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site plan 53 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 Installation Manual 280 V1.0 Material Safety Datasheet eSpire 280 SP Sprocket Special Permit Stat-x UL 1741 SB CRD certificate eSpire 280 eSpire 280 Datasheet 2.28.23

Fortress Power Confidential File 280 Ah Liquid Cooling Rack User’s Manual Fortress Power Confidential File To protect your personal safety, please be sure to read carefully and follow the safety requirements below: Symbols in This Document This manual uses the following symbols to highlight important information: WARNING: Indicates a hazardous situation which, if not avoided, could result in injury or death. CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor injury or damage to the equipment. NOTE: Indicates an important step or tip that leads to best results, but is not safety or damage related. General Information NOTE: The maintenance workers must be required to hold the Fortress Power maintenance authorization certificate to carry out maintenance work. WARNING: It is strictly forbidden to touch both pole terminals of ESS at the same time with both hands. WARNING: Be sure to disconnect the corresponding high and low voltage switches before performing maintenance on the ESS. Fortress Power Confidential File WARNING: Wear safety helmets, insulated gloves, insulated shoes, and goggles when operating or maintaining the ESS. Do not wear metal jewelry such as watches. WARNING: When cleaning the ESS, it is forbidden to wash the HV/LV connectors directly. WARNING: It is strictly forbidden to crush, pierce and burn artificially the batteries to damage the ESS. WARNING: The working environment of ESS should be free from corrosive, explosive, uninsulated gas or conductive gas and away from heat sources WARNING: Stepping on the top of the RACK is prohibited during use and maintenance. WARNING: If you have any questions, please contact the ESS supplier, operate without authorization is forbidden. WARNING: Use in series or parallel with other types of battery products is prohibited. Care and Maintenance Environmental Requirements RACK is capable of charging and discharging within the operating temperature range specified below. At the extremes of the temperature range, RACK may limit charge or discharge power to improve battery lifespan. Fortress Power Confidential File For best performance, the average ambient temperature over the system's lifetime should fall within the optimum temperature range specified below: Operating Temperature -30℃~55℃ Optimum Temperature -25~45°C Care and Cleaning If it is installed outside, keep the sides of RACK clear of leaves and other debris to maintain optimal airflow. CAUTION: Do not lean on stack anything on top of, or hang anything from RACK or from wires or conduit leading to RACK. CAUTION: To clean RACK use a soft. lint-free cloth. If needed, the cloth can be dampened with mild soap and water only. CAUTION: Do not use cleaning solvents to clean RACK, or expose RACK to flammable or harsh chemicals or vapors. RACK and the Gateway do not require pre-scheduled preventative maintenance. The only maintenance required by an owner is to keep the RACK unit free and clear of debris, especially around the air intake and exhaust. Fortress Power Confidential File CONTENT 1. Product Overview ................................................................................................................................... 7 1.1 Applicable Scope .............................................................................................................. 7 1.2 Main Feature ...................................................................................................................... 7 2. Transportation and Storage ..................................................................................................................8 2.1 Packaging ......................................................................................................................... 8 2.1.1 Rack Packing steps: .............................................................................................. 9 2.2 Transportation .................................................................................................................. 11 2.2.1 Requirements for Battery Transport Environment ................................................. 12 2.2.2 Requirements for Rack Transport ......................................................................... 12 2.3 Storage ............................................................................................................................ 13 3. Installation ................................................................................................................................................ 14 3.1 Main constituent parts for installation ............................................................................... 14 3.2 Preparation for installation ................................................................................................ 16 3.2.1 Unpacking ............................................................................................................... 16 3.2.2 Description of the installation process .................................................................... 17 3.3 Installation of the rack ....................................................................................................... 18 3.3.1 Installation Precautions .......................................................................................... 18 3.3.2 Site and environmental requirements ...................................................................... 20 3.3.3 Installation steps ..................................................................................................... 21 3.4 Electrical interface ............................................................................................................. 26 3.4.1 Wiring...................................................................................................................... 26 3.4.2 Precautions in wiring .............................................................................................. 31 4. commission check list ............................................................................................................................ 33 5. Operating Instructions .............................................................................................................................. 34 5.1 Rack Temperature Characteristics .................................................................................... 35 5.2 Cable Connection Confirmation ......................................................................................... 35 5.3 Status Checking of Equipment Switch .............................................................................. 