ST523

Installation & Operating Instructions

Technical manual

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English

REL. DATE NOTE TITLE

10 16/02/2018 I&O Manual - ST523_rev 10 ENG

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NOTICE

This document does not create any additional obligation for FZSONICK and does not
constitute additional warranties and representations. Anyone involved in handling, installing or
using the ST523 battery should read and understand this manual. In case of any doubts,
contact FZSONICK Customer Service.

MANUFACTURER DATA

FZSoNick S.A.
Via Laveggio, 15 Stabio 6855 (Switzerland)
Tel: +41 (0)91 6415511 - Fax: +41 (0)91 6415596 - Email: info@FZSoNick.com

www.FZSoNick.com

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EXPLANATORY SYMBOLS

Symbols used in this manual.

The text displayed under this symbol provides explanatory information or specific instructions.

GENERAL HAZARD
WARNING!!

The text appearing after this symbol warns that failure to

follow the instructions provided can cause
damages to the system equipment and physical injuries or
even death.

LIVE EQUIPMENT
WARNING!!

The text displayed under this symbol indicates that

the operation being described represents a risk of
electric shocks and therefore of electrocution.

Safety instructions have been classified according to the seriousness of the risk, as follows:

DANGER!
Indicates the existence of a hazard that could result in
death or serious physical injury if the safety
instructions are not observed.

WARNING!
Indicates the existence of a hazard that could result in
physical injury if the safety instructions are not
observed.

CAUTION!
Indicates the existence of a hazard that could result in
property damage if the safety instructions are not
observed

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ACRONYM LIST

ESS Energy Storage System

BESS Battery Energy Storage System

BMS Battery Management System

SDS Safety Data Sheet

PCS Power Conversion System

HMI Human Machine Interface

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English

Index
1. AVANT-PROPOS ..................................................................................................................... 11

2. PRELIMINARY INFORMATION ............................................................................................... 12

2.1 System identification data ................................................................................................ 12

2.1.1 Top label ............................................................................................................................... 12

2.1.2 Side BMS label ..................................................................................................................... 13

2.2 General Data ...................................................................................................................... 14

2.3 Battery Measurement ........................................................................................................ 15

2.4 Battery components identification ................................................................................... 16

2.5 Disclaimer .......................................................................................................................... 16

2.6 Warranty ............................................................................................................................. 17

2.7 Duties and responsibilities ............................................................................................... 17

3. SAFETY.................................................................................................................................... 19

3.1 Purpose .............................................................................................................................. 19

3.2 Introduction ....................................................................................................................... 19

3.3 Safety Signs ....................................................................................................................... 20

3.4 Safety Precautions ............................................................................................................ 21

3.5 General Safety ................................................................................................................... 21

3.5.1 Safeguards ............................................................................................................................ 22

3.6 Battery ST523 specific safety ........................................................................................... 24

3.6.1 Residual Risks ...................................................................................................................... 24

3.6.2 Personal Protective Equipment ........................................................................................ 26

3.6.3 Recommended ambient conditions ................................................................................ 26

3.6.4 Safety Data Sheet ................................................................................................................ 27

4. GENERAL INFORMATION ...................................................................................................... 28

4.1 Handling ............................................................................................................................. 28

4.2 Lifting device ..................................................................................................................... 29

4.3 Storage ............................................................................................................................... 30

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4.4 Packaging .......................................................................................................................... 30

4.5 Shipment ............................................................................................................................ 31

4.6 Unpacking And Inspections.............................................................................................. 33

4.7 Battery return and disposal .............................................................................................. 33

5. TECHNICAL INFORMATION ................................................................................................... 34

5.1 Service Life Definition ....................................................................................................... 34

5.2 Extended Outages ............................................................................................................. 34

5.3 Battery Protection ............................................................................................................. 34

5.3.1 Electronic Protection .......................................................................................................... 34

5.3.2 Thermal Protection ............................................................................................................. 35

5.3.3 Mechanical Protection ........................................................................................................ 35

5.3.4 Reliability .............................................................................................................................. 35

5.4 Maintenance....................................................................................................................... 35

5.5 Battery Specification ......................................................................................................... 36

5.6 BMS (Battery Management System)................................................................................. 37

5.7 BMS functions ................................................................................................................... 38

6. BATTERY INSTALLATION ...................................................................................................... 39

6.1 Tools and Hardware Required .......................................................................................... 39

6.2 Battery Installation ............................................................................................................ 39

6.3 Mounting the ST523 Battery ............................................................................................. 40

6.4 Cable Connection .............................................................................................................. 40

6.5 Recommended Spare Parts List ....................................................................................... 43

7. BATTERY IN OPERATION ...................................................................................................... 44

7.1 Battery Operating Procedures .......................................................................................... 44

7.2 Parallel Connection ........................................................................................................... 44

7.3 PCS expected working modes.......................................................................................... 46

7.4 Temperature management ................................................................................................ 46

7.5 Battery Warm-Up ............................................................................................................... 47

7.6 Battery Charging ............................................................................................................... 47

7.7 Floating .............................................................................................................................. 48

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7.8 Discharging........................................................................................................................ 48

7.9 Nominal Battery Capacity ................................................................................................. 49

7.10 Battery Cool Down .......................................................................................................... 49

APPENDIX 1 ................................................................................................................................ 51

I - Warm up process ................................................................................................................ 51

II - Battery charge .................................................................................................................... 52

III - Battery Floating ................................................................................................................. 55

IV - Battery Discharge ............................................................................................................. 56

V - Battery cool down .............................................................................................................. 60

APPENDIX 2 ................................................................................................................................ 61

APPENDIX 3 ................................................................................................................................ 61

APPENDIX 4 ................................................................................................................................ 61

APPENDIX 5 ................................................................................................................................ 61

APPENDIX 6 ................................................................................................................................ 61

APPENDIX 7 ................................................................................................................................ 61

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1. AVANT-PROPOS

Battery ST523 has been designed to be integrated in a Container solution for

outdoor applications with up to 64 ST523 SoNick batteries (Spring). This
solution includes an electrical panel with disconnect switches, AC panel, air
conditioning, PCS. Safety Regulations and other prescriptions not otherwise
specified that are valid for Spring are valid also for ST523 Battery.

