Installation & Operation Manual

Energy Storage System (ESS)

T50/T100

V02
 Your Smart Energy

IMPRINT

Germany
Alpha ESS Europe GmbH
Tel.: +49 (0)6103 459 160-1
E-mail: europe@alpha-ess.de
Web: www.alpha-ess.de
Add: Paul-Ehrlich-Straße 1a
63225 Langen

China
Alpha ESS Co., Ltd.
Tel.: +86 (0)513 806 868 91
E-mail: info@alpha-ess.com
Web: www.alpha-ess.com
Add: Jiuhua Road 888, High-Tech Industrial Development Zone
226300 Nantong City, Jiangsu Province

Australia
Alpha ESS Australia Pty. Ltd.
Tel.: +61 1300 968 933
E-mail: australia@alpha-ess.com
Web: www.alpha-ess.com.au
Add: Suite 2, Level 1, 530 Botany Road, Alexandria, NSW, 2015

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Copyright Statement

This manual is under the copyright of Alpha ESS Co., Ltd, with all rights reserved. Please
keep the manual properly and operate in strict accordance with all safety and operating
instructions in this manual. Please do not operate the system without reading through the
manual.

Version Information

Version Date Content

V1.0 July 16th, 2018 First edition

V1.1 Aug 2nd , 2018 Some grammar modified

V02 Aug 24nd , 2018 Format improved

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Content

IMPRINT .......................................................................................................... 1
Copyright Statement ...................................................................................... 2
Version Information ....................................................................................... 2
Content ........................................................................................................... 3
1. Introduction.............................................................................................. 5
Brief Introduction .............................................................................. 5
Explanation of Terms ........................................................................ 5
2. Safety Instructions .................................................................................. 7
Manual Keeping ................................................................................. 7
Operator Requirements..................................................................... 7
Protection of Warning Sign............................................................... 7
Setting of Warning Sign for Safety................................................... 7
Live Line Measurement ..................................................................... 7
Measuring Equipment ....................................................................... 8
Electrostatic Protection .................................................................... 8
Moisture Protection ........................................................................... 8
Operation After Power Failure .......................................................... 8
Minimum Personal Protection Equipment ..................................... 8
3. Product Description .............................................................................. 10
Product Appearance ........................................................................ 11
Product Characteristics .................................................................. 12
Parts Parameters ............................................................................. 12
Container................................................................................................... 12
PCS ........................................................................................................... 13
Battery System .......................................................................................... 15
Fire Extinguishing System ........................................................................ 19
Air Conditioner .......................................................................................... 19
Distribution Box ......................................................................................... 20
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4. Installation.............................................................................................. 20
Installation Precautions .................................................................. 20
Installation........................................................................................ 20
Container Installation ................................................................................ 20
Battery Installation .................................................................................... 22
Battery Side-Wiring ................................................................................... 23
Inverter Side-Wiring .................................................................................. 25

5. Operation................................................................................................ 27
Switch on.......................................................................................... 27
Check Before Operation ........................................................................... 27
Power-on Procedures ............................................................................... 27

Switch off ......................................................................................... 29

Dry Contact Description.................................................................. 29
Diesel Generator Control ................................................................ 30
Online Monitoring ............................................................................ 31
Register ..................................................................................................... 31
Registering License .................................................................................. 32
Generator Control Setting On Server ....................................................... 33
PV Junction Box Data Check.................................................................... 34

Emergency Stop .............................................................................. 34

6. Routine Maintenance ............................................................................ 35
Maintenance Plan ............................................................................ 35
Routine Inspection .................................................................................... 35
Routine Maintenance ................................................................................ 38

Notes................................................................................................. 41
7. Troubleshooting .................................................................................... 43
Battery and BMS troubleshooting .................................................. 43
Error Type ................................................................................................. 43
Emergency Handling Plan ........................................................................ 43

EMS Troubleshooting ...................................................................... 44

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1. Introduction

Brief Introduction
This manual applies for Storion T50/T100 Li-ion battery energy storage system, mainly
includes:
(1) Safety introduction
Introduces the product use, operating notes and qualification of operators of T50/T100 Li-
ion battery energy storage system.
(2) Product description
Describes product appearance, product characteristics, system composition and major
functions of T50/T100 Li-ion battery energy storage system.
(3) System installation
Introduces the installation of T50/T100, including attentions.
(4) Operation
Introduces the operation of T50/T100 system.
(5) Routine maintenance
Introduces items in maintenance of T50/T100 kWh Li-ion battery energy storage system,
including attentions.
(6) Trouble-shooting
Introduces the faults of T50/T100 Li-ion battery energy storage system, reasons to faults,
and processing method.

Explanation of Terms
(1) Lithium iron phosphate cell (LiFePO4)
Basic unit constituted by electric poles and electrolytes; Each cell is independent and
closed. (Notes: Paralleled cell cannot be regarded as an independent cell, even packed
again)
(2) Lithium iron phosphate pack
Combination made up of battery monitoring circuit, battery equalization circuit, electrical
connectors, communication interfaces, thermal management devices and multiple Lithium
iron phosphate cells(Notes: For packs from same company, all the details such as physical
size, working performance and interface specification should be consistent in order that all
the packs are interchangeable).
(3) Battery management system
Electronic equipment collection for monitoring the operating information of cells, packs and
system units (such as voltage, current, temperature, protective parameter of batteries),
evaluating the state of charge (SOC), the state of health (SOH) and cumulative
processed energy, protecting batteries for safety, etc.
(4) Battery system unit
Combination made up of batteries through series parallel combination inside and a battery
management system (BMS) in which accesses to DC side of a bidirectional converter.
(5) Storage unit
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Combination made up of a bidirectional converter and a battery system unit, which can be
used as an independent load or be controlled directly by monitoring system in an energy
storage power station.