36 5.4 Power up the Secondary Circuit ....................................................................................... 36 5.5 Power up of Primary Circuit of Battery Rack .................................................................... 37 5.6 Charging of Battery Rack. ................................................................................................. 38 5.7 Discharging of Battery Rack .............................................................................................. 38 5.8 Power Down of Primary Circuit of Battery Rack ................................................................ 39 5.9 Secondary Circuit Power Down ........................................................................................ 39 5.10 List of Rack Status .......................................................................................................... 40 6. Product Maintenance ............................................................................................................................ 42 6.1 Terms Explanation ........................................................................................................... 42 6.2 Operating Instructions for Normal Operating System ....................................................... 43 6.3 Operating Instructions for Intermittent Operating System ................................................. 43 6.4 Operating Instructions for Long-time Unused System ...................................................... 43 6.5 Function of Isolating Switch ............................................................................................... 44 6.6 Operating Method of Battery Maintenance ....................................................................... 44 6.7 Maintenance Requirements for Liquid Cooling System .................................................... 46 Fortress Power Confidential File 6.8 Fire Protection System Maintenance .............................................................................. 47 7. Diagnosis of common abnormal problems ................................................................................................ 48 7.1 The system alarm is divided into level alarm and non-level alarm. ....................................... 48 7.2 Countermeasures of system alarm .................................................................................. 50 7.3 Emergency Treatment Method ......................................................................................... 56 8. Requirements for Maintenance Personnel ........................................................................................ 59 9. After-sales Service.............................................................................................................................. 59 . ................................................................................................................................................................ 63 Notice ...................................................................................................................................... 64 Fortress Power Confidential File 1. Product Overview 1.1 Applicable Scope This manual is applicable to the battery racks of the following model: O852280-E/ O852280-P All references to “battery racks” in this manual, unless specifically indicated herein, refer to the product series mentioned above. Weight 3500kg Dimension 1300mm(W)*1300mm(D)*2340mm(H) Fortress Power Confidential File 1.2 Main Feature  The battery system can detect the battery operating status（Voltage, current, temperature, SOC/ SOH/SOP estimation, etc.），According to the current state of the battery and the actual performance of the electrical components to adjust the battery charge and discharge and energy storage  The battery system has functions such as insulation detection, high-voltage sampling, and status check of safety devices such as MSD and fuse. When the battery fails, the system will report and limit the charge or discharge current or power, delay the opening of the contactor, and protect the safety of the power system.  The battery system can control the cooling, heating and temperature settings of the liquid cooling unit  The cabinet body of the Rack meets the IP56 protection grade and supports use under outdoor conditions.  Rack equipped with Stat-X aerosol fire extinguishing system, It can detect the temperature and smoke status in the Rack in real time to prevent fire safety accidents such as accidental battery fire Fortress Power Confidential File 2. Transportation and Storage 2.1 Packaging The system is packaged as a whole to ensure that the product is well protected from any harmful gases, chemical contamination, static electricity, moisture and mechanical damage during handling, transport and storage. The name of product, specification, production date, quantity and lot number have been labeled on the packaging box. 2.1.1 Rack Packing steps: 1 Lay the tray flat, hang the Rack on the tray and fix it. 2 Fix the RACK with bolts. M16_1 M16x110 M16 flat gasket 3 Put it into the packaging bag from one to the bottom, wrap the scotch tape around the mouth of the bag, lay the top package flat on both sides, and fix it with scotch tape. Fortress Power Confidential File packing tape 6 Wrap the winding film from the bottom of the tray (sticking to the ground), the winding film should be no less than 3 layers 2.2 Transportation Trucks and shipping are preferred as means of transport while shelter and sun protection should be guaranteed during transportation. Please load and unload in a civilized way. Packing boxes with products inside can be transported by any means of transport. Batteries shall be handled with care in the middle of loading and unloading. Be cautious of throwing, rolling over and heavy pressure. Avoid direct contact with rain, snow and mechanical impacts. Fortress Power Confidential File 2.2.1 Requirements for Battery Transport Environment Based on battery features and with the purpose of maximizing the battery performance, the transport and storage of battery packs should meet the following requirements: Recommended storage temperature: ≤20℃; Allowable storage temperature: -40~60℃; Humidity: <95% (no condensation). 