The use of ST523 is intended only if integrated in a system and only for a
technical/laboratory utilization. If battery has to be used without integration
in a system or not for technical/laboratory utilization please contact FZSoNick
to require information about safe and correct use.

In case of lost or damage of this operating manual, contact the Manufacturer to request
another copy.
If any of the instructions provided are unclear, contact the Manufacturer to have your queries
answered.
Accidents can be avoided by following the technical instructions provided in this manual; in
any case, national safety regulations must always be complied with.

Manual Enclosures:
 Declaration of Conformity
 SDS
 APPENDIX 1: Battery performance
 APPENDIX 2: Hardware Interface Description
 APPENDIX 3: Installation an User Manual ST523 MONITOR
 APPENDIX 4: Web Interface User Manual
 APPENDIX 5: BATTERY ENERGY STORAGE SYSTEM TO PLC INTERFACING
 APPENDIX 6: BATTERY ENERGY STORAGE SYSTEM TO PCS INTERFACING
 APPENDIX 7: BATTERY ENERGY STORAGE SYSTEM TO PPC INTERFACING

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2. PRELIMINARY INFORMATION

2.1 System identification data

An identification and CE marking plate is affixed to every battery.

Figure 1 - ST523 Labels

2.1.1 Top label

The label n°1 in figure 1 contains battery technical information, the production date and the
battery serial number. See Table A for a typical description.

Figure 2 - Label 1

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Type ST523

Code Complete 803005719 RS Complete 803005727 CB

Voltage 620 Vdc

Capacity 38 Ah

IP Designed for IP55

Serial N° XXXXXXXXXXXXXXXXXXXXXXXXX

Production Date XX/XX/XXXX

Mains /

Cooling NO

Weight 256 kg

Table A

2.1.2 Side BMS label

Label n°2 contains the BMS serial number

Figure 3 - Label 2

In case of labels absence and wear, or in case of labels discordance with the instructions in this
manual, the user is required to contact FZSoNick that will provide the substitutive labels.
In case of non-compliance with this requirement, FZSoNick will not be responsible for this
inobservance and their consequences.

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2.2 General Data

Characteristics Values

Nominal Voltage 620 Vdc

Operating Voltage Range 450 to 750 Vdc
Nominal Capacity (Ah) 38 Ah (100% DOD)
Nominal Energy Capacity 22.5 kWh (100% DOD at C/10)
Max DC Link Voltage during 700 VDC (DC Bus)
Controlled Charge
Max Charge Current 15 A (direct charge)
Min Discharge Voltage 450 VDC (DC Bus)
Max Charge Operative Voltage 641 V
Max Discharge Current (non- 50 A
continuous)
Cooling Not Needed
Warm-up time from cold state to Max 15 hours
operational
Controlled charge operation Current control by internal DC/DC converter
Communications Individual battery: CAN-BUS
Multi-battery systems: Modbus TCP/IP over
Ethernet (managed by a gateway)
Round Trip Efficiency 90% round trip efficiency (at 6.25 kW constant
power Discharge 80% DOD &charging at
maximum power 6.25 kW)
Length 965.2 mm
Width 556.1 mm
Height 388.6 mm
Weight 256 kg
Continuous Operating
-20 to +60°C (-4 to 140°F)
Ambient Temperature
Table B

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2.3 Battery Measurement

Battery ST523
Code: 803005714

Battery ST523 for BESS

Code: 803005721

Figure 4

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2.4 Battery components identification

1-Cell pack

2-BMS (Battery Management System)

3-Harting Panel Plug

4-Harting Plug

Figure 5

2.5 Disclaimer

The manufacturer shall not be responsible for any damage caused by:

 untrained and/or unauthorized staff using the system;

 failure to follow instructions in part or in full;

 lack of maintenance;

 unauthorized modifications or repairs;

 prohibited applications (improper use);

 using non-genuine spare parts;

 exceptional environmental events.

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2.6 Warranty

The system is delivered by the supplier with valid warranty conditions at the time of purchase.
Contact your supplier for more details.

The equipment must not be tampered with by the user.

Any attempt to dismantle or to modify the system by the user will invalidate the warranty.

In any case, the manufacturer reserves the right to make changes to the system and its
performance criteria without informing the user and shall not be responsible for any errors
caused by an incorrect installation or improper use of the system.

For any unmentioned part, please refer to the contract.

2.7 Duties and responsibilities

 The system must be controlled and monitored by a person in order to avoid

conditions which could jeopardize his safety and the safety of other people.

 Before starting the system, make sure that any personal safety hazard is
appropriately removed.

 Warn all people in charge of any change made to the system or malfunctions that
could jeopardize safety.

 When working, strictly follow the instructions provided on signs and/or labels
affixed to the system.

 Check that the source of power is of the type required and that is in optimal
operating conditions (cables, pressure pipes, etc.).

 Before working on the system, make sure that the sources of power are physically
disconnected.

 The system cannot be used for applications different from those it was designed
for.

Do not use parts of the system detached from the assembly or the
configuration required by the manufacturer.

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 It is advisable to install a thermal cut-out upstream of the electrical power supply

in order to protect the wires from short-circuits or overloads.

 Provide suitable fire protection equipment near the system, i.e. one (1) off 9kg dry
chemical powder type fire extinguishers; water must never be used to extinguish
any starting fires(refer to SDS).

 Install in a location that could be easily ventilated in case of misuse.

 Check the wear of electrical cables; replace them if damaged; use cables of a
suitable section and compliant to specifications.