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2. Safety Instructions

Manual Keeping
This manual contains important information about operating the system. Before operating,
please read it very carefully.
The PCS should be operated in strict accordance with the description in the manual, in
case that it causes damage or loss to equipment, personnel and property.
This manual should be kept carefully for maintenance and reparation.

Operator Requirements
The operators should get a professional qualification, or be trained.
The operators should be familiar with the whole storage system, including compositions
and working principle of the system.
The operators should be familiar with the Product Instruction.
While maintaining it must ensure that two operators are in the field, and they cannot
operate any equipment until all of them are powered off and fully discharged.
It is strictly prohibited for any maintenance when equipments are on or charged.

Protection of Warning Sign

The warning sign contains important information for the system to operate safely, and it is
strictly prohibited to be torn or damaged.
Ensure that the warning sign is always clear.
The signs should be replaced immediately when damaged.

Setting of Warning Sign for Safety

While instructing, maintaining and repairing, in case of preventing unrelated personnel
nearby to cause incorrect operation or accident, the opinions below should be followed:
Obvious signs should be set at front switch and rear-level switch in case of accidents
caused by false switching.
Warning signs or tapes should be set near operating areas.
Keys of the system must be pulled out after maintenance or operation.

Live Line Measurement

High voltage in the container which may cause vital electric shock when touching by
accident.
Equipment protection must be taken in live line measurements (e.g.: insulation gloves).
The measuring equipment should be connected and used correctly to ensure personnel
safety. When measuring, at least two workers are needed.

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Measuring Equipment
For ensuring the electrical parameters to match requirements, related measuring
equipment are required when the system is being connected or tested.
Ensure that the connection and use matches specification in case of electric arc or shock.

Electrostatic Protection
Contact or improper operation of the printed circuit board or other ESD sensitive
components may result in damage to the device. Unnecessary contact should be avoided.

Moisture Protection
Moisture intrusion may highly likely well damage the system.
Do not open the container door when the humidity is larger than 95%.
Repair or maintaining activities in wet weather should be avoided or limited.

Operation After Power Failure

The battery system belongs to energy storage system, and it keeps fatal high voltage even
the DC side is disconnected, so touching the output of the battery is strictly prohibited.
The PCS keeps fatal voltage even both the DC or AC side are disconnected, so it must be
tested by multimeter for safety before operation.

Minimum Personal Protection Equipment

For the safety of operators to the system, when doing personal protective equipments are
required.
When stepping into the containers, as minimum the following protective equipments are
required:
No. Item Notes
1 Work clothes
2 Protective shoes
3 Protective glasses

When doing maintenance works such as checking cables or wires, measuring voltage,
replacing small electrical parts or cleaning modules and brackets, as minimum the
following protective equipments are required:
No. Item Notes
1 Work clothes
2 Protective shoes
3 Protective glasses
4 Insulated gloves For touching live parts
Note: All metal tools during maintenance should be insulated.

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When replacing modules, the following protective equipments are required:

No. Item Notes
1 Work clothes
2 Protective shoes
3 Protective glasses
4 Insulated gloves For touching live parts
Note: When replacing modules, the stacking machine should be used carefully in case that
the modules may fall down. All workmen are suggested to wear high-safety and high
strength protective shoes to protect their feet.

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3. Product Description
The AlphaESS T50/T100 energy storage system is an off-grid system. The excessive
energy generated by the PV will be stored in the batteries. The stored energy can be used
when the PV is not generating enough energy, for self-consumption at a certain time or to
shave off peak usage and fill valley usage.

The overall system connection diagram is as follows:

Figure 3-1 System application diagram

If your system without container, the overall system connection diagram is as follows:

Figure 3-2 System application diagram

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Product Appearance
Figure 3-3 is the layout diagram of the container storage system.

4
3

Figure 3-3 Container layout diagram

Figure 3-4 T50/T100 without container

Item Components
1 Battery system
2 Fire extinguishing system
3 Air conditioner
4 PWG2-50 /100 PCS

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Product Characteristics
LiFePO4 batteries produced by AlphaESS have longer lifespan and higher reliability, which
is able to satisfy the application of energy storage systems.
The system is highly modular designed, and it is easier to assemble, transport and maintain.
The system has a three-level BMS and is easier for system expansion.
The system adopts full time balancing technology so that the consistency of batteries and
modules can be well ensured.
The system is designed as a removable container which is tight, flexible, convenient for
installation and testing, suitable to the environment, and is able to satisfy different kinds of
application.
The system has current balance technology between strings in case of circulating current
or unbalanced power.
The system has relatively developed thermal management technology so that the
consistency of system environment can be ensured.
The system has both remote monitor function and local control function.
The system realizes flexible scheduling of electric power system through communication
among BMS, PCS and monitoring system.
The system realizes emergency fire protection by automatic alarming and fire extinguishing
system