2.2.2 Requirements for Rack Transport (1) Check before loading of battery rack into container 1) Before loading into container, it is necessary to check the outside and inside of the container to ensure the cleanliness of the inside, and the inside shall be equipped with hooks; 2) Before loading into container, check the package and external label of the cargo to ensure the integrity of external package. (2) Loading of battery rack into container 1) The forklift matched with the battery rack load shall be used in operation and shall pass the annual inspection. The forklift shall not move during lifting; 2) The weight of a battery rack is high. The container shall be stuffed with filling material and the tie belt shall be used to fix the battery rack in a container; 3) After being loaded into a container, the warehouse head shall recheck the tie belt and protection and then notify to release after confirmation. (3) Battery rack transport 1) The high-speed driving speed of the vehicle shall not exceed the speed specified by traffic laws, and the bumpy road section shall be avoided as far as possible; 2) It is forbidden to brake and make sharp turns when the vehicle is driving; 3) Keep the car in good condition, check the carrying situation of the car frequently. If problems are Fortress Power Confidential File found, feedback and solve in time. (4) Unloading of battery rack 1) Provide the packing list to the client for preparing proper unloading tools. 2.3 Storage The system should be stored in a dry warehouse to avoid exposure and rain. No harmful gases, flammable or explosive products and corrosive chemicals are allowed in the warehouse. Keep away from mechanical impact, heavy pressure and strong magnetic field. Avoid direct sunlight and the distance to heat source should be more than 2m away. The packaging box should be at least 20cm high from floor, and at least 50cm away from the wall, windows or air inlets. Recommended storage temperature: ≤20℃; Allowable storage temperature: -40~60℃; Humidity: <95% (no condensation). Under these conditions, The product shall be supplemented to 50% SOC at least once within 6 months after leaving the factory。 The capacity verification test and re-inspection are required every 12 months. 3. Installation The battery system is a high-voltage energy storage device, which is regarded as dangerous goods; operation and use by non-professional persons or improper operation and use of it might result in severe consequences, e.g. electric shock, combustion and explosion. The battery system must be installed and maintained by professional technicians and used in strict accordance with the relevant safety provisions. 3.1 Main constituent parts for installation Fortress Power Confidential File Table 1. Main constituent parts for installation Components Diagram Number Unit Remark Rack Pcs Dimension : W*D*H(mm) 1300*1300*2280 Weight ： 3500kg Voltage range ： 1164.8~1497.6V DC HV harness Set One for the positive pole and one for the negative pole on the control box. Auxiliary power supply harness Pcs Including power supply for chiller and power supply for BMS. Communication harness Set Building the connection between two adjoining racks, one for input and one for output. Fortress Power Confidential File 3.2 Preparation for installation 3.2.1 Unpacking Unpacking steps are as follow: 1. Remove the packing belt and winding film on box. 2. Remove the front and back panel from the front side and back side respectively. Remove the right side and left side panels. 3. Unscrew four nuts on the wooden pallet, remove the bolt and washer. 4. Move the rack out of the tray. 5. Unpacking completed. MSD Pcs Installation of MSD should be conducted after the fixation of racks and harness. Fortress Power Confidential File 3.2.2 Description of the installation process The installation process is mainly divided into two stages: rack installation and wiring. The main content and steps are as follows: Fortress Power Confidential File Table 2. Installation process Installation steps Specific implementation Remark Rack installation A． Transfer the rack to the designated location by means of forklift transfer or hoisting. The tool should meet the weight requirements, and the tilt angle should be smaller than 5°. B． Fix the bottom foot of the rack. M16 bolt，required torque is 3.3 Installation of the rack 3.3.1 Installation Precautions 150~200N.M C. Grounding of the rack. M8 bolt，required torque is 10N.M, wire size ≥50mm2 (cooper) The external casing of the equipment should be well grounded Wiring A．Power harness Including positive and negative poles, orange connector connects to HV+, black connector connects to HV-. B. Auxiliary power supply harness Including power supply for chiller and control circuit. C．Communication harness One for input and one for output. D．MSD Should be conducted after the fixation and inspection of racks and harness. Fortress Power Confidential File WARNING: The title angle should be smaller than 5°during the hoisting. WARNING: Do not hit the staff during landing. WARNING: Should set an isolation area for the operation of installation. WARNING: Move and transfer the rack in a manner way during hoisting. WARNING: RACK installation must be carried out only by Installers who have been trained in dealing with high voltage electricity. WARNING: Do not use or install the RACK if it is defective, appears cracked, broken, or otherwise damaged. WARNING:Do not attempt to open, disassemble, repair, tamper with, or modify RACK. WARNING: Do not conduct the installation under worse weather, such as rainstorm and sandstorm. WARNING:To protect RACK and its components from damage when transporting, Handle with care. Do not impact, pull, drag, or step on RACK. Do not subject RACK to any strong force. To help prevent damage, leave RACK in its shipping packaging until it is ready to be installed. WARNING: Do not insert foreign objects into any part of RACK. WARNING:Do not expose RACK or its components to direct flame. WARNING: Do not install RACK near heating equipment. WARNING: Do not immerse RACK or its components in water or other fluids. Fortress Power Confidential File CAUTION: Do not use cleaning solvents to clean RACK, or expose RACK to flammable or harsh chemicals or vapors. CAUTION: Do not use components without authority by Fortress Power. CAUTION: The schematic diagram of transfer and hoisting as shown in the figure is for reference only, the specific tools and equipment used in actual operation shall prevail. CAUTION: The minimum clearance between the racks should be back to back 100mm (0.5P rack) or 500mm (1P rack); 10 mm(side by side) The clearances above are for reference only, the actual clearance should comply with the local standards and regulations. WARNING: Please place the battery system on a level ground to ensure that it is placed stably without shaking or tilting; WARNING: Battery system installation should consider the load capacity of its installation ground and floor (according to the requirements of architectural drawings). 3.3.2 Site and environmental requirements Rack foundation requirements  Unspecified concrete grades are C30, the floor thickness is 200mm, each side protrudes 300mm from the edge of the electrical cabinet, and is equipped with three-level steel symbol 12@150.  Reinforcement adopts HRB400 grade, after derusting treatment, anticorrosive treatment should be carried out according to relevant specifications.  