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3. SAFETY

3.1 Purpose

This manual provides information required to install and operate the FZSONICK (FZSoNick)
ST523 battery.
Anyone involved in handling, installing or using the ST523 battery must read and understand
this manual.

Using the system for applications different from those described in this
manual and by inadequately trained staff is prohibited.

3.2 Introduction

The ST523 is a high specific energy, high temperature module based on the electro-chemistry
of a Sodium Nickel Chloride cell. It’s a 620 Volt – 38Ah complete battery system designed
for stationary applications.
Cells are assembled in series connected strings to achieve the desired battery terminal voltage.
This battery, assembled as a single string of Sodium-Nickel cells in a 240 cells series
configuration, is provided with internal electric heaters to achieve and maintain the internal
working temperature of 265°C. The thermal insulation of the battery is such that, with an
internal temperature of 265°C, the surface temperature of the enclosure is just a few degrees
above the environment.
Battery is provided with an electronic controller (BMS, Battery Management System)(Fig.11)
which manages all the battery functions and ensures a reliable and safe operation.

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3.3 Safety Signs

The cover label is fitted with danger notice signs highlighting the residual risks. The battery is
also fitted with mandatory and warning signs.

Figure 6

Hazardous voltage. Risk of electric shock. Authorized personnel only.

The battery surface may be hot.

Carefully read operating instruction and keep them handy nearby the battery.
Work on batteries only after have been instructed by qualified staff.

Wear eyes protection and protective clothing when working with batteries.
Observe accident prevention regulations.

Grounding cable must be connected.

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If the Harting Connector is disconnected, the Battery will be instantaneously

completely stopped.

3.4 Safety Precautions

To prevent damages to the batteries and physical injuries, following safety instructions need to
be followed all the times:
 Do not install the battery if you notice physical damage.
 When the BMS is removed, Do not place the battery on its power terminals, with the
front facing down or upside down.
 Do not pack the battery when internal temperature is above 80° C.
 Do not expose the battery to temperatures above 60°Cm(140°F) or below -20°C(40°F).
 Do not allow metal objects to rest on the battery or to fall across the power terminals.
 Remove rings or metal wristbands when working with the battery.

Unlike traditional batteries, Sodium Nickel battery can be charged or discharged only when the
internal temperature reaches the operating value (265°C). Whenever the internal temperature is
below, the battery acts as a passive device.
Before using, be sure to fully understand the battery functionality described in this manual.

3.5 General Safety

This section provides important information about safe handling of the battery and on limits
that must be observed during module operation. Operations in violation of these guidelines
may present a safety hazard to the operator, and may void the module’s warranty. The balance
of this document discusses the operation and maintenance of the battery as an integrated part
of a larger system.

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3.5.1 Safeguards

All safety instructions must be read carefully and must be fully understood before attempting
to use a Sodium Nickel Chloride battery. Contact FZSONICK (FZSoNick) for any questions.

3.5.1.1 Danger

An energy storage module can store a large amount of

electrochemical energy, even if in shipping conditions before being put into service.
Releasing that energy in an uncontrolled manner can result in physical injury and
equipment damage. Observe all safety precautions when handling a Sodium Nickel
Chloride battery.

Never disassemble the ST523 battery. This could result in

exposure to high voltage, high temperature, or leakage of molten salts which may
be corrosive. There are no user serviceable parts inside the ST523 battery. The
battery enclosure is designed to properly contain its chemical components and to
provide electrical and thermal insulation. Disassembly of the module may expose
the operator to hazardous conditions.

Never short-circuit the battery by either accidentally or

intentionally bringing any terminal connector in contact with another conductor.
This could cause personal injury or a fire, and will damage the battery.

Never drive nails, drill holes or otherwise tamper with the

external enclosure. Never hit the external enclosure of the battery with a hammer
or other tools.

ST523 battery must be only operated in conjunction with

its dedicated BMS module controller. Removal of the BMS could result in exposure
to dangerous voltages, surface temperatures, and in module damage.

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3.5.1.2 Warning

If excessive heat, discoloration of the battery surface,

deformation, or anything unusual is observed, the ST523 battery must be
immediately removed from service. Follow system integrator instructions to isolate it
from the Energy Storage System and contact FZSONICK.

If the battery is found emitting sort of a “slizzing” noise,

follow system integrator instructions to isolate it from the Energy Storage System
and contact FZSONICK. This sound is an indication of excessive internal heating.

A battery with an internal ISO error must be immediately

disconnected from service and let cool down “as is”.

If the BMS is removed, protect the whole flange or at least

the recessed power contacts with insulating tape in order to prevent accidental
contact with the terminals or short-circuit. (Fig.7).

Recessed
power contacts

Recessed
power contacts

Figure 7 - ST523 Flange

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If any part of the body accidentally comes in contact with

materials leaked from a damaged ST523 battery, immediately wash with plenty of
water. Remove any spill from clothes by washing them immediately with water.

3.5.1.3 Caution

Never throw the ST523 battery into fire.

Never put in contact ST523 terminals with other

metal/conductive object. Before shipment, pack the module for transport per
section 4.4.

A ST523 battery with an open or a heavily damaged case

must be stored in open air and protected against water. A module with a heavily
damaged external case must be wrapped with polyethylene sheets before packing
for shipment to avoid releasing hazardous materials and smell.

3.6 Battery ST523 specific safety

3.6.1 Residual Risks

The residual risks that could not be removed during the design stage and that are still present
on the system are listed below.
Instructions or regulations are provided for each residual risk, which the user must follow in
order
to avoid putting the operator and the maintenance staff at risk.

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THERMAL HAZARDS

All battery surfaces can be hot:

touch with care.

ELECTRICAL HAZARDS

Please insure of periodic inspection

of the electrical grounding (1).

Please Insure of periodic inspection

of the integrity of cables and
Harting connector (2).

Never short circuit the battery!

MECHANICAL HAZARDS

Do not attempt to move an ST523

battery without using the proper
lifting devices and observing the
specified procedure.

