The installation of energy storage DC systems mainly includes the structural fastening, electrical wiring, and debugging of equipment such as batteries, DC cables, and DC combiner cabinets. The transportation method of batteries largely determines the main workload and specific debugging and inspection process during the DC installation process.
At present, the transportation method of batteries in energy storage systems will be based on the requirements of the battery manufacturer, either by installing and integrating them into the system for overall transportation, or by independently packaging and transporting them separately from the system in the form of battery packs. Then, the unpacking, handling, installation, wiring, and debugging of the battery packs will be carried out on site. For the former, system integrators can basically complete the majority of system installation and debugging work in the factory, but they should strictly comply with relevant requirements and regulations for the battery pack and its structural fastening method, SOC during transportation, and positive and negative electrode leads.
For the latter, system integrators, based on cost and safety considerations, will not install, debug, disassemble, repackage, or transport the entire battery pack in the factory. Instead, they can only carry out surveying, production, and parallel connection of DC combiner cabinets, battery racks, and DC cables, and use weak current simulation to complete system debugging. Especially when the capacity of the integrated system is large, such as when a 40ft container may be designed with more than 2MWh of lithium batteries installed inside, the workload of secondary disassembly and transportation of the battery pack becomes too huge. Moreover, currently, the weight of a single battery pack is large, the integrated installation space is small, and in most cases, manual operation can only be relied on.
1 Preliminary preparation work:
1. Design drawing confirmation: Check the design drawings to ensure that the installation position, dimensions, cable routing, etc. meet the requirements.
2. Material inspection: Check the materials of the combiner cabinet, DC cables, connectors, etc. to ensure that they are undamaged and meet specifications.
3. Tool preparation: Prepare the necessary tools and materials, such as screwdrivers, wrenches, multimeters, level rulers, galvanized bolts, etc.
2 Installation and Inspection Process
1. From unboxing inspection to installation in place: Similar to the aforementioned distribution cabinet, attention should be paid to complete technical documentation; The components inside and outside the cabinet are complete and clean; Check the battery pack model and ensure that the appearance is undamaged; Accurate and stable movements, neat and beautiful structural arrangement, safe and reliable grounding, and proper personnel training and technical disclosure.
2. Battery pack handling and installation: The weight and volume of the battery pack are relatively large, and personnel should be prevented from twisting or injuring their hands and feet during the handling process; During the process of lifting the battery pack, prevent collisions or falls from the ground, otherwise the internal acidic and alkaline solutions may contaminate personnel and the environment, cause deformation or stress on the outer shell, and also lead to the puncture of the internal separator of the battery, causing internal short circuits; Installation personnel should wear protective equipment such as gloves, safety shoes, and helmets, handle with care during transportation, and cooperate with each other; The battery pack and battery rack are fixedly connected using torque wrenches; The installation sequence of batteries is from bottom to top and from inside to outside, layer by layer and column by column. Please ensure that the positive and negative electrode arrangement of the battery pack is consistent with the diagram.
3. DC cable wiring and connection: During the installation of DC cables inside the battery cluster, use a wrench or screwdriver to connect the battery packs in series. The tool handle should be wrapped with insulating tape and should not be placed randomly next to the battery terminals. The connected battery terminals should be promptly protected with insulation sleeves; During the installation of battery cluster lead wires, the DC cable convergence end should be tightened first, and then the wires should be routed along the cable tray to the corresponding battery cluster. The wiring in the cable tray should be neat and fixed every 2 meters; Clearly mark each outgoing line to prevent mixing; Check the insulation between the positive and negative poles of the cable, as well as the insulation between the positive and negative poles and the ground. For example, the insulation between the 110V battery busbar and the ground should not be less than 0 1M Ω The insulation of 220V battery pack to ground shall not be less than 0 2M Ω, connect to the corresponding battery cluster output switch box terminal after passing the test; When connecting wires, ensure that the screws or bolts are tightened and the contact resistance is less than 25m Ω to prevent loose wires from causing heating and combustion; Flame retardant cables should be used for wiring, and the wiring should be arranged neatly and aesthetically pleasing.
4. Battery system debugging: external control power supply is used for battery system debugging; With the help of the upper computer software, the internal three-level BMS communication docking of the battery system, cell data transmission, battery pack switch box status monitoring and action operation, battery pack fault simulation and re commissioning, and other debugging processes are completed.
5. Local controller communication cable connection and equipment distribution power wiring: Due to the fact that in addition to the battery DC parallel busbar and detection protection devices, the DC combiner cabinet may also integrate local controllers, control system distribution equipment, human-machine interfaces, UPS, etc., communication cables and control power connections should also be made after the cabinet is installed in the combiner box, especially between the local controller and BMS PCS Communication cable connections between equipment such as air conditioning, fire protection, and transformer measurement and control devices, as well as power cable connections for each device.
6. Inspection handover: Clean and inspect the installation site to prevent the omission of tools and debris; The battery pack is neatly stacked and the positive and negative poles are connected correctly; The wiring between the battery pack and the cabinet should be firm and reliable; The battery casing shows no signs of deformation, damage, or electrolyte leakage.
