Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
CellCube FB 10/20/30
V01.01
2. Scope
The descriptions, instructions and recommendations contained within this
document concern only the FB 10/20/30 energy storage system. Various
peripheral devices are not covered, such as photovoltaic installations, generators
and external appliances.
This document is intended as an aid for persons that have been trained and
certified by Cellstrom to conduct installation and maintenance work on the FB
10/20/30 energy storage system. A basic knowledge of the Vanadium Redox
Flow Battery technology is assumed.
3. Hazards
3.1. Symbols
The following hazard symbols or their equivalent in the country of installation
must be prominently displayed on the FB 10/20/30.
The warning symbols should be clean, legible and complete. If they are damaged
or illegible they should be replaced.
3.3.3. Electrical
The stacks should be treated as high power batteries. Even when disconnected
from the fluid and electrical circuits they will still contain some electrolyte and may
be able to give high discharge currents. Therefore, the terminals should be
covered with insulating material (e.g. electrician’s tape) if a stack is removed.
All tools should be insulated to prevent accidental short-circuits. A single stack
can deliver over 700A short-circuit current. This will cause an electric arc,
overheating of the tool and danger for the technician. For the same reason all
metallic jewellery must be removed before working on the battery, especially
necklaces and bracelets.
The inverter provides AC at a household mains level (typically 230 V or 3x 400V).
These voltages can be lethal! This should be treated with appropriate caution
3.3.4. Mechanical
There are no automated moving parts inside the FB 10/20/30 except for the fans,
motorised valves and pumps. These are relatively low power, protected and
unlikely to cause injury.
However, care should be taken when removing or replacing heavier items, like
chargers, inverters and stacks. In particular a new stack is several kilograms
lighter than one that was in service, due to the retained electrolyte weight. These
items should be carried by two people if it is required to move them any
significant distance.
When closing the service flaps take care not to squash your fingers.
The procedures outlined in this handbook for removal and exchange of
components must be followed.
The working area should be cordoned off with warning cones to prevent
accidental harm of third parties, especially when working in urban environments.
This is most necessary during the filling operations (electrolyte and oil) and
dealing with electrolyte leakages.
Unmount the four attachment swivels and replace them by plastic covers
(delivered with the battery).
You need the following tools: a wrench no. 30 and an allen key no. 14.
Cover the fork lift openings on the base of the metal frame with metal sheets
(delivered with the battery).
1 Communication interfaces
XCOM9 (ModBus) – communication external control system
XCOM10 Customer’s LAN / Internet
Option: XCOM1 to 4 - SMA interface (optional MC-Box or AS-Box)
Option: XCOM5 + 6 - Interface to Webbox
Option: XCOM7 + 8 - Multicluster communication interface
Option: XCOM11 – ModBus interface for further devices in the switching cabinet
2 Option: Relay switch (generator request, load shedding)
3 2x Circuit breaker for AC connection AC1 (island grid – PV, wind, loads,G)
4 2x Circuit breaker for AC connection AC2 (grid, generator)
5 2x Circuit breaker (6A) and relay switch for ventilation
6 Main earthing terminal
A central earthing point for the battery is located in the external switching cabinet.
Figure 5.5 – Placing the IBCs with electrolyte in front of the battery
Use one pump for each tank side to fill both tanks in parallel. Attach a hose to a
filling nozzle on each tank after removing the end cap and checking the O-ring.
The hose should be secured with at least 2 hose clamps.
Both tanks are filled in parallel. Each tank must be filled with exactly the same
amount of electrolyte. Before starting check the fill levels of all IBC containers.
Clean the IBCs around the screw caps before opening. Put each pump into a
separate IBC and loosely seal the opening with a splash protection sheet (ideally
transparent):
ATTENTION:
The valve of the gas barrier must be closed before starting the system.
If there is still air in the pumps you need to allow air to escape from the system.
The return hoses to one stack of each pump circuit should be disconnected and
the free end attached with a cable tie above the level of the manifold (see
picture).
If the air has escaped from the pumps the return hoses should be reconnected to
the stacks and secured with hose clamps (1,2 Nm torque).
Important - the hose should be pushed completely onto the hose nozzle. The
hose clamp should be positioned 1 - 2 mm away from the end of the hose.
The charger must be connected directly to the DC rail as shown in the following
picture. Only in case you have a FB20 or FB30 connect the left and the right
positive rail with the bridge cable. This is necessary to make all pumps running
during the flushing procedure.
Set Jumper 12 on the FBC to the right -> pumps will not be stopped when fluid
side is open.
Disconnect all string fuses (F1.1 – F1.10) from the DC rail using the NH fuse
handle.
Set the charger to 50 V and 50 A. The FBC starts, the red LED LD2 is on and the
display is active.
