instructions. WARNING • Disconnect all AC and DC switches /circuit breakers before performing any electrical connection. WARNING: • Sand and moisture penetration inside any piece of equipment may affect the performance of electric components in the panel. • Do not perform electrical tasks in sandy season or when the ambient relative humidity is above 95%. • Do not locate the system where excessive water may accumulate or in locations subject to flooding. Ensure that gutter downspouts, roof runoff, landscape irrigation, water sprinklers, or sump pump discharge will not cause water to accumulate near the system. 19 | P a g e WARNING:  Improper torque may cause fire to the connection point!  Fix the bolts by strictly following the torque requirements in this manual during electrical connection. WARNING:  Too small bending radius or excessive intertwining may damage the fiber!  Follow the recommended bend radius from the cable manufacturer.  Communication cable wire shield must be grounded at both ends of the device WARNING:  Ensure the electrical insulation is satisfied before laying the cables. Follow the EMC regulation and lay the power cable and communication cable in different layers.  Provide support and protection to the cables to reduce the stress of the cables when necessary. Five Safety Rules During electrical connections and other operations on the eSpire system, observe the following Five Safety Rules: • Always wear the correct personal protective equipment when performing operation or electrical wiring. • Disconnect all the external connections and disconnect the container internal power supply. • Avoid any accidental re-connections. • Verify that no voltage or current is present with appropriate testing devices. • Ground and short-circuit whenever necessary. Cover possible live parts to avoid accidental Contact. WARNING: Incorrect power or control cable connection may result in short circuit, follow the wiring sequence when connecting the power and control cables. The selected cable must have sufficient current carry capacity, the current carry capacity of the conductor must at least account for environmental conditions, insulation material, conductor material and cross-sectional area. • The wire diameter or size of all cables must be selected according to maximum. • Charging and discharging current of the system cabinet and for service factor per NEC code. • Cable of the same size and specification must be used in two or three battery cabinet applications. • Please select flame retardant cable and ensure to use properly sized cable. • Cable overload is strictly prohibited. 20 | P a g e 4.2.1 SchemaƟc Diagram and Wire RouƟng 4.2.1.1 eSpire 125 KW / 280 KWH Figure 17. SchemaƟc point to point diagram of 1 Batery System CABLE MANAGEMENT Tag Tag Type Description From To Responsible Party Minimum Recommended Cable Size Revenue Grade Meter Voltage Sensing Cable 3 Phase 480Vac + Neutral Voltage Sensing Cable Revenue Grade Meter Panel Critical Load Panel 3P/4W Customer (3) #12 AWG-THWN-2 + N AC Man Input/Output Power Supply Cable 3phase 480Vac Man Input/Output + N Power Supply Cable Contactor Customer Man Distribution Panel Customer #### Revenue Grade Meter Power Supply Cable Revenue Grade Meter DC Cable Keystone Microgrid Control Panel Revenue Grade Meter Panel Customer (2) #12 AWG-THWN-2 Revenue Grade Meter Communication Cable Revenue Grade Meter Communication Cable (Ethernet Cable) Keystone Microgrid Control Panel Revenue Grade Meter Panel Customer Cat 6 Ethernet Cable Contactor Dry Contact Contactor Dry Contact Cable Contactor Panel Keystone Microgrid Control Panel Customer (2) #12 AWG-THWN-2 21 | P a g e Contactor Control Voltage Cable Contactor Coil Control Voltage Cable 1 Ph/120Vac Keystone Microgrid Control Panel Contactor Panel Customer (2) #12 AWG-THWN-2 AC Main Input/Output Power Supply Cable 3 Phase 480V Man Input/Output + N Power Supply Cable Power Conversion System (Ac Side) Contactor Panel (Load Side) Customer (3) # 1/0 AWG-THWN-2 + N AC Input Power Supply Cable 1 Phase 480Vac Input