Floor board thickness 100mm, concrete strength class C15. Fortress Power Confidential File  The foundation bearing layer shall be undisturbed soil, and the characteristic value of bearing capacity shall not be less than 100Kpa. If the foundation support layer is weak soil, graded sandstone should be used for replacement, and the replacement depth should not be less than 500mm.The replacement soil layer must be compacted and compacted in layers, Layer thickness should not be greater than 300mm, The compaction coefficient is greater than 0.97. The edge of the replacement layer needs to exceed the base edge by 300mm, The characteristic value of bearing capacity after replacement is not less than 100Kpa, The content of particles with a particle size of less than 0.75mm at the time of refilling shall not exceed 10%.  During the foundation construction, precipitation measures should be taken, soaking the foundation pit is strictly prohibited; safe and reliable support measures should be taken for foundation pit excavation  Ground flatness requirement: within 2m, the flatness deviation is less than ±4mm 3.3.3 Installation steps Attention： （1): Recommended transfer mode of the Rack: Top hoisting transfer (2 ): If a forklift is used, pay attention to adding protection on the forklift arm to prevent the dirt on the forklift arm from polluting the Rack or the forklift from scratching the bottom of the Rack. A．Transfer the rack to the designated location by means of forklift transfer or hoisting. The lifting lug should be repainted after the installation. Fortress Power Confidential File Figure 2. Lifting lug on the rack The radius of the hole on the lifting lug is 11mm. B．Fix the bottom foot of the rack C. The bottom of each rack is fixed with M16 bolts. The torque of the torque wrenches is set to 150~200N.M. Fortress Power Confidential File Different layouts of racks are shown as following figures: 1) Before chemical bar planting, the brush layer of bar planting flour needs to be cleaned out, and then the next step after cleaning 2) The concrete strength grade is C25, and the chemical planting reinforcement needs to do the pull- out test 3) It is required that the tensile strength of the planted chemical anchor bolt is not less than twice the design value of the bearing capacity 4) Chemical anchors are recommended to use Hilti HVA chemical anchors. For specific design values, please refer to the table below Chemical anchor Design value of tensile bearing capacity（KN） Design value of shear capacity （KN） L1 L2 L R-M16 34.7 34.6 Fortress Power Confidential File 5) The construction of chemical anchors should comply with JGJ 145-2013《Technical specification for anchorage behind concrete structure》 6) If there is welding, measures should be taken to avoid overheating of the anchoring area and lead to the failure of the rebar glue 7) Adhesives for load-bearing structures must be tested for bond shear strength. During the inspection, the standard value of the bonding strength shall be determined according to the requirements of the confidence level of 0.9 and the guaranteed rate of 95% Fortress Power Confidential File Figure 5. Grounding of the rack 3.4 Electrical interface 3.4.1 Wiring 1 Installation of communication harness  Install the corresponding communication harness on JX2 and JX3:  In the first rack, JX2 is connected to the JX3 of the next rack, and JX3 is connected to MBMU.  In the middle rack, JX2 is connected to the JX3 of the next rack, and JX3 is connected to JX2 of the last rack.  In the terminal rack, JX3 is connected to JX2 of the last rack, and JX2 is connected to the terminal resistor connector. Figure 6. Communication harness Fortress Power Confidential File 2 Installation of auxiliary power supply harness  Install the auxiliary power supply harness (including the harness for chiller and BMS power supply) on JXH1. Figure 7. Auxiliary power supply harness 3 Installation of power harness  Isolation switch QS1 and breakers QF1, QF2 should be in OFF state.  Orange connector connects to HV+, black connector connects to HV-.  Push the plug of the HV connector into the receptacle during installation. When you can feel obvious resistance, press the secondary lock(the disassembly method is opposite);  If the second lock cannot be push in, it indicates that the HV connector is not be installed correctly. Fortress Power Confidential File Secondary Lock Figure 8. Power harness 4 The diagrams of installation and disassembly of HV connector are as follow:  Original state Figure 9. Original state of HV connector  Diagram of installation and disassembly Fortress Power Confidential File Figure 10. Installation of HV connector Figure 11. Disassembly of HV connector 5 After confirming that the above installation is correct, install the MSD.  Isolation switch QS1 and breakers QF1, QF2 should be in OFF state.  Open the battery compartment door. Fortress Power Confidential File Figure 12. Installation of MSD 6 Install eight MSD upper cover on the panel of each module box.  Put the handle in the vertical state and align the cover of the maintenance switch with the receptacle. Figure 13. MSD diagram  Push it in and rotate the handle. Fortress Power Confidential File Figure 14. MSD diagram-state 1  When you can hear the “da da” sound, push in the secondary lock (the disassembly method is opposite), and the installation is completed. Figure 15. MSD diagram-state 2 Fortress Power Confidential File 3.4.2 Precautions in wiring CAUTION: JX1 is a debugging interface, which needs to be kept in a sealed state. CAUTION: The connector need to be tighten during the installation of JX2 and JX3. WARNING: The power supply harness for the chiller is different from the BMS, and no errors are allowed to occur during wiring. Besides, JXH1-1 and JXH1-2 need be connected to UPS. WARNING: To ensure the high voltage connector is locked. WARNING: To ensure the MSD is locked. WARNING: The positive and negative poles on the DC combiner cabinet cannot be reversed during wiring. WARNING: Strictly prevent any form of short circuit during the connection process. WARNING: It is strictly forbidden for the operator to operate without training. WARNING: It is strictly forbidden for the operator to operate freehand without wearing protective equipment. WARNING: All connections must be made under explicit guidance, and any form of guessing and vague trial operation methods are strictly prohibited. WARNING: The key points of the connection are: ensure the connection is correct, reliable (will not be loosened), good contact, no short circuit. CAUTION: After the connection is completed, it must be measured and confirmed point by point. Fortress Power Confidential File WARNING: Before wiring, make sure the rack is in OFF state by setting QF1, QF2 and QS1 in off state. CAUTION: If there are other uncertain factors, need to be confirmed by professionals before implementation. 