After all pumps are working together and the pressure is within the given limits
the system responds: “Flushing successful”.
the controller then automatically changes to normal operation mode
The test mode can also be selected manually using the left pushbutton (jumping
over the test steps).
In case there is a problem with pump pressure check the system. If there is still
air in the fluid circuit the flushing procedure should be repeated.
After successful flushing switch off the battery. Check if there is no voltage on the
DC-rail. If used take out the bridge cable between positive DC-rail A and B.
Connect monitor, keyboard and mouse to the miniPC so you are able to monitor
the system.
Switch on the circuit breakers in the external switch cabinet (FAC2_A, FAC2_B)
to provide the external power supply.
Insert 2 to 3 string fuses, depending on the max. power of the charger (5 kW
charger = 2 strings, 6 kW charger = 3 strings).
The charger should be set to 60V and to maximum current. Start the battery and
check if all pumps are running (FB Modular Monitoring).
Warning: Do not charge the battery if pumps are not running! Stacks
may get damaged.
Important: For safety reasons first charging of the battery should only be done via
inverters from grid or generator.
Start the Master inverter of cluster A. Set the inverter’s charging power to 15 kW
(using the Power Control Software). Insert the missing string fuses in cluster A
and start Slave1 and Slave 2. As soon as the inverters are charging from
grid/generator you can switch off the power charger.
After charging the electrolyte with ~ 60 kWh (in case of the 100 kWh type) it will
have reached a state of charge (SOC) of 0%. The OCV-voltage (and hence the
SOC) will climb slowly but steadily.
If an SOC of 5% is reached cluster B can be added. Be sure that the DC-rails of
cluster A and B are not connected. Insert the NH fuses for all strings on cluster B.
If there is enough voltage on the right DC-rail (B) the pumps of circuit 2 will start
immediately. If this is not the case stop the system and restart it again.
As soon as there is a stable voltage >50V on the right DC-rail switch on the
inverters of cluster B starting with the Master.
Attention: Be sure that during operation of the battery the circuit breakers
F50 and F51 in the external switching cabinet are always switched on.
Only in the on position all AC ventilators are in operation.
The FB 10/20/30 needs access to the internet. In case of failure warnings and
alarm messages will be sent via e-mail to the Cellstrom Service Center.
Remote monitoring and data transfer is carried out via TeamViewer. As a
prerequisite access to the internet via http port 80 is requested.
For e-mail communication access is needed to:
If a modem is used, put customers SIM card into the data modem. The antenna
is mounted on top of the external switching cabinet. The position of the antenna
can be optimized for best transmission with the program GSMCHKV01.
During operation several parameters are stored in logfiles. This data is sent from
the FBC to the miniPC where it is stored. Per day you get a file with approx. 20
MB.
5.6.2. TeamViewer
A few parameters need to be configured to assure correct and safe operation.
For details please see the Service Information SI_28. In case of troubles contact
the Cellstrom Service Center (see chapter 11).
SMA status:
Additional:
Error list:
Check System:
Before opening the tank cover open the valve of the gas barrier (see figure
below) to let some overpressure escape from the tank head space.
ATTENTION:
Keep away all naked flames and sparks battery. Smoking is strictly
prohibited in the immediate vicinity.
Wait for at least 15 minutes.
Before the system is taken into operation again the valve must be set to the
closed position.
Remove the return hoses (OUT) of one stack in each pump circuit. Prepare
cleaning paper to catch any electrolyte dripping out.
Wait for at least 5 minutes for remaining electrolyte to drain back into the tanks.
The hand valve in the pump chamber must be in the open position (see figure
below).
The right torque for tightening the hose clamp is 1,2 Nm.
7.2. Leakages
Material and tools:
• Cleaning paper, waste sacks
• Eye wash bottle
• Water in open container (250 ml – 2 l)
• Water in spray bottle
• Warning devices (warning cones, warning tape)
• Personal protective equipment (see safety section)
Park the vehicle with the replacement stack as close to the FB 10/20/30 as
possible. Cordon off the working area using warning cones and tape.
Switch off the battery by pressing and holding both pushbuttons (A and B) on the
FBC-board for 5 seconds. Switch off all inverters (DC-switch at the front) and
remove all string fuses from the DC-rail. Afterwards press the emergency stop
button (= safe state).
Open the valve of the gas barrier for at least 15 minutes -> refer to chapter 7.1.1.
Open the hydraulic system to drain the fluid circuits -> refer to chapter 7.1.2.
Shortcut the open nozzles OUT+ and OUT- with the short hose and tighten the
hose clips.
Now disconnect the inlet hoses as well. The stack is now completely
disconnected from the fluid system.
In case there are any electrolyte residues on the stack they have to be diluted
with water before wiping them away with cleaning paper. You shouldn’t inhale
any electrolyte dust so refrain from scratching it away in dry condition.