Parts Parameters

Container
Battery Enclosure
Manufacture AlphaESS /
10’GP energy storage
Model Name /
container
Dimensions (L x W x H in mm) 2991 x 2438 x 2591
Quantity 1
Ventilation e.g. natural, air conditioned Air conditioned
Access to all battery terminals Yes Yes
Racking of batteries Horizontal or Vertical Vertical
SPA-H, t2.0; Thermal
Enclosure shading details Shell material details insulation composite board:
stone wool
The fixed foundation of the
Foundation type
container is cement pile
Hold down method

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PCS

3.3.2.1 Product Instruction

T50/T100 INV is a hybrid inverter. It has DC/DC and DC/AC modules. It can transform the
DC electricity from PV panels into three-phase AC electricity to supply the loads. The
DC/DC module can charge batteries by using the PV panels generated electricity. The
DC/AC module is bidirectional, so the grid electricity can also through this inverter charge
the batteries.

3.3.2.2 Appearance Instruction

No. Description No. Description

1 Power indicator 7 PCS module
2 Normal indicator 8 STS module
3 Fault indicator 9 PV DC switch
4 Scram button 10 Battery switch
5 Display screen 11 Load switch
6 Handle 12 Diesel switch

3.3.2.3 Technical Parameters

No. Item Parameter
AC Side Data

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1 Rated Power 50 kW
2 Max Output Power 52.5 kVA
3 Rated Voltage 400 V
4 Max Output Current 72 A
5 AC Connection 3P4W (Transformerless)
6 Operation Voltage Range 400 V ± 15 %
7 Rated Frequency 50 Hz / 60 Hz
8 Frequency Range 50 Hz / 60 Hz ± 2.5 %
9 THDI @ Rated Power <3%
10 Power Factor -0.8 ~ +0.8
DC Data (Battery Side)
11 Rated Power 50 kW
12 Max. Stable Operation Power 50 kW
13 Max Long Term Operation Current 160 A
14 DC Voltage Range 250 – 520 V
PV Side Data
15 PV Voltage Range 500 – 900 V
16 Max Long Term Operation Current 110 A
17 Max. Stable Operation Power 55 kW
General Data
18 Max Efficiency 0.96
19 Dimensions (W x H x L) 800 x 2160 x 800 mm
20 Weight 500 kg
21 Altitude 3000 m
22 Ingress Protection IP20
23 Noise < 70 dB

24 Operation Temperature -25 ℃ ~ +55 ℃

25 Cooling Concept Forced Air

26 Humidity 0~95% (Non-Condensing)
27 Communication Interfaces Ethernet‚ RS485‚ CAN2.0

3.3.2.4 Emergence Stop Switch

The converter stops working immediately after pushing down the button.
If you will restart the converter, please execute in the following order:

a) Conduct counter clockwise rotation on the emergency stop switch and then loosen the
locking status.
b) Push the AC breaker into “OFF” position, pull up the emergence button then turn the
AC breaker “ON”.
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c) Launch the machine and run after the requirement

Battery System
Item Description Parameter Remark
1 Nominal discharge power 50 kW / 100 kW
2 Energy storage capacity According to the project Ambient temperature
situation is 30℃, measured at
DC side
3 Continuous discharge current 1C (continuous)
4 Direct voltage 250 ~ 520 V
5 Communication interface RS485, CAN2.0

3.3.3.1 M48112-S

Figure 3-5 Battery appearance

Figure 3-6 Battery front cover

Battery interface definition:

No. Description No. Description
1 Battery negative pole 5 Dip switch
2 Battery positive pole 6 COM port
3 Earthing point 7 Information label
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4 LED light
Battery technical parameters:
No. Item Technical parameter Remarks
1 Battery model M48112-S
2 Assembly method 16S2P
3 Nominal voltage 51.2 V

4 Voltage range 48～58 V

Max. charge / discharge

5 Nominal capacity 112 Ah
current 1C
6 Nominal stored energy 5.737 kWh
7 Work power consumption 0.4752 W
8 Dormant power consumption 1.52 mW Battery dormant state
9 Max. charge/discharge current 112 A Constant current mode

10 DC internal resistance ＜20 mΩ Factory default

Transportation/storage
11 -20 ～ 45 ℃
temperature range
Charge work temperature
12 0～50 ℃
range
Discharge work temperature
13 -10～50 ℃
range
14 Communication mode CAN
15 Weight 70 ± 2.0 kg
494.6 x 615.3 x 162.6
16 Size (W x D x H)
(±5) mm

17 Humidity 15%～85%

3.3.3.2 HV900112

Figure 3-7 HV900112 front cover

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HV900112 interface definition:

No. Description No. Description
1 DCin+ 7 DCout-
2 DCin- 8 AC input
3 Earthing point 9 AC Air switch
4 Plastic circuit breaker 10 BMU COM port
5 Information label 11 LMU COM port
6 DCout+ 12 LED

HV900112 technical parameters:

No. Item Technical parameter Remarks
1 High-voltage control box HV900112
2 Working voltage range 200 ~ 900 V
3 Rated current 112 A
4 Dimensions (W x D x H) 450*520*162 (±5) mm
5 Weight 20 kg
6 Power consumption <10 W

3.3.3.3 Top BMU Box (with EMS)

Through the TOP BMU Box with EMS the functions such as remote monitoring, remote
upgrade etc. can be realized.