Power Supply Cable Power Conversion System (AC Side) Keystone Microgrid Control Panel Customer (2) #10 AWG-THWN-2 Power Conversion System Input/Output Signal Cables 3 Inputs & 2 Outputs Dry Contact Cable Power Conversion System (J-Board) Keystone Microgrid Control Panel Customer (10) #12 AWG-THWN-2 Communication Cable Cable (Communication Cable) Power Conversion System (J-Board) Keystone Microgrid Control Panel Customer Cat 6 Ethernet Cable High Dc Voltage Sensing Cable High DC Voltage Sensing Cable (1500Vdc) Power Conversion System (DC Side) Keystone Microgrid Control Panel Customer (2) 12 AWG-THWN-2 + N Battery #1 High DC Voltage Power Supply Cable Battery #2 High DC Voltage Power Supply Cable (1500Vdc) Power Conversion System (DC Side) Battery Cabinet #1 Fortress (2) #1/0 AWG-THWN-2 HVAC & Control Panel Power Supply Cable for Battery #1 Battery #1 HVAC & Control Panel Power Supply Wire Harness (220Vac) Keystone Microgrid Control Panel Battery Cabinet #1 (JXH1) Fortress (4) #12 AWG-THWN-2 BMS And Fire Control Panel Signal Cable BMS And Fire Control Wire Harness Keystone Microgrid Control Panel (Fire Control Panel) Battery Cabinet #1 Fortress (6) #0.22mm Size 22 | P a g e 4.2.1.2 eSpire 125 KW / 560 KWH Figure 18. SchemaƟc point to point diagram of 2 Batery System Cable Management Tag Tag Type Description From To Responsible Party Minimum Recommended Cable Size Revenue Grade Meter Voltage Sensing Cable 3 Phase 480Vac + Neutral Voltage Sensing Cable Revenue Grade Meter Panel Critical Load Panel 3P/4W Customer (3) #12AWG-THWN-2 AC Main Input/Output Power Supply Cable 3 Phase 480Vac Main Input/Output + N Power Supply Cable Contactor Customer Main Distribution Panel Customer #### Revenue Grade Meter Power Supply Cable Revenue Grade Meter DC Cable Keystone Microgrid Control Panel Revenue Grade Meter Panel Customer (2) #12 AWG-THWN-2 Revenue Grade Meter Communication Cable Revenue Grade Meter Communication Cable (Ethernet Cable) Keystone Microgrid Control Panel Revenue Grade Meter Panel Customer Cat 6 Ethernet Cable Contactor Dry Contact Contactor Dry Contact Cable Contactor Panel Keystone Microgrid Control Panel Customer (2) #12 AWG-THWN-2 23 | P a g e 6 Contactor Control Voltage Cable Contactor Coil Control Voltage Cable 1Phase 120Vac Keystone Microgrid Control Panel Contactor Panel Customer (2) #12 AWG-THWN-2 AC Main Input/Output Power Supply Cable 3 Phase 480V Main Input/Output + N Power Supply Cable Power Conversion System (AC Side) Contactor Panel (Load Side) Customer (3) # 1/ AWG-THWN-2 N AC Input Power Supply Cable 1Phase 480Vac Input Power Supply Cable Power Conversion System (AC Side) Keystone Microgrid Control Panel Customer (2) #10AWG-THWN-2 9 Power Conversion System Input/Output Signal Cables 3 Inputs & 2 Outputs Dry Contact Cable Power Conversion System (J-Board) Keystone Microgrid Control Panel Customer (10) #12AWG-THWN-2 10 Communication Cable Ethernet Cable (Communication Cable) Power Conversion System (J-Board) Keystone Microgrid Control Panel Customer Cat 6 Ethernet Cable 11 High DC Voltage Sensing Cable High DC Voltage Sensing Cable (1500Vdc) Power Conversion System (DC Side) Keystone Microgrid Control Panel Customer (2) 12AWG-THWN-2 12 Battery#1 High DC Voltage Power Supply Cable Battery#1 High DC Voltage Power Supply Cable (1500Vdc) Power Conversion System (DC Side) Battery Cabinet#1 Fortress (2) #1/0AWG-THWN-2 13 Battery#2 High DC Voltage Power Supply Cable Battery#2 High DC Voltage Power Supply Cable (1500vdc) Power Conversion System (DC Side) Battery Cabinet#2 Fortress (2) #1/0AWG-THWN-2 14 HVAC & Control Panel Power Supply Cable for Battery#2 Battery#2 HVAC & Control Panel Power Supply Wire Harness (220Vac) Keystone Microgrid Control Panel Battery Cabinet#2 (Jxh1) Fortress (4) #12AWG-THWN-2 BMS Control Signal Cable BMS Control Panel Wire Harness Battery Cabinet#1 (Jx2) Battery Cabinet#2 (Jx3) Fortress (6) #0.22mm Size 16 HVAC & Control Panel Power Supply Cable for Battery#1 Battery#1 HVAC & Control Panel Power Supply Wire Harness (220vac) Keystone Microgrid Control Panel Battery Cabinet#1 (Jxh1) Fortress (4) #12AWG-THWN-2 BMS and Fire Control Panel Signal Cable BMS And Fire Control Wire Harness Keystone Microgrid Control Panel (Fire Control Panel) Battery Cabinent#1 Fortress (6) #0.22mm Size 24 | P a g e 4.2.2 Recommended CT’s Placement Figure 19. Signal Wiring and CT’s recommendaƟons 4.2.3 Recommended installaƟon steps for eSpire System 1. Ensure electrical conduit pipes between each piece of equipment have been laid during concrete pad construcƟon. Each piece of equipment has cable holes on the botom of the panel. 