Now connect also IN+ with IN-. Write the last SOC onto the stack. The higher the
SOC was the more gas might be produced inside the stack during transport
(overpressure inside the stack).
Disconnect the electrical cables from the stack terminals. Insulate the stack
connectors thoroughly with electrician’s tape (there may still be a significant
voltage across the terminals).
ATTENTION: Work carefully - danger of short cut of the stack terminals!
The stack is heavy (ca. 40 kg), 2 people are required to carry it!
Remove the stack with the help of the stack slide. Secure the slide on 4 points as
shown on the following picture before you use it.
Transfer the stack to a plastic drip tray. The stack has to be packed into a tight
plastic bag for transport and sent back to Cellstrom declared as dangerous good.
ATTENTION: If it is not possible to send the stack back to Cellstrom then it
has to be destroyed irrecoverably by a certified disposal company. Don’t
disassemble the stack, this is very dangerous!
Insert the new stack and reconnect in the reverse order of disconnection. Tighten
the screws at the electrical stack terminals with a torque of 6 Nm. If they are not
tightened enough the connections can get very hot -> danger of burning hands.
Finally the stacks must be reconnected to the hoses and the hose clamps
tightened with a torque of 1,2 Nm -> please refer to chapter 7.1.3.
Important:
Be sure to close the valve of the gas barrier again before you restart the system
-> see chapter 7.1.1.
Restart:
• Release Emergency Stop button
• Insert string fuses and start battery
• Start flushing sequence in FBC test mode (reset with S1 and press both
pushbuttons A & B)
• Check tightness during degassing process
• After successful degassing FBC switches automatically into normal
operation mode
• Switch on the inverters starting with the slaves
Secure the working area with warning cones and tape. Switch off the battery by
pressing and holding both pushbuttons (A and B) at the FBC-board until the
battery switches off. Switch off all inverters (DC-switch at the front). Afterwards
press the emergency stop button (= safe state).
Open the valve of the gas barrier for at least 15 minutes -> refer to chapter 7.1.1.
Open the hydraulic system to drain the fluid circuits -> refer to chapter 7.1.2.
Note the positions of the OCV connections (stickers available?). Unscrew the
OCV cell and lift it high to drain it as much as possible. Mark the position of hoses
(IN / OUT +/-). Remove all hoses starting with top connections and secure them
with cable ties so no electrolyte can drip out. Watch carefully not to rotate the
open OCV cell too much. Always keep the open nozzles on top. Empty the rest of
electrolyte into a bucket and clean the OCV cell. Seal the open nozzles with short
hose pieces shortcutting Out+ with Out- and In+ with In-. Install new OCV Cell
and reconnect hoses in the reverse sequence.
Important:
Be sure to close the valve of the gas barrier again before you restart the system
-> see chapter 7.1.1.
Restart:
Secure working area. Switch off the battery by pressing and holding both
pushbuttons (A and B) at the FBC-board until the battery switches off. Switch off
all inverters (DC-switch at the front). Afterwards press the emergency stop button
(= safe state).
Open the valve of the gas barrier for at least 15 minutes -> refer to chapter 7.1.1.
Open the hydraulic system to drain the fluid circuits -> refer to chapter 7.1.2.
Open the pipe coming from the faulty pump at the screw fitting and connect the
adapter for the air pump as shown in the following pictures. Close the open end
of the pipe with the end cap. Prepare enough paper and a beaker to collect any
dripping electrolyte.
By using the air pump the electrolyte level can be reduced to below the hand
valve. Therefore the faulty pump will be almost free of electrolyte. Firmly pump air
into the tank until you hear air entering the tanks (bubbling sound). One person
continues pumping while the other one closes the hand valve. Be sure to move
the valve to the correct position so the pump to be exchanged remains free of
electrolyte (see figure below). At each possible position the valve snaps in place.
The faulty pump can now be removed and exchanged without significant spillage
of electrolyte. First disconnect the electrical connections.
Unscrew the two clamps (use allen key no.5).
Open the screw fitting with a special spanner wrench (article no. 2616). Prepare
paper to collect any remaining electrolyte.
Now the hand valve can be changed to the open position to fill the pumps with
electrolyte. The pumps are not self-priming therefore at least at one stack the
OUT-hose must remain open at that point. The pump head will now fill up with
electrolyte -> visual check, it must turn dark.
Finally the hoses must be reconnected to the stacks and the hose clamps
tightened with a torque of 1,2 Nm -> please refer to chapter 7.1.3.
Important:
Be sure to close the valve of the gas barrier again before you restart the system
-> see chapter 7.1.1.
Restart:
If the motor valve does not operate the motor can be exchanged separately from
the rest of the valve without having to switch off the FB 10/20/30.
Disconnect the plug from the FBC socket X11 before you exchange the motor.