17

Figure 3-8 Front cover of TOP BMU box with EMS

Top BMU box with EMS interface definition:

No. Description No. Description

1 BMU COM port 9 PCS COM port
2 BMU COM port 10 PV COM port
3 Ethernet 11 Dry contact
4 Reserve power supply 12 EMS display screen

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5 Dry contact 13 DB9 COM

6 Electricity meter 14 Storage card
7 EMS 15 Burning port
8 Air conditioner 16 COM pin board
17 DIP switch

Technical parameters：
No. Item Technical parameter
1 Dimensions(W x D x H) 215 x 623 x 436 mm
2 COM RS-485×4; Ethernet 10/100/1000Mbps×1
3 Internal storage CF card, 4 GB
4 Events diary Recent one-month happenings
5 Work voltage 24 V
6 Power consumption <10 W

3.3.3.4 Junction box

1 3 1 2 4 2

5 5

1 3 1 2 4 2

Wiring definition
No. Description No. Description
1 DC IN INV- 4 DC OUT+
2 DC IN INV+ 5 Handle
3 DC OUT-

Technical parameters
No. Description Technical parameter
1 Dimensions (W*D*H) 447x205x162 mm
2 Weight 7 kg

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Fire Extinguishing System

The container has fire detection, alarm, control and firefighting systems. Alarm bells will be
ringing once either the smoke detector or the heat detector is activated. When the smoke
detector and heat detector are activated at the same time, after confirming there is fire, the
fire monitoring device will give a signal to the fire control panel, audible and visual warning
signals are automatically generated and then the fire panel starts counting down. After that,
the fire extinguisher will start and spray gas.
When the alarming bells ring, the control system will send signal to cut off the DC
connection of batteries by tripping all DC breakers. After the audible and visual alarm starts,
the PLC will get signal and AC breakers will be tripped. Personnel in the container should
evacuate immediately, meanwhile the control system will start counting down and then
send signal to spray gas after the counting down. The electromagnetic valve will act and
the cylinder will spray gas to fill the container in a short time. The accident indication lamp
starts to warn personnel to keep away from the container. As soon as the cylinder acts, the
PLC will get signal from the fire monitoring device, send it to power station control system,
and trip all PCS AC circuit breakers at once.
When the power supply of fire extinguishing system is missing, either DC or AC supply, the
fire panel will send a trouble signal to PLC and show that something is wrong with power
supply.

Air Conditioner

3.3.5.1 Introduction
A CC2000PA cabinet air conditioner consists of the following main components:
Compressor, condenser, temperature controller, capillary tube or expansion valve and fans.
It features compact structure, light, low energy consumption and low noise. The cabinet air
conditioner adopts AC power supply and uses the environmental-friendly refrigerant R134a
to achieve high efficiency, energy saving, safety, and reliability. The cabinet air conditioner
is equipped with RJ45 ports to implement communication and remote control.

Table 1 Air conditioner technical parameters:

No. Project Technical Parameter

1 Auxiliary power type 220 V, 50 HZ
2 Refrigerating capacity 2000 W
3 Rated power 616 W
4 Rated current 2.8 A
5 Maximum power 880 W
6 Maximum current 4A

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Distribution Box
The distribution box (in the container) figure is shown as below:

Table 2 Distribution box swith discription

No. Description No. Description

1 AC input 7 Exhaust fan
2 Air conditioner 8 BMS
3 PCS lighting 9 Container fan
4 Battery lighting 10 Camera
5 Socket 11 Camera
6 Emergency

4. Installation

Installation Precautions
The following sites are not allowed for installation:
- Sites which are salty and where humid air can penetrate.
- Flooded areas.
- Earthquake areas –additional security measures are required here.
- Sites that are higher than 3000 meters above the sea level.
- Sites with explosive or potentially explosive atmosphere.
- Sites with extreme change of ambient temperature.
- Sites with highly flammable materials or gases.

Installation
If you don’t need the container, please skip to 4.2.2 directly.

Container Installation

4.2.1.1 Base Requirements

1. This container has been made based on the new 10'GP mark TEU dimensions;
2991*2438*2591 (long * wide * high).

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2. The self-weight of the container is about 2 t, the accessories such as internal PCS are
about 1 t, one battery rack with batteries is about 700kg and the total weight of the system
is about 5.8 t.

3. Foundation height is considered to be the highest historical water level of the area.

4. Two earthing points are provided outside the container.

5. People should be able to bend down and pull the cables under the manhole so it’s better
that the height is not less than 1600mm (changeable according to the real situation).

6. Pay attention to the drainage of the inlet-outlet holes and the foundation.

4.2.1.2 Container Hoisting

Step1: Hoist the container to the corresponding foundation as the lifting plan.
NOTE：The lifting rope is fixed on the upper corner of the container B, B’, B’’, B’’’ and the

length of the four ropes are equal.

The hooks position should be on the top of the container. The length of the rope adapted
should ensure that the angle between the ropes and the roof of the container is greater than
60 degrees. Maintain the horizontal level of the container in the lifting process.
Step2: Put it on a prepared foundation.
Step3: Open the container emergency door.

