ABB ESI-S, Installation, Operation And Maintanance Manual

Page 1: ... INSTRUCTION MANUAL Energy Storage Inverter ESI S Installation operation and maintenance instructions ...

Page 2: ...ocation requirements 32 5 3 Standard enclosure dimensions and clearances 33 5 4 Instructions for mounting the inverter 34 5 5 Inverter noise level 35 5 6 Airflow and cooling requirements 36 5 7 Instructions for mounting the ESI Manager in enclosures 37 6 Electrical design and installation 39 6 1 What this chapter contains 39 6 2 Instructions for connecting the ESI Manager to a inverter system 40 6...

Page 3: ...easurements menu 93 7 8 1 The Overview menu 93 7 8 2 The System values menu 95 7 8 3 The Min Max logging menu 101 7 9 The Settings menu 103 7 9 1 The Battery operation menu 104 7 9 2 The Customer settings menu 105 7 9 3 The Commissioning menu 115 7 9 4 The Installation settings menu 129 7 9 5 Set Language 134 7 10 The ESI monitoring menu 135 7 10 1 The Status of module menu 135 7 10 2 The Inverter...

Page 4: ...onsulting inverter statistics and manufacturer data 191 9 8 Inverter behavior on fault retrieving error information 191 10 Maintenance instructions 194 10 1 What this chapter contains 194 10 2 Maintenance intervals 194 10 3 Standard maintenance procedure 195 10 3 1 Step 1 Check the ambient temperature conditions 195 10 3 2Step 2 Record the inverter operating status 195 10 3 3Step 3 Shut the system...

Page 5: ...Manual Energy Storage Inverter ESI S Table of contents 5 11 4 2 Fault tracing 207 12 Technical specifications 219 12 1 What this chapter contains 219 12 2 Technical specifications 219 ...

Page 6: ...this manual 1 3 Compatibility The manual is compatible with all inverters of the ESI range with ESI Manager software the following versions or higher V1 V26 r3001 V2 V11 r23 V3 V2 r0 V4 V0 1 r8 The ratings in the present manual are given in kVA based on a 400V network and are given also in Amps The current ratings are not changing with the network voltage 1 4 Configuration of the Energy Storage Sy...

Page 7: ...s given in Chapter 6 Loads Three phase Single phase Generation Wind turbines Solar panels ESS Supply Island Islanding contactor We distinguish two types of islanding Intentional The BESS receives the order from the main controller user to disconnect itself and the loads from the grid The system reconnects the island to the grid when it receives the signal from the main controller Unintentional the...

Page 8: ... Each phase receives its own active and reactive power targets independently from the 2 other phases However this configuration is available only in 4W mode 1 6 Contents Chapter 1 Introduction to this manual Chapter 2 Safety instructions Chapter 3 Upon reception Chapter 4 Hardware description Chapter 5 Mechanical design and installation Chapter 6 Electrical design and installation Chapter 7 The ES...

Page 9: ...rking on electrical installations Also make sure that all local safety regulations are fulfilled DANGER To ensure safe access supplies to each individual enclosure must be isolated before opening WARNING This equipment contains capacitors that are connected between phase and earth A leakage current will flow during normal operation Therefore a good earth connection is essential and must be properl...

Page 10: ...nnected it can result in full line voltage between chassis and earth ground Severe injury or death can result if the chassis and earth ground are touched simultaneously WARNING The neutral current in an ESI S inverter may be as high as 3 times the line current hence do not use a 4 pole breaker to connect this type of inverter as the rating of the neutral pole may not be adequate ...

Page 11: ...or transportation damage Your inverter equipment comes with a package Verify that all items are present i e USB storage device containing this manual the electrical drawing the rubber seal to cover a knock out to be used for multi unit operation the communication cable needed for multi unit operation the two eyebolts Any loss or damage should be notified immediately to your ABB representative Note...

Page 12: ...es to locations with immediate neighborhood of industrial sources with chemical emissions b Locations without special precautions to minimize the presence of sand or dust Also applies to locations in close proximity to sand or dust sources In order to lift the equipment once it is at the installation location Remove the top cover of the protecting box see Figure 3 Remove the 4 panel securing screw...

Page 13: ... put aside Figure 6 Unplugging the ESI Manager from the main system Remove the two screws fixing the inverter unit to the wooden support see Figure 7 Right side Bottom Figure 7 Position of the inverter fixation screws that need to be removed Fix the two eyebolts provided with the inverter see Figure 8 Figure 8 Fix the eyebolts before lifting the ESI S ...