4. Commission check list NO. Test items Specific description Consequent Exterior Flat shell, uniform color OK■ NG□ Clear logo, complete and correct silk screen OK■ NG□ Check the screws Check whether the screws are loose, slippery, damaged, etc. OK■ NG□ Confirm the high voltage connection circuit Check whether the high-voltage positive and negative poles of 1#1system junction cabinet and electric cabinet are correct and whether they are connected reversely Check whether the high-voltage positive and negative poles of 1#2 system junction cabinet and electric cabinet are correct and whether they are connected reversely OK■ OK■ NG□ NG□ Start the system Close the QF1 and QF2 switches of the main control box, and see if the low-voltage indicator light is on or the water- cooling unit is turned on. 1#1 system electric cabinet 1-1～1-6 RACK 1#2 system electric cabinet 2-1～2-6 RACK OK■ OK■ NG□ NG□ System parameter check 1#1 Maximum temperature value： Minimum temperature value： Whether≤5℃ Maximum voltage value： Minimum voltage value： Whether≤20mV Whether the cell voltage, the number of temperature OK■ OK■ OK■ NG□ NG□ NG□ Fortress Power Confidential File 5. Operating Instructions In order to ensure the long-term safe and reliable operation of your energy storage system, please read and follow the instructions below: [Note] Fortress Power will not be liable for any damage caused by failure to use the battery system in accordance with the specified requirements or beyond the specified range and other losses arising out of such damage. samples and the fan are running normally 1#2 Maximum temperature value： Minimum temperature value： Whether≤5℃ Maximum voltage value： Minimum voltage value： Whether≤20mV Whether the cell voltage, the number of temperature samples and the fan are running normally OK■ OK■ OK■ NG□ NG□ NG□ System high pressure closure Close all high-voltage relays and corresponding circuit breakers of the RACK. Measure whether the bus voltage is normal. Multimeter measured voltage：XXX V OK■ NG□ System high pressure calibration Close all high voltage relays of the electric cabinet, and the upper computer calibrates the voltage of the electric cabinet OK■ NG□ Software version confirmation Confirm the system software version OK■ NG□ RACK and PCS communication Can PCS control the power on and off of the product OK■ NG□ Charge and discharge check Charge and discharge the product with low current through PCS OK■ NG□ Fortress Power Confidential File 5.1 Rack Temperature Characteristics  Operating ambient temperature:-20℃~55℃（discharge）/ 0℃~55℃（charge）  Safe storage ambient temperature:-30℃~60℃  Recommended storage environment temperature: average temperature ≤25 ℃  Optimum operating ambient temperature:20℃~40℃ 5.2 Cable Connection Confirmation  Before power on, check the connection cable of the whole system, and make sure that the cable connection is reliable without aging fracture and insulation damage.  Check whether the positive and negative poles of the DC output power cable in the battery rack are connected correctly;  Check whether the power connection of the battery cupboard is correct;  Check whether all communication wires and cables and sub connections at the connection end are tight and reliable; Fortress Power Confidential File 5.3 Status Checking of Equipment Switch  Close the QF1 and QF2 isolation switch on the battery rack (red frame in above figure). 5.4 Power up the Secondary Circuit After connecting AC power supply, the indicator lights of every battery rack is as follows: System status Indicator light for the secondary circuit● Indicator Light for the primary circuit● Alarm indicator light ● Power ON Green light is ON Red light is OFF Yellow light is OFF  If the combination of the lights on and off is inconsistent with the above list, it means that the system is not normally started up. Repeat the steps. Fortress Power Confidential File  If the system fails to start up after repeating the steps for 5 times, please conduct preliminary troubleshooting of system failure according to the “Failure and Alarm Handling and Countermeasures in chapter 8”;  If the problem cannot be solved, please contact the manufacturer for system troubleshooting. 5.5 Power up of Primary Circuit of Battery Rack  After the secondary circuit is electrified, charge the primary circuit for the battery rack. At this moment, the positive and negative output ends of the battery rack will generate about 1372.8V (50%SOC) DC high voltage. After electrification, the light combination will correspond to the following state: System status Indicator light for the secondary circuit● Indicator Light for the primary circuit● Alarm indicator light ● Power ON Green light is ON Red light is ON Yellow light is OFF  If the combination of the lights on and off is inconsistent with the above list, it means that the system is not properly powered on. Repeat the steps.  If the system fails to be powered on after repeating the steps for 5 times, please conduct preliminary troubleshooting of system failure according to the “Failure and Alarm Handling and Countermeasures in chapter 8”; If the problem cannot be solved, please contact the manufacturer for system troubleshooting. 5.6 Charging of Battery Rack  After powering on the primary circuit, if BMS detects the charging current, the battery rack will enter the charging state for charging. At this time, corresponding states of indicator lights are as follows: Fortress Power Confidential File System state Indicator light for the secondary circuit● Indicator Light for the primary circuit● Alarm indicator light ● Power ON Green light is ON Red light is ON Yellow light is OFF 5.7 Discharging of Battery Rack  After powering on the primary circuit, if BMS detects the discharging current, the battery rack will enter the discharging state for discharging. At this time, corresponding states of indicator lights are as follows: System state Indicator light for the secondary circuit● Indicator Light for the primary circuit● Alarm indicator light ● Power ON Green light is ON Red light is on Yellow light is OFF 5.8 Power Down of Primary Circuit of Battery Rack  During power down of primary circuit, the main circuit of the battery rack is disconnected and there is no high voltage at both ends of the positive and negative output poles, and the combination of lights on and off will correspond to the following state: System state Indicator light for the secondary circuit● Indicator Light for the primary circuit● Alarm indicator light ● Power ON Green light is ON Red light is OFF Yellow light is OFF Note: When there is charging and discharging flow in the main circuit of the battery system, the system will not be able to carry out the power down operation. Only when the charging and discharging flow is less than 5A can the power down operation be carried out. Fortress Power Confidential File 5.9 Secondary Circuit Power Down  The primary circuit indicator light is OFF. After disconnecting the AC power supply, corresponding states of indicator lights are as follows:  If the combination of the lights on and off is inconsistent with the above list, it means that the system is not shut down normally. Repeat the steps.  