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Step4: Remove two sides of iron sheet 1, 2.

Battery Installation
If you don’t need the container, you can only see this chart to install the storage system.

Battery cluster No.

number

Cluster No.
number Battery gear
No.

Battery SN No.

a. Check the cluster No. on the battery cover.

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b. Put the same cluster of batteries on the same rack with the serial number sequence of

01, 02, 03…07 from top to bottom.

c. All of the cluster battery gear No. shall be consistent.

d. When you are installing the battery, please handle gently to avoid scratches because of

the heavy battery.

e.After completing one rack, please check whether the installed batteries have the same

cluster No. and whether the gear No. is consistent.

f. Use the screws in packing list to fix each battery.

Battery Side-Wiring

Table 3 Parts in package required by battery wiring:

No. Item Description No. Item Description

1 5
Screw Power cable
M6*16 Black-black
(Battery package) 2500mm

2 6
Nut Power cable
M6*4 Red-red
(Battery package) 130mm

3 7
Power line Network cable 300mm
Red-black Connect the LMU port
130mm of HV900112 with
(Battery package) battery COM.

4 8

Network cable Terminal resistance

280mm Insert the BMU port of
(Battery package) HV900112

a. Please see the following figure, connect the power and COM cables among batteries.

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b. Take the item 8, the terminal resistance in Table 3 away from the LMU internet
access of HV900112 and insert it into the top battery COM port of one battery cluster. You
can see the detailed information in the battery picture.

HV900112 Top battery of one battery cluster

c. Connect the comminucation cables to the LMU port of HV900112 control box as the
following diagram shows.

Figure 4-1 Battery side-communication cables connection

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d. Connect the power cables as the below picture shows:

Figure 4-2 Battery side-power cables connection

Inverter Side-Wiring
The connection positions are in the bottom down position of the inverter cabinet. The
cables shall be passed through the hole on the base of cabinet into the cable trench. Open
the front door and remove the inner door, you can see the wiring copper bar. In view of the
requirements of connecting cables, single or multiple cables with suitable diameter shall
be selected.
We suggest to use 35mm2 cables to connect both AC and PV port.

Figure 4-3 Inverter wiring diagram

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Position Description Position Description

1 PV DC input positive pole 7 Load output phase B
2 PV DC input negative pole 8 Load output phase C
3 Battery input positive pole 9 Diesel input phase A
4 Battery input negative pole 10 Diesel input phase B
5 Ground connect 11 Diesel input phase C
6 Load output phase A 12 Neutral connect

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5. Operation

Switch on

Check Before Operation

Before operation please check the equipment according to the following procedures:
If no sign of damage is inspected visually outside the inverter module and all of the battery
switch, PV switch and load switch, diesel engine switch are in the "OFF" position, you will
a. check whether the DC input wiring of the energy storage system and the AC output
wiring are normal and whether the earthing is good;
b. check whether the wire connection polarity is normal;

Power-on Procedures
The system shall be turned on in the correct sequence to avoid any damage.

A. Turn on the plastic case breakers of HV900112 in each cluster respectively.

From left to right: OFF- triggered position-ON

Figure 5-1 Plastic circuit breaker in switch-off status

B. Turn on the AC switches of HV900112 in each cluster respectively.

Figure 5-2 AC switch in switch-on status

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C. Turn on NO.8 switch-BMS (see Table 2) of the distribution box:

D. After power-on the LED on the batteries and HV900112 starts flashing.
E. After two minutes, turn on the battery and PV switches of inverter by pushing up the
switch handles, the inverter will be powered on.

Figure 5-3 PV switch and battery switch in switch-off satus

F. turn on the load and diesel switches by pushing up the switch handles.

Figure 5-4 Load switch and diesel switch in switch-off satus

G. Normal system operation

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Switch off
Enter into EMS menu
Main interface -> Setting -> Password (the initial password for installers is 1111)

(1) (2)

Enter Function menu -> INVcmd -> ModeOff -> yes

(3) (4)

The inverter will be powered off.

Then switch off all of the breakers.
Note: automatically power-on if the system is still powered after 5 min.

Dry Contact Description

1. Connect DO_2 to the dry contact of the diesel generator, port 2 and 3 is normally closed

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contact, 1 and 2 is normally open contact, you can connect the diesel dry contact control the
2 and 3.
2. Connect DI_2 to the fire fighting dry contact, port 14 and 15 are respectively corresponding to
the composite fire alarm of connecting fire fighting.
3. Please connect the diesel control dry contact as the below picture shows:

Note: normally open/closed contact which connects the Genset according to the genset
controller.

Diesel Generator Control

Enter into EMS menu
Main interface -> Setting -> Password (the initial password for installers is 1111)
Enter function menu -> Generator allocation

Table 4 Setting Parameter for Diesel Generator Control

No. Parameter Description

1 GeneratorEN
2 GeneratorMode
3 GCSOCStart
4 GCSOCEnd
5 GCOutputMode
6 GCChargePower
7 GCRatedPower
Yes-Diesel generator enabled
No-Diesel generator disabled
Fix SOC mode
Lower limit of the configured SOC range
Upper limit of the configured SOC range
Optional 6, 7 mode
Battery charging power
Diesel generator output rated power

When the diesel generator is enabled, it will supply the load at the first.