If you notice hot fumes emission from the battery please:

 do not inhale smoke;
 ventilate the room;
 stop the battery.

In the case of fire the allowed fire extinguishing method is dry chemical
powder extinguisher (please refer to battery SDS).

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3.6.2 Personal Protective Equipment

The operator is responsible for keeping his Personal Protective Equipment (PPE) available and
in good working conditions while operating or maintaining the ST523 batteries.

Safety glasses must be worn

Anyone who uses the system must wear safety glasses.

Safety gloves must be worn

Anyone who intends to install or move the battery must wear cut resistant
safety gloves.

Class III (EN 374-3) PVC coated gloves

Safety shoes must be worn

Anyone who intends to install or move the battery must wear safety shoes.

Safety shoes without metal tip.

A gas mask must be worn in case of fire

Full masks EN137 standard compliant, type 2 classification with E yellow filters
for acid gases and steams.

3.6.3 Recommended ambient conditions

Minimum temperature of -20°C and maximum temperature of +60°C.

Maximum humidity: 95% non-condensing.
Install in a location that could be easily ventilated.

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Always use the batteries in a restricted access (technical/laboratory) area, that responds to the
site safety and security applicable standards (ie. UNI 9795, ect.). Only authorized staff are
allowed to enter in the battery area.

Provide in the testing area 1 powder fire extinguisher (D class, 9kg).

3.6.4 Safety Data Sheet

The ST523 Safety Data Sheet (SDS) is available to be consulted. The SDS contains hazard
identification, first aid, firefighting, handling information, and other critical information for the
operator. Review and understand the contents of the SDS before operating the ST523 battery.

Sodium Nickel Chloride batteries, with a damaged external case or whenever

internal damage is suspected to be damaged, must be removed from service
and must be handled by trained technicians with suitable Personal Protective
Equipment including gloves and respiratory protection.

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4. GENERAL INFORMATION

ATTENTION! The battery system is a power plant.

The use of non-conductive tools or tools rendered non-conductive by means of an insulating

material is highly recommended.
High energy batteries should always be handled carefully to avoid the possibility of creating a
short circuit. In some circumstances, when in operation, the battery surface may be hot.
Due to the potential risk of the voltage of the battery, the personnel operating the battery
system (installation, fault clearance, and all other phases of handling, etc) must be qualified
and well trained.
The shipment, installation, use and maintenance as well as the sell-off of the batteries must be
executed following the instructions contained in the User Manual.
The chassis of the batteries must be electrically connected to the shelf structure where they will
be installed in order to have all the accessible parts at the same potential. All the iron
structures (shelf, electrical cabinet…) must be connected to the ground.
Personnel should inspect the nearby environment where batteries will be handled to identify
and eliminate all potential sources of electrical and physical damage to the batteries. Avoid
conditions that could result in short-circuits, overheating, puncture or crush.

4.1 Handling

Due to the weight of the ST523 (256 kg/564 lbs) and the confined space in an Energy Storage
System, handling of a battery may be difficult. As a result, ST523 must be handled with
maximum care using the lifting, placing, and transport devices supplied by FZSONICK.
Before attempting to move an ST523 battery, ensure that the battery case is not damaged.
Note that sharp objects and sharp edges can damage the battery box surface which can result
in a misalignment of critical parts. A battery with a high heat loss must be removed from
service immediately.
Under no circumstances shall any work be carried out on the battery housing (e.g. bending
protruding edges, removing burrs, drilling, filing, welding, brazing etc.). If a welding operation

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is necessary on the Energy Storage System, first remove the FZSONICK battery from the ESS
and protect the battery from sparks or other damage.
Under no circumstances should any mechanical stress be applied to the BMS or its power
connector.
Battery handling should be performed by the provided lifting (please refer to paragraph 4.2).

4.2 Lifting device

Figure 8 - Lifting device

This specific accessory has been designed for safe battery handling. Lifting device must be
correctly applied to the lifting points provided for this purpose.
Ensure that all the 4 lifting points are correctly located, and then insert the safety pins (Fig. 9)
to avoid the unhooking of the lifting points. Ensure that only vertical forces are applied.

Figure 9 - Safety pins

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4.3 Storage

The battery must be cooled down before its storage. The average cool down time is 4 to 5
days.
The decreasing average temperature is 1.5 °C/h from 260 °C to 60 °C.
The suitable environment for battery storage is in a cool, dry, and well-ventilated place.
Sodium Nickel batteries should be stored in an identified area of the warehouse equipped with
Class ''D'' fire extinguishers. The battery can be stored for any length of time in the cold state
without changing its characteristics or state of charge.
If the battery is stored without BMS, the flange must be protected to avoid any contact with
exposed terminals to protect against moisture and dust. FZSONICK can provide a BMS Flange
Cap to protect the flange.
For extended storage periods ST523 must be stored in a dry environment at ambient
temperature with no possibility of condensation. The storage temperature shall be between –
40°C and +50°C (-40 °F and 122 °F).

The atmosphere must not be aggressive.

The ST523 cells exhibit a high electrical resistance when cold. Even very
small measurement currents can damage the cells. A small current in the
cold state can damage the battery. Do not attempt to make any
measurements or to connect any load to the terminals of the battery
when it is in the cold state.

4.4 Packaging

ST523 battery is shipped cold and completely discharged in a crate to avoid any risk of
uncontrolled movement or drops and surrounded by a protective foam cushion. In case of
battery return, it should be packed in the original crate only after turning it off and letting it
cool down for 4-5 days.
The package should include the relevant safety information for the transport: please contact
FZSONICK for the details.

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Figure 10- ST523 Packaging

4.5 Shipment

The ST523 battery must be transported cold and fully discharged whenever possible.
The battery must be packed in the original wooden shipping container or equivalent, fixed with
straps to avoid any risk of uncontrolled movement or impact.