2. Mount the PCS, batery cabinet, and Keystone Control Microgrid Control panel on the constructed concrete pad and ensure each piece of equipment is laid out side by side according to the drawing. 3. Anchor each piece of equipment on the concrete pad *(as per individual equipment manual). 4. Use Fisher and run wire harnesses and power cables through the conduit pipes. 5. Connect all interconnecƟon cables before connecƟng the external power source. 6. Seal all conduit pipes and holes in each piece of equipment. 25 | P a g e 4.2.4 ConnecƟons Electrical site preparaƟon for the eSpire system must be performed by licensed electrical contractors, and all the interconnecƟon cables must be wired to the correct terminals. 4.2.4.1 Keystone Micro Grid Control Panel SchemaƟcs Figure 20. FuncƟonal Block Diagram of Control Panel *Note: Please refer the Appendix for the internal schemaƟcs of the Keystone Microgrid Control Panel Note: Each piece of Equipment must be powered off when performing electrical work. Ensure to follow all naƟonal, state, and local codes when performing electrical work. 4.2.4.2 3 Phase AC ConnecƟons Between Customer Mains Circuit Breaker and PCS AC Input power to PCS ConnecƟon (3Phase 480VAC to PCS) Ensure the customer’s upstream circuit breaker or disconnect switch is properly sized. *Note: PCS Rated Current is 151A @ 480Vac. For 480Vac connecƟons, we recommended using a minimum of 1/0 AWG. i. Run the 3-phase AC input Power cable through the electrical conduit pipe between the customer’s upstream circuit breaker to the AC side of the disconnect. ii. Connect one end to the upstream circuit breaker (load side) and the other end of the power cable to the AC input power of the PCS. iii. Run the ground cable through the same conduit along with the power cables and connect one end of the cable to PCS and the other to the service entrance ground system. *Note that the system must be grounded as required by NEC. *For more details, refer to the PCS user manual. 26 | P a g e 4.2.4.3 3 Phase AC ConnecƟons between PCS and Keystone Microgrid Control Panel AC Input power to Control Panel ConnecƟon (1 Phase 480VAC to Fortress control panel) i. Run 1 phase AC output cable from PCS through the electrical conduit pipe to the Keystone Microgrid Control Panel Transformer primary side. ii. Refer to the schematic wiring for the internal wiring of the Keystone Microgrid Control Panel *Note that the Fortress Control panel must be grounded to the Service Entrance system as required by the NEC. 4.2.4.4 ConnecƟons Batery Cabinet to PCS ConnecƟon: (Max Length 15Ō) High voltage DC power cable connecƟon between PCS and batery cabinet. The posiƟve high-voltage dc power cable is denoted as orange in color, while the NegaƟve high-voltage dc power cable is denoted as black. *Note: High-voltage DC power cable requires a high-voltage (HV) connector at one end of the cable and a cable lug at the other. i. Hydraulic clamp is required to clamp the HV connector on each end of the high-voltage dc power cable. (orange + & black -) ii. Run the high voltage dc power cable through the electrical conduit pipe between the battery cabinet and PCS. iii. Plug the high-voltage dc power cable with orange connector (+) into the high-voltage terminal in the battery cabinet while the other end should be connected to the DC side of the PCS (+ terminal) iv. Plug the high voltage dc power cable with black connector (-) to the high voltage terminal in the battery cabinet while the other end should be connected to the