If the system fails to shut down after repeating the steps for 5 times, please conduct preliminary troubleshooting of system failure according to the “Failure and Alarm Handling and Countermeasures in chapter 8”; If the problem cannot be solved, please contact the manufacturer for system troubleshooting. 5.10 List of Rack Status System state Indicator light for the secondary circuit● Indicator Light for the primary circuit● Alarm indicator light ● Power OFF Yellow light is OFF Red light is OFF Yellow light is OFF Failure Green light is ON Red light is OFF Yellow light is ON Power ON Green light is ON Red light is OFF Yellow light is OFF Power up of Primary Circuit Green light is ON Red light is ON Yellow light is OFF Charge/Discharge Green light is ON Red light is ON Yellow light is OFF System state Indicator light for the secondary circuit● Indicator Light for the primary circuit● Alarm indicator light ● Power OFF Green light is OFF Red light is OFF Yellow light goes out Fortress Power Confidential File 5.11 Flowchart for powering on the cabinet correctly connected Is power supply no availdable? yes Decision Block 1、The auxiliary power supply delivers electricity 2、Set electric cabinets QF1 and QF2 in closed loop Execution or Information Blo Is the auxiliary source is No powered on properly? Yes 1. Go to pg.7 in manual and check error/fault 2. OR: contact Fortress support 1、Close the main control box QS disconnecter 2. Deliver high voltage command through BMS(EMS) (precharge completed) No Is the power of the main circuit normal? Yes Fortress Power Confidential File Was Primary circuit powered off? charge 是否完成 Yes 1. Go to pg.7 in manual and No check error/fault 2. OR: contact Fortress support 'HFLVLRQ %ORFN 1. Disconnect the electrical cabinet QS 2. Disconnect electric cabinets QF1 and QF2 3、Turn off the auxiliary power switch ([HFXWLRQ RU ,QIRUPDWLRQ %R[ Did the secondary source is powered off Go to pg.7 in manual and check error 1R OR: contact Fortress support <HV 6. Product Maintenance 6.1 Terms Explanation  Normal operating：Refers to the system that works every day.  Intermittent operating：Refers to a system that does not have a fixed monthly running frequency and cannot guarantee daily work.  Long-time unused：The battery system that has not started working for more than 3 months (the battery system needs to be charged to 40% SOC before being suspended). Fortress Power Confidential File 6.2 Operating Instructions for Normal Operating System  Perform battery maintenance on the system every twelve months to prevent battery damage. Refer to Section 6.6 for specific maintenance operating method.  Conduct an inspection of ESS every twelve months (refer to Appendix 1) and make inspection record. 6.3 Operating Instructions for Intermittent Operating System  The operating instructions are the same as those of normal operating system. 6.4 Operating Instructions for Long-time Unused System  SOC range of battery storage: 30%~50%., avoid long-term storage of batteries below 15% SOC. If the battery is not used for a long time, it is necessary to cut off the power-consuming equipment in time  Conduct an inspection of ESS every three months (refer to Appendix 1) and make inspection record.  Perform battery maintenance on the system every three months to prevent battery damage. Refer to Section 6.6 for specific maintenance operating method.  Before the first usage of long-time unused system, the battery system must be fully charged at least once to activate the battery system in order to recover the battery performance to the best condition. Fortress Power Confidential File Tips If the energy storage system is not used for a long time, it will cause irreversible damage to the battery. Please perform regular maintenance. 6.5 Function of Isolating Switch a) The isolating switch is an electrical component used to manually cut off the high voltage circuit for safety protection (pictured, right). b) Before the maintenance work is performed on the system, the relevant personnel must disconnect the isolating switch. After the maintenance work is completed, ensure that the isolating switch is in the ON state. 6.6 Operating Method of Battery Maintenance In order to ensure the long-term safe and reliable operation of your energy storage system, please read and follow the instructions below: Maintenance process: Plan 1 This plan is applicable when SOC of the battery system is low 1 Discharge the battery system to the cut-off condition (Average cell voltage< 3.1V or the lowest voltage<2.8V), then stop discharging, standing for 1 hour. 2 Full charging automatically to the battery system (The highest voltage>3.65V), after charging, standing for 1 hour. 3 Discharge the battery system to 40% and stop Plan 2 This plan is applicable when SOC of the battery system is high 1 Full charging automatically to the battery system (The highest voltage>3.65V), after charging, standing for 1 hour. 2 Discharge the battery system to the cut-off condition (Average cell voltage< 3.1V or the lowest voltage<2.8V), then stop discharging, standing for 1 hour. 3 Charge the battery system to 40% and stop Fortress Power Confidential File 6.7 Maintenance Requirements for Liquid Cooling System  In case of liquid leakage inside the electric cabinet, please stop the machine in time and contact Fortress Power for maintenance.  The coolant shall be BASF GLYSANTIN G30 and Sinopec OEVC electric vehicle thermal-35 recommended by Fortress Power. Once every five years. If the coolant deteriorates to the following level, it needs to be replaced.  PH value ＜ 6.5 or PH value＞ 9.5   Chloride concentration > 60ppm  Appearance: turbid coolant with impurities  The energy storage water cooling pipeline uses a liquid level alarm. If the liquid level sensor prompts an alarm, the liquid needs to be added.  If you purchase the coolant by yourself, you need to choose the coolant with the ice point lower than the local minimum temperature. It is recommended that the concentration of 40% ~ 50% glycol is good for aluminum corrosion resistance, and the maintenance should be carried out according to the requirements of the coolant supplier. It is recommended to increase the maintenance frequency. Any damage to the relevant parts of the electric cabinet caused by the use of other coolants not recommended by Fortress Power is not covered by the warranty.  The water cooling pipeline is observed during annual maintenance, and if it is damaged, it needs to be replace immediately. For the specific replacement operation method, see Appendix 2  For the maintenance of water cooling chiller , please refer to appendix the user manual of water cooling chiller. Tips 1 Check to ensure environmental safety, system safety, no alarm, no fault before performing maintenance operations. 