Do not attempt to pack a hot battery in a shipping container.

A battery with a damaged external case must be wrapped with polyethylene sheets before
packing to avoid the risk of release of hazardous material or smells.
The shipping container must include the required safety information for transport. Contact
FZSONICK for details.

Sodium Nickel Chloride batteries are classified as dangerous goods (hazardous materials) for
transportation purposes. Consequently, anyone who is in charge of shipping this product must
comply with all the rules and regulations, covering the shipping of dangerous goods.

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UN number: 3292 “Batteries or cells containing sodium”

4.3 “Water reactive substances In contact

Class:
with water produces flammable gas”

Packing group: Il Materials of medium danger

433 for air shipment

Packing instructions: P408 for road shipment

P408 for sea shipment

Kemler nr: Not identified

ERG: 4W

Protect from humidity and water

Particular caution:
Handle with care

Table C

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Transport classification conforming to the following specific regulations:

For road or rail transport ADR/RID (SDR)

For air transport IATA

For sea transport IMDG

Table D
Use ADR vehicles only if the gross weight for each transport unit is > 333 kg.
During air transport: use only cargo flight.

In order to comply with current shipment regulations, the batteries are to be in the following
conditions:
 ambient temperature with internal temperature lower than 80°C (Please refer to
Appendix I-V)
 as far as possible discharged;
 labeled and packed conforming to international rules (ADR, IATA, IMDG)

4.6 Unpacking And Inspections

FZSONICK carefully tests and inspects the battery before shipment.

Upon receiving a shipment of batteries, open the wooden crate box and check the battery and
hardware against the packing list.
Report any damage immediately to the shipper if the crate shows signs of damage in transit.
Also notify to FZSONICK customer service.

4.7 Battery return and disposal

A Sodium Nickel Chloride battery must be shipped only when its internal temperature is below
80°C, whenever possible, in a discharged state.
Do not burn or dispose of the battery. End of life or defective batteries are to be returned to
FZSONICK, where recycling and/or disposal of the different parts will be performed.
Notify FZSONICK customer service prior to returning the battery.

Never dispose of old batteries with other ordinary solid wastes. Please
contact FZSONICK for details.

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5. TECHNICAL INFORMATION

The battery’s primary function is to store electrical energy and to supply it to an external
electrical load when needed. The battery management system also provides secondary
functions that are essential to achieve the required service life duration.

5.1 Service Life Definition

The service life of the ST523 battery is the period of useful service under the conditions
defined in the battery specification expressed as the period elapsed between the start of life
and the time where the ampere-hour maximum capacity has fallen to 80% of the rated
capacity. Battery capacity will slowly decrease even after the 80% mark has passed, unlike other
chemistries.

5.2 Extended Outages

Extended outages do not any consequences on the battery health. In case of a prolonged
discharge, the battery disconnects itself from the load when its energy is expended and, if the
main DC supply doesn’t come back, the internal temperature will start to decrease. When cold
the battery is completely inactive and can be stored in such condition for a virtually infinite
period of time which is virtually infinite.
As soon as power is restored, the battery goes automatically in the warm-up state.

5.3 Battery Protection

Each battery has its own built in electrical, thermal, and mechanical protection.

5.3.1 Electronic Protection

Electronic protections are considered as primary safety. During normal operations the battery
are supervised by the BMS, verifying that current and voltage limitations in every conditions of
work are respected.
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5.3.2 Thermal Protection

Thermal protection devices are used to prevent battery overheating situations. The following is
a list of the thermal protections built in each battery:
 A redundant closed-loop temperature system is managed by the BMS in order to keep
cell temperature within the operating limits.
 The BMS will temporarily disconnect the battery path should its internal temperature
exceed 350°C (662°F).

5.3.3 Mechanical Protection

Batteries are encased in a double stainless steel case. The cells are hermetically sealed with
metal cases which fully enclose the active materials. That structure has been designed in order
to prevent leakage of the active materials.

5.3.4 Reliability

A battery failure in a multi-battery installation will not cause the battery backup system to fail
nor will it cause the other batteries to malfunction. The defective battery will disconnect from
other batteries. Available energy in a n-battery system will be just reduced by 1/nth of the
total energy.

5.4 Maintenance

The FZSONICK Sodium Nickel Chloride batteries do not require any maintenance.

Please Insure a periodic inspection of the electrical grounding and of the

integrity of cables and Harting connector.

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5.5 Battery Specification
Characteristics
Nominal Voltage
Operating Voltage Range
Nominal Capacity
Nominal Energy
Max DC Link Voltage during
Controlled Charge
Max Charge Current
Min Discharge Voltage
Max Charge Operative Voltage
Max Discharge Current (non-
continuous)
Cooling
Warm-up time from cold state
to operational
Controlled charge operation
Communications
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Values
620 Vdc
450 to 700 Vdc
38 Ah (100% DOD)
22.5 kWh (100% DOD a c/10)
700 VDC (DC Bus)
15 A (direct charge)
450 VDC (DC Bus)
641 VDC
50 A
Not Needed
Maximum 15 hours
Current control by internal DC/DC
converter
Individual battery: CAN-BUS
Multi-battery systems: Modbus TCP/IP
over Ethernet (managed by a gateway)
Table E
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5.6 BMS (Battery Management System)

Figure 11- Battery Management System

BMS supervises the battery operation, monitors battery parameters and operating temperature.
Main features of BMS are:

 Temperature Management

 Charge Control

 Over/Under Voltage Protection

 Over Current Protection

 Built-in DC/DC step-down converter supplying its internal electronics with 24 Vdc

 24 Vac auxiliary input for pre-operative BMS check, FW updates and Log download

 Advanced self-diagnostic with redundancy

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5.7 BMS functions

Main functions of the integrated Battery Management System (BMS) are:

 Battery Thermal Management: battery needs to reach internal operative temperature

before starting receiving or delivering energy. The thermal management of the BMS
performs the warm-up process automatically as soon as it is powered.

