GivEnergy Commercial 30KW Power Conversion System Installation Guide

COMMERCIAL ENERGY
STORAGE SOLUTIONS POWER CONVERSION SYSTEM (PCS)
INSTALLATION MANUAL
30 | 50 | 100 | 150 | 250 AND 500KW PCS

SAFETY

Safety instructions
Extra care and attention must be taken when installing and maintaining any GivEnergy equipment.
The system is capable of retaining a high voltage, even when disconnected.
If you suspect something is wrong with the inverter, contact GivEnergy on 01377 252 874 or email [email protected]
If there are any damaged or missing parts, please contact the distributor immediately. Returns must be provided in original or equivalent packaging
All electrical installations must be carried out by a qualifi ed and registered electrician and in accordance with local wiring regulations
During operation, the heat sink may become hot. Do not touch the heat sink at the sides, or the top of the inverter when in operation
The inverter is designed to be connected to the grid; connecting your inverter to a generator or other power source can result in damage to the inverter or external devices
All GivEnergy equipment must be installed by a GivEnergy Approved Installer

| Before removing any covers the PCS should have the AC and DC supply isolated for a minimum of 15 minutes
---|---
| The PCS must be installed in an accessible location, the status display must be visible and not obstructed
| The PCS must be installed in a well ventilated area, free of any obstacles. The ambient temperature should be below 45ºC to ensure optimal operation
| The inverter must be installed vertically with connections always positioned at the bottom, never install horizontally, and avoid tilting the unit
| Do not install in direct sunlight or near water sources

COMPONENTS

HANDLING

Required tools and equipment
Gloves
Socket/spanner set
Screwdrivers
Suitably rated lifting equipment
Please note that due to the weight of the PCS, it may not be possible to utilise the delivery vehicle’s tail lift. As such, a suitably rated forklift truck, telehandler, or similar will be required.

Delivery and unpackaging
The PCS will be delivered palletised in a wooden box.

1. Starting with the top, release the metal retaining clips by unfolding them to a straight position then lift the top off
2. Working around each side one at a time, release the remaining retaining clips and remove each panel.
3. Remove the plastic and foam packaging.
4. Remove the lower black trim on all sides of the PCS – be careful not to lose any of the bolts.
5. Unbolt the PCS from its pallet on all sides.
6. Lift the PCS to allow removal of the pallet, being careful not to put any body part in a potential trap area
7. The PCS can now be positioned using the lifting equipment or a standard pallet truck.
8. The key to the door is attached to the handle

Key dimensions

INSTALLATION ENVIRONMENT

Environment criteria
To ensure optimal operation and lifetime of the PCS, it must be installed in an environment that meets the following criteria at a minimum:
The PCS must only be installed internally on level flat ground. It is possible to fix it to the floor on each corner if required.
-30°C to 55°C
0 to 95% non-condensing humidity
<5000m altitude
In an area with adequate ventilation
Ventilation
The PCS must have a suitable airfl ow to ensure optimal operation. If the PCS is being fi tted against a
wall then a vent/duct must be installed prior to fi nally positioning the PCS.
Please see ‘PCS Ventilation guide’ for more information.
Access
It is recommended that access to the area the system is located within is restricted. A password protected screen and locked door prevent immediate danger to the general public, however some basic parameters and operations such as the emergency stop button are accessible.
The system should always be installed in a well lit area where access can be made available for maintenance purposes.

ELECTRICAL AND DATA CONNECTIONS

Electrical and data connections

A 400v 3 phase AC supply is required. For maintenance purposes, it is recommended that this supply can be locally isolated. AC and DC connection terminals are found at the bottom of the PCS below the MCCBs and switches within the front door. Connections are accessed by removing the terminal cover. Depending on the PCS version, this may be the lower section below the MCCBs and switches or, the whole lower front cover. Take care not to lose the fixing bolts.
All connections require ring terminal lugs, do not over tighten the connections.
Cable sizing will be determined by length of run, cable type, installation type and maximum current rating of the PCS.

input (per pole)
---|---|---|---|---
30kW| ≥25mm2x 3| ≥25mm2| ≥16mm2| input 50mm2
50kW| ≥35mm2x 3| ≥35mm2| ≥16mm2| input 70mm2
100kW| ≥50mm2x 3| ≥50mm2| ≥25mm2| input 95mm2
250kW| ≥120mm2x 3| ≥120mm2| ≥50mm2| 2-way input 120mm2
500kW| ≥185mm2x 3| ≥185mm2| ≥195mm2| 4-way input 120mm2
630kW| ≥240mm2x 3| ≥120mm2| ≥120mm2| 4-way input 120mm2

Bolt dimensions and required torques

AC grid supply

Before connecting to any terminals, ensure all MCCBs and switches are in the OFF position and ALL supplies are safely isolated and tested.
The grid supply is connected to the QAC2 terminals marked grid. If uncertain the grid MCCB can easily be identifi ed as it has a large contactor directly above.
If off grid functionality is a selected option this can be achieved via the same cable as the supply. This is common when providing back-up power to a whole site – please speak to a GivEnergy representative if uncertain.
The AC supply must be tested for correct voltage, polarity and phase rotation before turning on the MCCB within the PCS.
A ‘clean’ earth should be provided to the PCS, this should be a separate earth ran directly from the MET of the site. EPS/UPS output
Before connecting to any terminals, ensure all MCCBs and switches are in the OFF position and ALL supplies are safely isolated and tested.
The EPS/UPS output is connected to the QAC1 terminals marked EPS or Backup. If uncertain this can easily be identified as the MCCB does not have a contactor directly above.
The backup output terminals can be used when installing the PCS with a two cable method, this is common when providing back-up power to certain dedicated or essential circuits. Please speak to a GivEnergy representative if uncertain.