2 After the battery maintenance of ESS is completed, you can notify our after-sales engineer to perform data analysis for free. Fortress Power Confidential File 6.8 Fire Protection System Maintenance  The service life of the aerosol is 10 years, and replacement are required every 10 years.  Check the temperature sensor and smoke sensor every 12 months:  Open the rack door, the rack is powered by low voltage, and observe that the sensor indicator flashes once every few seconds, which is the normal working state.  Dust regularly: to ensure the free circulation of air in the cabinet, clean the system every 6 months. Especially for dusty application scenarios，especially the air inlet and outlet of the fan、Floor drain, and use a vacuum cleaner when necessary. Power must be cut off before dust removal; do not rinse with water.  The catkins need to be maintained and cleaned at least once a week during the catkin season to prevent the mesh from being blocked. 7. Diagnosis of common abnormal problems 7.1 The system alarm is divided into level alarm and non-level alarm. Non-level alarm means that when an alarm occurs, certain equipment has been damaged or malfunctioned. There is no need to distinguish the severity with alarm level. 0 means normal, and 1 means that the corresponding equipment has malfunctioned. Treatment measures of failure at different levels: Level alarm Non-level alarm Monomer over-voltage Pre-charge timeout Fortress Power Confidential File Monomer under-voltage Short circuit of pre-charge load Monomer over-temperature Adhesion (main positive, main negative) Monomer low-temperature Open circuit (main positive, main negative) Charging over-current Coil abnormality (continuous monitoring) Discharge over-current Larger temperature difference Higher SOC Over voltage of system Lower SOC Lower system voltage Larger voltage difference Voltage invalidation Temperature invalidation - module single-point Temperature invalidation - module double-point Current invalidation Equalization anomaly Inner and cumulative sum voltage difference Open circuit of high voltage circuit CCAN communication SCAN communication CSC power supply Fortress Power Confidential File 7.2 Countermeasures of system alarm When you enable the battery rack, if it cannot work normally, please do not hastily determine that the battery rack is out-of-order, please refer to Table 8-2 for possible reasons. At the same time, pay attention to check whether it is caused by external environment, such as temperature, noncompliant humidity or load overload. If the maintenance or replacement of spare parts is involved, the after-sales user’s manual shall prevail. Meanwhile, the disassembly and installation are not allowed without authorization. This chapter contains only a few simple failure diagnosis procedures. If the answer to the diagnosis is not very unequivocal, or the information obtained is not sufficient to settle the problem, please contact the local office or distributor of the Fortress Power. Precharged relay power supply Abnormal power supply of SBMU Power supply of current sensor Abnormal FUSE state of main control cabinet Abnormal MSD state of battery rack Higher relay cut-off current Fortress Power Confidential File S/N Failure or alarm phenomena Possible cause of failure Troubleshooting scheme The low voltage indicator light of the battery rack is not on 1.Poor contact of wiring harness Check indicator light wiring harness 2. SBMU failure Replacement of SBMU 3. Breakdown of indicator Replacement of indicator light The high voltage indicator light of the battery rack is not on 1. Poor contact of wiring harness Replacement of relay 2. SBMU failure Replacement of SBMU 3. Breakdown of indicator Replacement of indicator light Precharged relay cannot be closed 1. Poor connection of relay wiring harness Check wiring harness connection 2. Relay failure Replacement of precharged relay 3. SBMU failure Replacement of SBMU Main positive relay cannot be closed 1. Poor connection of main positive relay wiring harness Check wiring harness connection 2. Main relay failure Replacement of main negative relay 3. SBMU failure Replacement of SBMU Main negative relay cannot be closed 1. Poor connection of main negative relay wiring harness Check wiring harness connection 2. Main negative relay failure Replacement of main negative relay 3. SBMU failure Replacement of SBMU Adhesion of main positive relay 1. Damage of main positive relay Replacement of main positive relay Adhesion of main negative relay 1.Damage of main negative relay Replacement of main negative relay Fortress Power Confidential File Abnormal monomer voltage detection 1.Poor connection of voltage detection wiring harness Check wiring harness connection 2. CSC failure Replacement of CSC Abnormal monomer temperature detection 1. Poor connection of temperature detection wiring harness Check wiring harness connection 2. Temperature sensor failure Replacement of temperature sensor 3. CSC failure Replacement of CSC Abnormal total voltage detection 1.Poor connection of total voltage detection wiring harness Check wiring harness connection 2. SBMU failure Replacement of SBMU Ferroelectric memory failure 1. SBMU ferroelectric memory failure Replacement of SBMU Internal communication abnormal 1. Poor connection of internal CAN wire Unplug and check CAN cable System parameters are not configured 1. The battery system parameters are not configured Configure system parameters Temperature extreme 1. The battery temperature exceeds the normal working range Stop charging and discharging Voltage extreme 1.Single cell voltage exceeds the normal allowable threshold Stop charging and discharging CSU 5V power supply is abnormal 1. Bad wiring of 5V power supply harness Check the wiring harness 2. SBMU abnormal power generation Replace SBMU CSC 12V power supply is abnormal 1.Poor wiring of 12V power supply harness Check the wiring harness 2. CSC power generation abnormal Replace CSC SBMU automatic shutdown 1. MBMU wake-up signal wire is Check the wiring harness Fortress Power Confidential File badly wired 2. MBMU wake-up signal output failure Replace SBMU Smoke sensor is abnormal 1. Bad sensor wiring Check the wiring harness connection 2. Smoke sensor malfunction Replace the smoke sensor Temperature sensor abnormal 1. Bad sensor wiring Check the wiring harness connection 2. Temperature sensor failure Replace temperature sensor Monomer over-voltage alarm 1. Poor equalization Stop charging and standby equalization 2. System over-discharge Stop charging Monomer under-voltage alarm 1. Poor equalization Stop discharge and standby equalization 2. System over-discharge Stop discharge Monomer over-temperature alarm 1. Excessive temperature of individual cores Check whether the air conditioner is in operation 2.Excessive charging- discharge