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1. When the SOC drops below the lower limit of the configured SOC range, the diesel
generator will start; when it raises beyond the upper limit, the diesel generator will then be
turned off.
2. Charging power mode
If the mode 6 - battery charging power mode is selected, the diesel generator will charge
the batteries with the configured power;
3. Diesel generator rated power mode
If the mode 7 – diesel generator output rated power mode is selected, the diesel generator
will charge to the batteries with the rest power under the condition of satisfying load.
The rest power is Prest = Poutput – Pload.
You can also set the control mode on the website, see 5.5.3

Online Monitoring

Register
You have to create a new account on our webserver for the normal monitoring. In addition,
a part of our warranty is based on this connection to our webserver. The data before the
registration would not be retained on the webserver.
So please use the following steps:

Open the portal: www.alphaess.com.

Please fill in “Username”, “Password” and click “Login”, if you have registered.
If not, please register following these steps

Figure 5-5 Monitoring Login Interface

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In this form, all blanks marked with an

asterisk must be filled out, you can

choose End user or installer.

More detailed information can be obtained

in Online Monitoring Webserver

installation Manual.

Figure 5-6 Register Interface

Registering License

Click Install new system to

register the license No.

Figure 5-7 Menu for Installer

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Figure 5-8 System Registering Interface

Input S/N, Check Code, License No., Date, Name, and Contact No. to complete the
registering process.

Generator Control Setting On Server

You can set according to the actual conditions by customers.

There are two options, SOC control or time control.
At the first, please click Generator to enable it.
 Choose SOC control to set SOC range. If the SOC drops below the lower limit of the
configured SOC range, the diesel generator will start; when it raises beyond the upper
limit, the diesel generator will then be turned off.
 If you set the battery charge power, it will charge the batteries with the configured
battery charge power.
 If you set the Generator output power. it will charge the batteries with the rest power
under the condition of satisfying load. The rest power is P=Poutput – Pload.
 Choose time control, the diesel generator will start during the configured working
time.

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PV Junction Box Data Check

Click on stored energy system list -> input SN -> click operating data -> Check by choosing
the required operating data type.

Emergency Stop
When the energy storage system is abnormal, you can press the emergency stop button
"EPO" on the cabinet door, turn off the diesel engine switch, load switch, PV switch and
battery switch.
In order to prevent personal injury, if you want to repair or open the machine after power-
off, please measure the voltage at the input port with the multimeter at the first. Before the
relevant operation, please confirm that there is no grid electric supply!

The upper cover plate cannot be opened until the DC-link capacitance inside the module
discharges completely about 15 minutes later (see warning label on the surface of module
for details).

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6. Routine Maintenance

Maintenance Plan
 check if wire connection loose
 check if cables aged/damaged
 check if cable insulating ribbon drop
 check if cable terminal screw loose, any overheat sign
 check if ground connection is well

Routine Inspection
Minimum PPE
Training/qualificat (Personal
Item Details Frequency Notes
ion requirements protection
equipment)
Check the
Once Work cloth;
Foundation foundation for tilt No tilt or sink
6 months Protective shoes
or sink
Check the
container No rusting or
Container Once Work cloth;
surface for damage on
surface 6 months Protective shoes
rusting or container surface
damage
Check the The doors should
Container Once Work cloth;
container door be opened and
door 6 months Protective shoes
for damage closed normally
Check the
indicator lights
Indicate Once No flashing lights or Work cloth;
outside the
light 6 months ringing bells outside Protective shoes
container for
damage
Check the
earthing bar of Once Work cloth;
Footing No rusting
the container for 6 months Protective shoes
rusting.
Check the The passage
Inside container should be clean
Once Work cloth;
environmen passage; the and tidy and the
6 month Protective shoes
t passage should ground mat should
be tidy not be damaged
Air Check the air Once The air conditioner Work cloth;
conditioner conditioner 6 months should work Protective shoes

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normally and the

inside temperature
should be between
5 to 40 degree
Check the
Lighting lighting supply;
Once All the lights should Work cloth;
power all the lights
6 months work normally Protective shoes
supply should work
normally
Check the
All emergency
emergency
lights should work
Emergency lighting Once Work cloth;
normally after
lighting equipments; all 6 months Protective shoes
power supply is
the lights should
down
work normally
The equipments
Check the should be on
firefighting without any alarms
equipments; the and the pressure of
Firefighting Once Work cloth;
equipments gas tank should be
equipment 6 months Protective shoes
should be on normal (by
without any checking the
alarms indicator needle,
green means OK)
Check the
Bracket Once 6 No rusting or Work cloth;
brackets for rust
surface month damage Protective shoes
or damage
Check the fixing All bolts are tight Work cloth;
of brackets Protective shoes;
Bracket between Once 6 Wrenches
fixing brackets and months
ground of the
container
Check the No rusting or Work cloth;
Module Once 6
modules for rust damage Protective shoes
surface months
or damage
Check the fixing All bolts on module Work cloth;
of modules are tight Protective shoes;
Module Once 6
between Wrenches;
fixing months
modules and Insulated gloves
brackets
Module Check the Once 6 All bolts of copper Work cloth;
connection module serial months bars and cables are Protective shoes;