 Battery Charge Process: the BMS is equipped with a built-in charge controller which is
able to regulate the charging parameters (voltage and current) in order to obtain the
best charging performance

 Battery Power/Energy Output Checks: the BMS calculates the battery SOC to provide a
reliable and safe operation and to avoid overcharge or over discharge.

 Battery Operating Conditions Checks: the BMS continuously measures all the battery
parameters such as voltages, currents, temperatures, insulation levels providing a
continuous monitoring of the operating conditions.

 Redundant Control: the controller is equipped with a safety redundant microprocessor

for safe operations.

 Battery communication: BMS manages CAN Open communication protocol.

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6. BATTERY INSTALLATION

6.1 Tools and Hardware Required

 Combination wrench set, screwdrivers

 Multi-meter

6.2 Battery Installation

The ST523 battery when active contains some materials in a liquid form.
In any case, never lean the battery against its connector or upside down or with the front
facing down.
Provide adequate shelf loading capacity (please refer to ST523 datasheet for the weight and
the size of battery), ensure that there is sufficient aisle space.
The battery must be properly locked to the shelf, ensuring complete mechanical stability.

Figure 12

The battery fixing should be designed to not be damaged in case of over-temperature. Ensure
that no combustible and flammable materials of any kind are located in the surroundings of
the battery.
To avoid possible deformation on the battery case, due to localized pressure, the
recommendation is to install the battery on a flat surface protected with a protective cushion,
with an angle, running across the battery edges, to stop any slide on the horizontal directions.

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As minimum requirement, the battery must be mounted on angle iron brackets at least 50mm
wide, running across the battery edges.

The mounting brackets should have a cushion for the protection of the battery case.
The protective cushion must be of a heat resistant type, non-combustible, for example
fiberglass mat cushion.

Never drill, weld or modify battery surface to lock it to structure.

6.3 Mounting the ST523 Battery

Refer to paragraph 4.3 for proper lifting operations. Once the battery is out of its wooden
shipping box it shall to be permanently mounted as described below. The battery mount shall
be designed to be resistant to over temperature event. Ensure that no combustible materials of
any kind are located in the surrounding of the battery.
The maximum inclination allowed while handling the battery is 30 degrees.
The ST523 must be mounted on a flat horizontal surface. In one possible configuration, the
battery may be mounted on a base made of 50 mm wide(2x2 inch) angle iron brackets,
running across the battery edges, with additional load-bearing material to reach a horizontal
surface coverage of a least 30% of the battery footprint.

6.4 Cable Connection

All electrical connections to the battery take place via a HARTING connector (Figure 13-A and
13-B).

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Figure 13-A

Figure 13-B

The following table shows the Harting connector pin-out.

Connector
Connector Description Notes
pins
J1-1 24V Safety External Enable (12-36Vdc
BT_en +
(recessed) 10 mA)
J1-5 24V Safety External Enable (12-36Vdc
BT_en -
(recessed) 10 mA)
24Vac 50/60 Hz 22VA External Aux
J1 J1-2 24 Vac IN
Power
24Vac 50/60 Hz 22VA External Aux
J1-3 24 Vac IN
Power
NO relay contact 250Vac 4A
J1-7 RLY 1 C
(aux. fan)

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NO relay contact 250Vac 4A

J1-8 RLY 1 NO
(aux. fan)
NC relay contact 250Vac 4A
J1-4 RLY 2 C
(external contactor disconnect)
NC relay contact 250Vac 4A
J1-6 RLY2 NC
(external contactor disconnect)
J2-7 CAN-H CanBus High
J2-2 CAN-L CanBus Low
J2-3 CAN GND CanBus Ground

J2-5 CAN shield CanBus Shield

J2-9 T+ RS485 RS485 High

J2 DB9
J2-4 T- RS485 RS485 Low

J2-8 RS485 GND RS485 Ground

J2-1 SafeRLY-B1 Safety Relay external bridge

J2-6 SafeRLY-B2 Safety Relay external bridge

J3-1 P+ DC Link Positive

J3
J3-2 P- DC Link Negative
Gnd Ground Connection
Table F

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6.5 Recommended Spare Parts List

SPARE PARTS LIST FOR ST523

Article description Article code Quantity

Gateway
803000359
Gateway MOXA UC8418-LX (-10C° / +60C°)

803000360
Gateway MOXA UC8418-T-LX (-40C° / +75C°)

803000376
USB memory stick for Moxa Gateway

Harting connector
802105859
HARTING female cover Plug

LIFTING DEVICE:
LIFTING DEVICE without lifting sling. 804000203
1
LIFTING SLINGS FOR LIFTING DEVICE. 804000204
BMS:

BMS Unit (Battery Management System) 803005722

PACKINGS:
803000372
PACKING x 1 BATTERY STAND ALONE

Table G

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7. BATTERY IN OPERATION

7.1 Battery Operating Procedures

Note: Start up, shut down, and operation of an integrated system is the responsibility of the
system integrator. The ST523 battery operates with an internal temperature in the range 260-
350°C (500-662°F). The battery must be heated to operating temperature before using, and
must be cooled to ambient temperature before transporting.

7.2 Parallel Connection

ST523 battery can be connected in parallel to the same PCS.

Each ST523 battery is equipped with its own BMS for battery management and
communications. Systems of more than one ST523 batteries are controlled by an Energy
Gateway controller. This controller allows monitoring of actual values and alarm/fault status.
Remote control may be available through the main control of PCS.
It’s no possible to employ the CAN bus communication between the batteries and the GW, but
only to the PCS via Modbus TCP; the PCS can have the use of the second CAN bus line of the
GW.

1) Before connecting any cables, match proper polarity (only connect positive to positive and
negative to negative).
2) Connect the positive terminal of each battery together or to the same DC bus bar
3) Connect the negative terminal of each battery together or to the same DC bus bar
4) For more than one paralleled string of batteries, repeat steps 1 to 3.