current Appropriately reduce charging and discharge current Monomer under-temperature alarm 1. Lower temperature of individual cores Check whether the heating function is on (if the equipment cabinet has heating function) 2. Lower ambient temperature No charging Cabinet overpressure alarm 1. System overcharge Stop charging Cabinet under voltage alarm 1. System over discharge Stop discharge Cabinet over temperature alarm 1. The RACK temperature is too high Check if the air conditioner is running 2. Temperature sensor failure Replace temperature sensor RACK low temperature alarm 1. RACK temperature is too low Check whether the air conditioning heating function is turned on 2. The ambient temperature is too low No charging Fortress Power Confidential File Charging over-current alarm 1. Excessive current of system charging Reduce charging power Discharge over-current alarm 1. Excessive current of system discharge Reduce system load The unit does not run without display The chiller is not powered on Check if there is electricity at the power input of the chiller Suffered a lightning strike and the fuse burned Check whether the fuse of the water- cooled unit is burned out, and replace it after burning External circulation fan does not run The power input of the air conditioner is abnormal, such as overvoltage or undervoltage. Check the unit display, determine whether there is a corresponding alarm in the chiller, and correct it Air conditioner is on standby Normal phenomenon, when the chiller is powered on, it enters the automatic control logic after 30s standby Fan stuck Check if there are foreign objects stuck in the fan Loose terminal Check whether the fan docking terminal is loose The compressor does not start The external fan starts after the compressor starts Abnormal noise of external circulation fan Fan bearing wear Replace the fan Fan blades scrape other objects Check if there are cables or other interference with the fan blades The compressor does not start Power off (standby) Check the main power switch, and check whether the operation display interface has been turned on Loose circuit connection Forbidden circuit connector Fortress Power Confidential File Compressor motor burned out Check the motor and replace it immediately if any defect is found Compressor not working No cooling requirements Check the indoor return air temperature display and the output status of the compressor in the operation interface Stop delay The compressor has the shortest stop time under normal conditions. If the temperature rises to the opening point again during this period, the compressor will still start with a delay High exhaust pressure Dirty condenser Check if the condenser is dirty and clean the condenser External circulation fan does not work Refer to the description of the external fan not running The internal circulation pump does not start Power off (standby) Check the main power switch, and check whether the operation display interface has been turned on Loose circuit connection Fasten the circuit connector The pump body is burned out Check the water pump, if it is found to be burned out, replace it immediately There is air or no cooling medium in the cooling medium, which causes the pump to protect itself Check whether there is air or no cooling medium in the system. If there is air or no cooling medium in the system, it needs to be evacuated or supplemented with cooling medium Electric heating tube does not work No cooling requirements Check whether the outlet water Fortress Power Confidential File 7.3 Emergency Treatment Method （Scenario 1）Fire Step 1: Evacuate people to safe area, delimit the safety isolation zone and call the police according to the situation. Step 2: If possible, proceed as follows in the case of personal safety: 1） If the wiring harness is smoking or on fire, use carbon dioxide or dry powder fire extinguisher to extinguish the fire. 2） If the batteries are on fire, use a high pressure water gun to extinguish the fire at a distance. 3 ）If you accidentally inhale smoke, please transfer and seek medical attention as soon as possible. Step 3: Notify the manufacturer to obtain further handling suggestions. （Scenario 2）Flooding Tips If the fire is caused by abnormal charging or discharging, be sure to turn off the power first and then extinguish the fire. temperature and heating set point are set properly Loose circuit connection Fasten the circuit connector Electric heating tube burned out Check the electric heating tube, if it is found to be burned out, replace it immediately Fortress Power Confidential File Step 1: Regardless of whether the system is powered on, evacuate people to safe area and delimit the safety isolation zone. Step 2: Notify the supplier to perform an overhaul after the flood faded. Step 3: It is forbidden to start the system until the manufacturer provides the safety results of the system. 8. Requirements for Maintenance Personnel According to the after-sales user manual, the maintenance personnel shall be authorized by Fortress Power before carrying out maintenance based on the maintenance document. Authorization of specific maintainers will be discussed during the implementation phase of the project, and Fortress Power will provide training and guidance accordingly. Fortress Power Confidential File Appendix 1 Inspection project Method Yes–√ No- × Not applicable-O Abnormal record Is the fire extinguishing system Visual inspection Whether the fire extinguishing system is within the validity period Visual inspection Is the cooling system complete Visual inspection Is the cooling system air duct blocked Visual inspection Whether the appearance of the electric cabinet is deformed Visual inspection Whether the appearance of the electric cabinet is rusted or damaged Visual inspection Is there water vapor inside the electric cabinet Visual inspection Whether the LV harness is loose or damaged Visual inspection Whether the HV harness is loose or damaged Visual inspection Whether the wiring harness interferes with the structural parts Visual inspection Whether the high voltage connection is ablated Visual inspection Whether the fixing bolt of structural parts is loose or missing Visual inspection Is MSD complete and reliable Visual inspection Fortress Power Confidential File Whether the water cooling pipe is damaged Visual inspection Is there a foul smell in the battery compartment Sniffing Is there a pungent smell in the electric cabinet Sniffing Whether HV connection part has burnt smell Sniffing Is the summary data complete Monitor master computer Is the cell voltage data complete Monitor master computer Is the cell temperature data complete Monitor master computer Whether there is an abnormal alarm in the alarm bar Monitor master computer Note: If any abnormalities are found during the inspection, please feedback in time, and contact the relevant personnel for processing.