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and parallel tight Wrenches;

connection Insulated gloves
The bolts on Work cloth;
module surface Protective shoes;
should be Wrenches;
Check the
electrically Insulated gloves
Module module for Once 6
connected to the
grounding correct months
bracket surface and
grounding
grounding
bars(tested by a
multimeter)
Check the All red and black Work cloth;
terminals of covers should be Protective shoes;
Module Once 6
modules for complete Wrenches;
terminal months
insulation Insulated gloves
protection
Check the on-off The circuit breaker Work cloth;
function and function should be Protective shoes;
Circuit Once 6
tripping function OK; When breaker Wrenches;
breaker months
of circuit is off , no voltage is Insulated gloves
breakers allowed
All data on PCS Work cloth;
PCS Check the PCS Once 6 including voltage, Protective shoes;
display screen months power and current
is OK
Check inside No alarming events Work cloth;
temperature of on PCS Protective shoes;
PCS inside PCS, including
Once 6
temperatur module
months
e temperature and
cabinet
temperature
Check the No overheating Work cloth;
terminals of Once 6 marks or burning Protective shoes;
PCS cable
PCS cables for months marks
overheat marks
Check the PCS No rusting or Work cloth;
PCS Once 6
for correct damage Protective shoes;
grounding months
grounding
All fixing bolts Work cloth;
Check the
Once 6 should be tight Protective shoes;
PCS fixing fixings of PCS
months Wrenches;
with container
Insulated gloves

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Routine Maintenance
Maintenance Training/qualification
Item Equipment
cycle requirements
Work clothes;
Painting on Protective
Container
rusting shoes; 6 months Corresponding color number
surface
position Anticorrosive
paint
Work clothes;
Container
Protective
inside 6 month Clean dusts and rubbish
shoes;
cleaning
Broom; Cloth
Visually check if the wiring is
loose;
Turn the fan to check if it is
smooth and if there is
Work clothes;
Air any abnormal noise;
Protective 6 months
conditioner Visually check if the drainage
shoes;
mouth is blocked
Check the cleanness of the
condenser and clean it
with compressed air
Work clothes;
Protective
Painting on
shoes; 6 months Corresponding color number
brackets
Anticorrosive
paint
Work clothes;
Fixing on Protective Fixing between brackets and
6 months
brackets shoes; container ground
Wrench
Battery Work clothes;
system Grounding Protective
3 months Use multimeter to test grounding.
of brackets shoes;
Screwdriver
Work clothes;
Battery
Protective The brackets and modules should
system 6 months
shoes; be clean
cleaning
Cloth
Work clothes;
Painting on
Protective 6 months Corresponding color number
modules
shoes;

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Insulating
paint
Work clothes;
Fixing on Protective Fixing between modules and
3 months
modules shoes; brackets
Wrench
Work clothes;
Connecting
Protective
cooper bar 3 months Serial copper bars
shoes;
fixing
Wrench
Work clothes;
Insulation Protective
3 months Protecting cover on module poles
protection shoes;

Work clothes;
Module
Protective
tamper 3 months Tamper proof labels
shoes;
proof labels

Work clothes;
Module Protective
3 months Use multimeter to test grounding.
grounding shoes;
Wrench
Battery Work clothes;
Whole discharge-charge-
capacity Protective 6 months
discharge cycle
calibration shoes;
Work clothes;
Battery data Analyze BMS data recorded (by
Protective 6 months
analyze Alpha staff)
shoes;
Junction Work clothes;
Junction box cable Protective
6 months All bolts are tight
box terminal shoes;
fixing Wrench
Check whether the converter is
damaged or deformed or not.
Listen whether abnormal sound is
Operating available during the operation of
Work clothes;
status and converter.
Protective
PCS environmen 6 months Check all varieties during the
shoes;
t of the operation of converter.
system Check whether the major parts are
Ok or not.
Check the heating of converter`s
case and use thermal imager to

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monitor the heating situation of the

system.
View whether the air inlet/outlet is
normal or not.
Check the humidity and dust
around the converter and ensure
the filters in air inlet are OK.
Attention! Check the ventilation in
the air inlet hole. If the module
cannot be effectively cooled down,
it may be damaged due to
overheating.
Clean circuit board and
components.
Work clothes;
Check the temperature and dust of
System Protective 6 months or
the radiator. If necessary, use the
clean shoes; 12 months
compressed air from the fan to
clean the module.
Change the air strainer.
Check whether the power cable is
losse and fasten it with the torque.
Check whether there are damages
The Work clothes; on power cable and control cable,
connection Protective especially the cable skin contacts
6 months
of power shoes; with the metal surface.
circuit Check whether the insulated
ribbon is stripped from the electric
cable’s wiring terminal.

Check whether the screw in

control terminal is loose. If yes,
Connection use the screw driver to fasten.
Work clothes;
of terminal Check whether the main-circuit’s
Protective
and winding 6 months terminal is loose or overheating on
shoes;
displaceme bolt.
nt Visually check the connection of
converter and the winding
displacement.
Maintenanc Check whether some cracks
Work clothes;
e and appear on the fan’s blade.
Protective
alteration of 12 months Listen whether there are some
shoes;
cooling fan abnormal vibration sounds during
the operation of fan.