NEVER connect ST523 batteries in series. ONLY parallel connection is

allowed. Each ST523 battery is a 620 Vdc battery and is to be considered as
a 620 Vdc battery system.

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The main allowed states for a single Battery are shown below:

- OFF: the BMS’s is powered off (No presence of power supply and signals of harting
connector), no communication is possible.
- OFF-LINE or COOL-DOWN: The battery internal switches are open; communication (with
the Gateway of the BESS or with the STMonitor) is possible. The BMS’s is powered by
the AUX power line (delivered by a 24 Vac - 50/60 Hz source) or by DC BUS.
- WARM UP: In this state the BMS’s draws power from the DC BUS just for the warming
up of the battery. Please refer to paragraph 7.5 for a more specific description.
- ON-LINE (Battery in Imode): when the battery reaches the working temperature, their
internal contactors are closed, "Mosfet-I" work while "Mosfet-V" are stopped. Battery is
ready to exchange power.
- CHARGER ON (Battery in Vmode): in this state the DC BUS is higher respect the DC Bus
in \11Imode state (follow the indications of the FZSONICK Technicians), the battery
inserts the Control Charged Circuit and the “Mosfet-V” work while “Mosfet-I” are
opened.

Figure 14

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7.3 PCS expected working modes

During operation, to assure proper working of the system, it is assumed that the PCS can be
configured in the following modes:

- STOP: the PCS is not active and no current is exchanged with the DC BUS. In general,
the DC BUS could be at 0V or at the battery voltage.

- IMODE: the PCS acts as a bidirectional current generator. The PCS sets the current
according to user requests (positive or negative Power) and according to the current
and voltage ranges provided by Gateway. The DC BUS voltage is determined by the
batteries and decreases moving from charging current to discharging current. In this
working mode is allowed both DISCHARGE and FREE-CHARGE.

- VMODE: the PCS acts a voltage generator. The DC BUS voltage will follow the Gateway
voltage set point. The current will be determined by the batteries (eg. During warm up
a power each battery absorbs a power variable from 100 W to 1000 W; during top of
charge, beside the power needed to compensate for thermal losses, each battery
requires an additional current ranging from 0 to 5 Amps). In this working mode is
allowed both the WARM-UP and the CONTROLLED-CHARGE.

7.4 Temperature management

ST523 battery operates with an internal temperature in the range of 260°C-350°C and must be
heated up before of the operation. The warm-up process takes about 15 hours.
The battery can be cooled down (heaters de-activated) in the following cases:
- An internal loss of electric insulation is detected by the BMS.
- A battery must be in cold status for storage and transport.

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7.5 Battery Warm-Up

The ST523 battery needs to reach internal operative temperature before starting to exchange
energy.
The BMS performs the warm-up process automatically as soon as it is powered without any
command from the Energy Gateway.
The following tables summarize the requires voltage and power ranges per battery. In general
the overall power requirements could be computed considering the number of batteries in the
system.

WARM-UP IN V MODE

Parameter Min. Nominal Max. Unit

Warm-up DC BUS 600 670 700 V
Voltage
Heating Power 175 1000 W
(controlled by BMS) floating@20°C
Heating PWM 300 Hz
frequency
Warm Up duration 11 15 h
(from 20°C Battery)
Table H

Please refer to APPENDIX 1-I for more specific details.

7.6 Battery Charging

Charge can take place when the battery is:

- In the right temperature window and voltage range;
- Is not fully charged;
- There is not external insulation error. In none external device of the ESS system (cables,
PCS..) has been detected an electrical insulation loss.

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There are two different way to charge:

- Free charge in Imode;
- Controlled charge in Vmode.
CONTROLLED CHARGE MODE: in this state the DCBUS voltage is fixed by the PCS at a level
higher than battery voltage. The BMS charge controllers are activated to perform a full charge.

The following table summarize the required voltage and power ranges per battery.

Parameter Min. Nominal Max Unit

DC BUS Voltage 660 670 700 V
Required Power (controlled
by BMS)(charging + heat 10 3500 W
loss)
Controlled Charge Duration
15 Hours
(from 0% State of Charge)
Table I

Please refer to APPENDIX 1-II for more specific details about charge

7.7 Floating

When a battery connected to the DC bus is fully charged, the internal Charge Controllers are
switched off. In this condition the battery current has two main components.
The first one is due to the power consumption of the electronics controller and the second is
due to the power consumption used to compensate for the heat losses.
The former component of the float current is constant over the battery operating temperature
range while the latter depends on battery ambient temperature.
The average float power consumption at 20°C is 175W. Please refer to APPENDIX 1-III for more
specific details.

7.8 Discharging

A discharge is always possible in case the battery is in float or charge state.

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When the battery is performing a warm-up or is in alarm condition, discharge is not possible.
When PCS confirms the activation of the I-mode, the BMS's close the Discharge Internal Solid
State Switches, allowing a low impedance, bidirectional, current path to the cells. Discharge
current limits and DC Voltage limits are dynamically updated by the gateway.
Please refer to APPENDIX 1-IV for more specific details.

7.9 Nominal Battery Capacity

The nominal battery capacity of FZSONICK ST523 battery is 38 Ah in term of capacity and 22.5
kWh in term of energy. At higher discharge rates, the capacity is lower because of the internal
resistance losses; at lower discharge rates the useful capacity is lower due to the fact that
some power is needed to maintain the battery at the internally operative temperature and this
power is drawn from the battery itself. The ST523 discharge performance is not significantly
affected by temperature variations, especially compared with other battery technologies. Even if
the outside ambient temperature varies greatly, its internal temperature will remain within the
operative range and then the capacity and life are not affected.