Secure the working area warning cones and tape. Switch off the battery by
pressing and holding both pushbuttons (A and B) at the FBC-board until the
battery switches off. Switch off all inverters (DC-switch at the front). Afterwards
press the emergency stop button (= safe state).
Open the valve of the gas barrier for at least 15 minutes -> refer to chapter 7.1.1.
Open the hydraulic system to drain the fluid circuits -> refer to chapter 7.1.2.
The balance valve should now be largely free of electrolyte and can be removed,
after electrical disconnection, using the strap oil filter wrench.
Important:
Be sure to close the valve of the gas barrier again before you restart the system
-> see chapter 7.1.1.
Restart:
Secure the working area with warning cones and tape. Switch off the battery by
pressing and holding both pushbuttons (A and B) at the FBC-board until the
battery switches off. Switch off all inverters (DC-switch at the front). Afterwards
press the emergency stop button (= safe state).
Open the valve of the gas barrier for at least 15 minutes -> refer to chapter 7.1.1.
Open the hydraulic system to drain the fluid circuits -> refer to chapter 7.1.2.
Important:
Be sure to close the valve of the gas barrier again before you restart the system
-> see chapter 7.1.1.
Restart:
Secure the working area with warning cones and tape. Switch off the battery by
pressing and holding both pushbuttons (A and B) at the FBC-board until the
battery switches off. Switch off all inverters (DC-switch at the front). Afterwards
press the emergency stop button (= safe state).
ATTENTION:
Nothing is permitted to fall into the tank, all tools and screws must be
removed from the top of the tank before opening the tank cover.
When opening the tank observe the following safety precautions (see also
Service Information SI21).
• Open the screws of the level sensor unit by hand (don’t use any electric
tools). Put the screws away from the opening so they can’t fall into the
tank accidently.
• Smoking and handling with open flames is forbidden within a range of 10
meters
• Avoid flying sparks (attention on construction sites)
• Avoid electrostatic charging (use an earthing strap, no synthetic clothes)
Important:
Be sure to close the valve of the gas barrier again before you restart the system
-> see chapter 7.1.1.
ATTENTION:
Nothing is permitted to fall into the tank. All tools and screws must be
removed from the top of the tank before opening it.
When opening the tank observe the following safety precautions (see also
Service Information SI21).
• Smoking and handling with open flames is forbidden within a range of 10
meters
• Avoid flying sparks (attention on construction sites)
• Avoid electrostatic charging (use an earthing strap, no synthetic clothes)
Disconnect X.52 on FBC sensor is without power. Disconnect the plug at the
sensor (next to the OCV-cell). Screw out the faulty sensor and exchange it
against the new one. Be sure to screw the sensor on tight. Then reconnect X52.
Restart battery and check for correct indication of the hydrogen value.
For all other temperature sensors disconnect the appropriate sensor cable at the
FBC board (X24 – X26). Exchange sensor and check function.
Secure working area. Switch off the battery by pressing and holding both
pushbuttons (A and B) at the FBC-board until the battery switches off. Afterwards
press the emergency stop button (= safe state).
Switch off all inverters using the DC circuit breakers at the front. Similarly the
circuit breaker on the AC side must be switched off. Now the inverter can be
opened and all cables disconnected.
Mount the rails and take out the inverter as shown in the following pictures.
Before taking the inverter off the rails prepare an adequate supporting base so
you don’t squash your fingers and also don’t damage the front cover.
ATTENTION: Due to the very heavy weight (64 kg) it is necessary to do
this job with at least 2 people.
Insert a new inverter by reversing the order of these operations. Watch out for the
fastening torque on the cable shoes.
Note: Install SMA piggyback communication board and SD card (if MASTER-
inverter was exchanged).
Dismount defective DC/DC converter. Eventually mark cables. Apply heat sink
paste to new DC/DC converter, connect cables and mount unit. Insert fuses, start
battery and check functionality.
1 Charging stopped
2 Battery switched off, only communication on
3 Charging stopped, ventilation on
4 System switched off, only manual restart possible
5 System switched off – Emergency Stop, failure is reset after FBC restart
6 Pumps in circuit 1 stopped
7 Pumps in circuit 2 stopped
8 Charging disabled in circuit 1
9 Charging disabled in circuit 2
10 Pump pressure in circuit 1 = 800mbar
11 Pump pressure in circuit 2 = 800mbar
Outside:
removal of plant covering from the battery housing
check-up of the external electric cabinet and external cabling (closing, tightness, dirt,
isolation)
Inside:
check for tightness - rainwater, condensation: remove and seal
String No. 10 9 8 7 6 1 2 3 4 5
Stack No. 19 17 15 13 11 1 3 5 7 9
Stack No. 20 18 16 14 12 2 4 6 8 10