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Please change the fan

immediately if some faults
occurred on the fan.
Conduct routine inspection on the
corrosion of metal components.
(once half a year)
Work clothes;
Breaker Yearly inspection on the contactor
Protective 6 months or 12
maintenanc (auxiliary switch or micro-switch)
shoes; months
e and ensure it good mechanical
running.
Check the operation parameters
(especially voltage and insulation).
Check the emergency stop switch
and LCD
Work clothes; Simulate power off and check
Safety Protective 6 months or 12 whether communication signals
function shoes; months are available during power off.
Check the warning label. If
necessary, please change it in
time.

Notes
After all of the equipments are out of operation, the following notes should be paid attention
to while maintaining:
Related safety standards and specifications should be followed in operation and
maintenance.
Disconnect all the electrical connections so that the equipment would not be powered on.
Wait at least 15 minutes after disconnection in case that the residual voltage of capacitors
down to safe voltage. Use a multimeter to ensure the equipment is completely uncharged.
The amount of maintenance staff should be not less than two while maintaining.
The equipment should be repaired by professional staff and it is strictly forbidden for
maintenance staff to open equipments on their own.
Appropriate protective measures should be taken while maintaining, such as insulated
gloves, shoes, and anti-noise ear plugs.
Usually the location of the storage system is far away from urban areas. Related
emergency rescue measures should be prepared in order to be implemented when
necessary.
Life is priceless. Make sure no one would get hurt first.
When a fire happened in the container, just make sure the fire system is on (should be on),
then leave the container as soon as possible. After running out, make sure all doors are
closed. The fire extinguishing system would automatically work. Do not try to put the fire
out manually.
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When a fire happened in the PCS container, just close the door and press the emergency
button manually.
When the fire is outside the containers, please make sure all doors are closed in case of
smoke. Smoke may cause warnings of sensor, but it will not trigger fire system. If the fire
spreads into the container, the temperature sensor would work and the whole system
would start.
For single cell, it is better to be sank into water to block burning.
The batteries need to be charged to 30%~50%SOC rate when the whole system is static
(that is, the batteries has not been charged for two weeks or longer) for a long time, in case
of over discharge.
Please contact us in time if there are any conditions that could not be explained in the
manual.

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7. Troubleshooting

Battery and BMS troubleshooting

Error Type
Alarm Displayed in EMS Processing method
Cell temperature different fault Cell-Temp-Diff Contact with Alpha service
Balancer fault Balancer Err Contact with Alpha service
Module charge over current
Chrg-Ov-Curr Contact with Alpha service
fault
Module discharge over current
Disch-Ov-Curr Contact with Alpha service
fault
Pole over temperature fault Pole-Ov-Temp Contact with Alpha service
Cell over volt fault Cell-Ov-Volt Contact with Alpha service
cell volt different fault Cell-Volt-Diff Contact with Alpha service
cell discharge under
Disch-Low-Temp Contact with Alpha service
temperature fault
Cell under volt fault Cell-Low-Volt Contact with Alpha service
Cut off BMS at the first, then operate
Insulation resistan fault IR_Fail in power sequence when power the
system
Check communication connection
between batteries (LMU and LMU),
LMU Communication fault Commu_fail_LMU
battery and HV900112 (LMU and
BMU)
Cell over temperature fault Cell-Ov-Temp Contact with Alpha service
Check communication cable between
HV90012s (BMU and BMU), also
BMU Communication fault Commu_fail_BMU
HV900112 and TOP BMU Box (BMU
and TOP BMU)
Cell charge under temperature
Chrg-Low-Temp Contact with Alpha service
fault
Wire beam fault Wire-Harness-Err Contact with Alpha service
Relay fault relay Err Cut off BMS
Temperature sensor fault Temp-Sen-Err Contact with Alpha service

Emergency Handling Plan

In order to prevent accidents such as electric shock, fire or explosion, the emergency
switch should be pressed immediately to stop the equipments when abnormal sound, smell
or sparks is found.
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Disconnect the AC breaker.

Check the control power supply. If it is OK, return the power supply to find out the reason.
Please record every detail related to the fault, so we can analyze and solve the fault better.
Any operation of equipments is strictly forbidden, please contact us as soon as possible.
When the batteries are on fire, please make sure the fire extinguishing system is on. If that,
do not try to put the fire out manually. That is dangerous because the special chemical
property of lithium-ion batteries (though LiFePO4 is safer, there is possibility of danger).
Water or other liquid is not recommended. Just keep all doors closed and the fire system
will automatically work. Under this premise, the emergency button should be pressed down
in order that the DC breaker will trip.
As battery cell contains little Oxygen inside and all cells have got explosion-proof valve,
explosion hardly happens.

EMS Troubleshooting
Alarm
Inverter Disconnect
Grid Meter Disconnect
Battery Disconnect
PV Meter Disconnect
SD not inserted or SD writing
error
Network card error
Displayed in EMS Processing method
Check communication connection
INV Lost
between EMS and inverter
Check communication connection
Meter Lost
between EMS and grid meter
Check communication connection
BMS Lost
between EMS and battery system
Check communication connection
PV-Meter Lost
between EMS and grid meter
SD lost Replug SD card
NetCard Err Contact with Alpha

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