DC side of the PCS (-terminal) Figure 21. High Voltage DC Power Cable SchemaƟcs PCS Type of cable Battery Cabinet HV + Terminal HV – Terminal HV DC Connection cable Red (2/0AWG) HV DC Connection cable Black (2/0AWG) HV + Terminal HV - Terminal 27 | P a g e 4.2.4.5 ConnecƟons between Batery Cabinet to Control Panel a. HVAC and Control panel power supply (Wire harness JXH1) (Max Length 12Ō) *Note: The HVAC and power supply wire harness are terminated on a round female connector socket on one end of the wire harness, while the other end of the wire harness is required to be connected to the terminal block in the control panel. i. Run the HVAC (230Vac L-N) and power supply (230Vac L-N) wire harness through the electrical conduit pipe between the battery cabinet and control panel. ii. Plug the round female connector socket into the male terminal JXH1 on the battery cabinet. iii. Connect the HVAC (230Vac L- N) power cable to the load side of the QF2 circuit breaker in the control panel. iv. Connect the power supply(230Vac-L-N) cable for the control panel to terminal XT3 and XT4 Figure 22. HVAC and Control Panel Cable SchemaƟcs b. BMS Fire-Alarm Wire Harness (Wire harness JX3) (Max Length 12Ō) i. Run the BMS-Fire alarm wire harness through the electrical conduit pipe between Battery Cabinet 1 and the Fortress Control panel. ii. The BMS fire alarm wire harness is terminated on a round female connector socket on one end of the wire harness, while the other end of the wire harness is required to be connected to the terminal block in the Fortress control panel. Battery Cabinet Type of cable Fortress Control Panel (Fire Alarm system) Terminal Plug JXH1 Power Cable to the JXH1 terminal on the battery cabinet HVAC control panel 12AWG 15Ft HVAC power cable L to QF2 L terminal Circuit Breaker HVAC power cable N to QF2 N terminal Control panel cable 12AWG 15Ft Control power cable L to terminal block XT3 Terminal Block Control power cable N to terminal block XT4 28 | P a g e Figure 23. Fire Alarm Wire Harness SchemaƟcs 4.2.4.6 ConnecƟons Between PCS and Fortress Control Panel a. High voltage dc sensing cable between PCS and control panel. RecommendaƟon (12AWG 1500VDC insulaƟon) i. Run the high voltage dc sensing cables through the electrical conduit pipe between the PCS and control panel. ii. Connect one end of the high voltage dc sensing cable (Red) to the positive DC terminal of the PCS and the other end to the terminal block (XT-19) in the control panel. iii. Connect one end of the high-voltage dc sensing cable (Black) to the negative DC terminal of the PCS and the other end to the terminal block (XT-20) in the control panel. Battery Cabinet Type of cable/signal Control Panel (Fire Alarm system) Terminal JX3 Terminal Fire alarm wire harness (18 AWG 15 Ft) Wire signal 1 to Zone 2 + Fire Alarm Terminal Wire signal 2 to Zone 2 - Wire signal 3 to Zone 1 + Wire signal 4 to Zone 1 - Wire signal 5 to Exiting + Wire signal 6 to Exiting - Wire signal JX- 1 to JX2 left terminal Connector JX2 Wire signal JX-2 to JX2 right terminal 29 | P a g e Figure 24. High Voltage DC sensing cable SchemaƟc b. CommunicaƟons cable between the PCS ad Control Panel i. Run the CAT5e or CAT 6 Ethernet Cable through the electrical conduit pipe between the control panel and PCS. ii. Connect one end of the communication cable to the Ethernet Switch in the control panel and the other end to the RJ45 port terminal in the PCS. 4.2.4.7 TerminaƟon cable between Batery and Batery Cabinet Terminal resistor cable (Double layer insulated) 100 Ohms x 1 i. Plug the terminal resistor cable into the batery cabinet (terminal JX2) Figure 25. Terminal Resistor PCS Type of cable Fortress Control Panel HV + Terminal HV – Terminal DC Voltage Sensing cable XT2-26 (12AWG) DC Voltage Sensing cable XT2-25 (12AWG) Terminal block XT-19 Terminal block XT-20 PCS Type of cable Fortress Control Panel RJ45 Port Terminal Cat 5e or Cat 6 Ethernet Ethernet Switch Battery Cabinet Type of cable/signal Control panel (Fire Alarm system) Terminal JX2 Terminal Terminating Resistor N/A N/A