DC connections
Before connecting to any terminals, ensure all MCCBs and switches are in the OFF position and ALL supplies are safely isolated and tested.
Using the cables provided, connect the positive and negative cables to the DC input terminals on the lef t hand side marked QDC.
Take great care to ensure correct polarity, the DC supply must be tested for correct voltage and polarity before turning on the DC switch within the PCS.

Supply to battery/DC cabinet
A power supply is required to supply the battery cabinet (or DC cabinet if fitted), using the wiring harness provided connect into battery cabinet output terminals in the bottom right hand side of the PCS.

Data connections
The PCS takes an external control signal from the GivEnergy EMS located within the battery racking/ cabinet(s) or DC cabinet.
Depending on the version of the PCS, the data connections can either be found to the lef t hand side outside of the AC and DC connection cover, OR in the centre behind the AC and DC connection cover.
The PCS communicates with the EMS via CAN bus, using the cable supplied with the battery cabinet(s) connect to the terminals marked BMS CAN H and CAN L.
Once all connections are made and tested, the lower black trim can be re- installed on all accessible areas using 2 bolts on each side to secure.
Once electrical testing is completed the lower cable entry cover should also be reinstalled.

Power-on procedure
Once all connections are terminated correctly with satisfactory test results, the following turn-on procedure should be followed:

1. Release the emergency stop button if pressed
2. Turn on the AC Supply MCCB (QAC2)
3. Wait for the screen to power up and display grid voltage*
4. Turn on the EPS output MCCB (QAC1)
5. Wait for the screen to show voltage on ‘load’
6. Turn on the battery system following the instructions
7. Turn on the DC switch and check for the correct DC voltage on the screen
8. Follow instructions in the ‘Operational Settings’ section

*On first start up/initial commissioning, it is advised that the operational settings are checked af ter step 2 before proceeding to next steps.
Shutdown procedure
In an emergency press the emergency stop button on the PCS first then all battery cabinets/racks.

1. Follow instructions in the ‘Operational Settings’ section
2. Press the emergency stop button
3. Turn off the AC and EPS MCCBs
4. Turn off the DC switch

Caution: Always wait at least 15 minutes for the internal capacitors to discharge before removing safety covers.

OPERATIONAL SETTINGS

A number of settings should be confi rmed on initial start-up to ensure correct operation. It is recommended that these settings are checked prior to connecting the PCS to the battery system. The commissioning engineer will provide the required settings. The setup can be accessed by pressing Menu > System. The default password for access to the settings with the PCS screen is: ‘888888’.*

To run the PCS in automatic mode
Press Menu > System > Parameter Setting > Control Mode > Remote
The EMS will then automatically control the PCS based on the parameters set via the online portal, the PCS will automatically turn on or off as required.

To run the PCS in local mode
Press Menu > System > Parameter Setting > Control Mode > Local
Set the required power using constant power, discharging is a positive number, charging is a negative number (eg. 15 = 15kW discharge, -32 = 32kW charge).
Press Menu > Turn On

*If the default password is changed please inform GivEnergy for maintenance and warranty purposes. If the default password is forgotten, the PCS will have to be fully reset at the purchaser’s cost.

PCS SCREEN INFORMATION

Operational information can be seen on the screen. Tap the screen to light it up if it is off or dull.
Settings access is for access to the menu — speak to your installer or GivEnergy.
Each of the icons on the screen can be pressed to show more detailed live information.

Menu button| System parameter setting| Control mode| Local – Control operation from PCS screen Remote – Control via EMS
---|---|---|---
Constant power| Operating power of PCS
(Auto set when in remote control)
Advanced settings| GivEnergy operation only
System battery setup| GivEnergy operation only
System automatic operation| Set time schedules for local operation

INITIAL TESTING / COMMISSIONING

All GivEnergy commercial storage solutions include an on-site commissioning service. Our engineer will ensure correct communication with meter, battery packs, EMS and PCS. To aid in this testing, the engineer will initially run a low power test in ‘manual ’ mode — setting the system to complete a 5 minute charge
followed by a 5 minute discharge and a rate of 10kW.
Once this is complete, where electrical supply parameters allow, a full power charge and discharge will be ran for a period of 15 minutes each. Depending on electrical limitations on site, this test can be adjusted to power levels with site tolerance.
Any additional tests can now be completed, including system specifi c operation such as back up power.
Once the above testing is successfully completed, the system will be set to run in its agreed operational modes and a demonstration can be given to the client and/or installer.
Our engineer will supply commissioning paperwork once complete, the date of which will commence the PCS warranty.

MAINTENANCE AND SUPPORT

Maintenance
Ensure that the front door and rear ventilation are not restricted or clogged with dust.
An annual check of all emergency stop buttons and protective devices is recommended.
Support
Free remote suppor t is included with all systems for the period of the warranty.
Phone: 01377 252 874
Email: [email protected]
GivEnergy Commercial Ltd.
Newspaper House
Chemical Lane
Longbridge Hayes Road
ST6 4QZ

www.givenergy.co.uk

References

• Smart, clean energy storage for your home or business | GivEnergy

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