7.10 Battery Cool Down

The ST523 battery is kept at its operating temperature with internal heaters, controlled by the
BMS. ST523 battery is enclosed with special insulation material to limit both the thermal losses
and the temperature gradients inside the battery. If the battery is operative, the thermal
management of the BMS keeps the internal temperature at a set value.
As soon as the BMS is powered off, heaters are powered off and the internal temperature
starts to decrease with a typical behavior.
If the battery is removed from the DC bus, it turns off and starts cooling down right after.
Please refer to APPENDIX 1-V for more specific details

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APPENDIX 1

I - Warm up process

The graph below shows the internal temperature evolution of a ST523 battery during the
warm-up process.

Figure I
Battery ST523, Warm-up process: Average Internal Temperature (°C) versus duration (h). Bus
Voltage: 670V. Bus Power: average 1 kW.

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II - Battery charge

The following graphs shows experimental charge curves for No. 1 battery ST523 performed at
6,25kW constant power (I mode charge):

- Single battery ST523 Data: charge at constant Power 6,25 kW, 641 V, from different SOC%, at
set point temperature. Battery SOC versus time (Figure II). Charge duration (Table A).

Figure II
Battery ST523, Imode Charge with Maximum Power 6,25 kW, from different SOC (%) and Internal Set
Point Temperature: Battery SOC (%) versus duration (h). Voltage Limit: 641V.

Table A
Battery ST523, Imode Charge with Maximum Power 6,25 kW.

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- Single battery ST523 Data: charge at constant Power 6,25 kW, 641 V, from different SOC%,
after discharge at 8A end (initial temp higher than set point temperature). Battery SOC
versus time (Figure III). Charge duration (Table B). Bus Power (W) versus SOC (%) (Figure IV).

Figure III
Battery ST523, Imode Charge with Maximum Power 6,25 kW, from different SOC (%) after dch 8A end:
Battery SOC (%) versus duration (h). Voltage Limit: 641V.

Table B
Battery ST523, Imode Charge with Maximum Power 6,25 kW, after dch 8A end.

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Figure IV
Battery ST523, Imode Charge with Maximum Power 6,25 kW, from different SOC (%) after dch 8A end:
Bus Power (kW) versus battery SOC (%). Charge Maximum Voltage: 641V.

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III - Battery Floating

The float power consumption of the ST523 battery depends on the ambient temperature
where the battery is installed. This behavior is mainly due to the variations of the heat power
requirements with the temperature. The graph below shows the power consumption of a single
battery ST523 at different ambient temperatures (Figure V).

Figure V
Battery ST523, Power Consumption in floating condition (W) versus Ambient Temperature (°C).

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IV - Battery Discharge

Table below shows the ST523 capacity and energy (in terms of Ah and kWh) at different
constant current and power discharge rates.
During the discharge with high current, the internal heaters won’t consume any energy as the
battery will be warm up due to Joule effect. During operation at high temperatures the
capacity is not affected.

Constant Current Discharge

Table C
Battery ST523, Constant Current Discharge Data.

Discharged bus Discharged bus EOD Bus

Current Time
Rate Capacity Energy Voltage
(A) (h)
(Ah) (kWh) (V)
C/16 2,38 16,0 38,0 22,7 547
C/10 3,80 10,0 38,0 22,5 545
C/8 4,75 8,0 38,0 22,3 544
C/6 6,33 6,0 38,0 22,1 540
8,00 4,8 38,0 21,9 533
C/4 9,50 4,0 38,0 21,7 531
C/3 12,67 3,0 38,0 21,3 517
C/2 19,00 1,9 35,9 19,5 505
C/1 38,00 0,6 24,4 12,3 479

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Figure VI
Battery ST523, constant current discharges: Discharged Capacity (Ah) versus Discharge Current (A), with
isotemporal lines.

Figure VII
Battery ST523, constant current discharges: Discharge Voltage (V) versus discharge duration (h), at
different discharge rates.

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Constant Power Discharge

Table D
Battery ST523, Constant Power Discharge Data.

Discharged bus Discharged bus EOD Bus

Power Time
Capacity Energy Voltage
(kW) (h)
(Ah) (KWh) (V)
2,82 8,0 38,0 22,4 542
3,86 5,7 38,0 22,0 533
4,56 4,8 38,0 22,0 530
6,14 3,5 38,0 21,5 522
7,77 2,7 38,0 21,1 503,7
11,67 1,5 32,3 17,3 505
23,19 0,4 20,0 9,7 455

Figure VIII
Battery ST523, constant power discharges: Discharged Energy (kWh) versus Discharge Power (kW), with
isotemporal lines.

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Discharge at different Ambient Temperature

The battery has an internal standard operative temperature of 270°C which guarantees high
performances and durability regardless of the ambient temperature. Both discharge and
charge operations are regardless of outside temperature, because even if external temperatures
are variable, the internal temperature remains within the operating range.
The following figure shows how the voltages and SOC% maintain stable over limit temperature
range -25°C to +65°C; the battery is able to supply a constant power discharge even during
the most harsh thermal conditions.

Figure IX
Battery ST523, discharge at 6,25 kW at different room temperature: Bus Voltage (V) versus Time (h).

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V - Battery cool down

The graph below shows the internal temperature behavior of a ST523 battery during the cool
down process.

Figure X
Battery ST523, cool down process: Average Internal Temperature (°C) versus time (h).

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APPENDIX 2

Refer to document number BE1002S515 for Hardware Interface Description.

APPENDIX 3

Refer to document number BE1002S511 for Installation User Manual.

Refer to document number BE1002S512 User Manual ST523 Monitor.

APPENDIX 4

Refer to document number BE1002S510 for Web Interface Manual.

APPENDIX 5

Refer to document number BE1002S514 for Battery Energy Storage System to PLC Interfacing.

APPENDIX 6

Refer to document number BE1002S513 for Battery Energy Storage System to PCS Interfacing.

APPENDIX 7

Refer to document number BE1002S518 for Battery Energy Storage System to PPC Interfacing.

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