Page 14: ...ency as well as a serial number and an ABB internal article code 3 6 Storage If your ESI S is not installed once unpacked it should be stored in a clean indoor dry dust free and non corrosive environment The storage temperature must be between 25 C 13 F and 70 C 158 F with a maximum relative humidity of 95 non condensing Table 2 Maximum allowed ambient conditions for storage Storage in the protect...

Page 15: ...interface This device also acts as the user s connection point for the alarm warning contacts the remote control functionality the other digital input functionality and the interface for external communication A current voltage generator power unit that converts the control signals generated by the inverter controller into the inverter current or voltage The current voltage generator is connected ...

Page 16: ...cation connection Not mandatory 6 Earth connections from the enclosure to installation earth Mandatory 7 Battery connection Mandatory 8 Voltage measurement Not mandatory Mandatory connections are connections that must be present to make the inverter operational Connections that are not mandatory can be made to enhance the inverter s basic functionality For more information on cabling the user conn...

Page 17: ...stomer In addition to using master panels only ESI S units can be connected in a master slave arrangement 4 3 The ESI current voltage generator hardware The power circuit of an ESI S unit is represented hereafter Preload circuit IGBT inverter N L AC power supply 1 2 9 7 5 6 8 Output filter 4 3 Figure 12 Power circuit diagram of an ESI S inverter The description of the main components is given in T...

Page 18: ...e the high frequency noise is absorbed The IGBT inverter is equipped with DC capacitors that act as energy storage reservoirs 2 The battery is connected 9 on the DC capacitors 4 of the inverter The preload of these DC capacitors is done thanks to the grid This avoid inrush current coming from the battery All units contain a DC capacitors preloading resistor 5 which charges the DC capacitors up to ...

Page 19: ...nverter consists of a master unit only the customer has to Wire the CT signals on a designated terminal if required Connect the AC power lines with or without neutral Connect the DC power line Connect the control of the DC contactor Connect the voltage measurement and islanding contactor control if required Set up the installation parameters and user s requirements with the ESI Manager He may also...

Page 20: ...able of displaying the relevant information about that specific unit only Certain parameters which are specific to that unit e g related to temperature probes can be set or changed locally using the ESI Manager installed on that unit The ESI Manager on the master unit has a unit selection button which allows the user to select the unit number which he wants to consult The data then displayed on th...

Page 21: ...re made at the rear side of the ESI Manager Figure 15 depicts the terminals that are present on the ESI Manager rear side 1 2 3 4 5 6 7 8 9 10 Figure 15 ESI Manager rear side terminal designation The terminal designation is given in Table 7 Table 7 Terminal designation Item Customer terminals 1 Digital input 1 and 2 2 Digital outputs 1 to 6 with one common point 3 Alarm outputs 2 outputs with comp...

Page 22: ...o drive the digital inputs has to comply with the following characteristics Vlow 0 Vdc Vhigh 15 24 Vdc Driving current 13 mA 24 Vdc Rint 1 88 kΩ The digital inputs have free of potential contacts opto isolated When implementing any of the functions described above please note that according to the setup done with the ESI Manager for the input considered the inverter may behave differently Table 8 ...

Page 23: ...auxiliary settings Information on cabling the digital input contacts is given in Section 6 14 Information on setting up the digital inputs with the ESI Manager is given in Section 7 9 2 4 By default the digital inputs are disabled In a master master inverter arrangement only the master that has the control over the complete system will monitor its digital outputs For full redundant functionality i...

Page 24: ...c Warning 3 The programmable warning 3 is activated c Battery charging The battery is currently charging Connected to grid The ESS is connected to grid i e not in islanding Remarks a In order to set up this function navigate to Welcome Settings Customer set Digital Outputs b More information on the standby function is given in Section 7 9 4 1 c Different programmable warnings and alarms can be def...

Page 25: ...on has disappeared for another preset time Information on changing the alarm activation deactivation time is given in Section 7 9 2 4 1 In a master master arrangement only the master that has the control over the complete system will activate its alarm contact For full redundant functionality it is recommended to monitor the alarm contacts of all the units in the system The maximum continuous alar...

Page 26: ...For background information on the Modbus RTU and TCP communication interface refer to the dedicated Modbus manual For background information on the PQF Link communication interface refer to the dedicated PQF Link manual 9 The ESI Manager can communicate with PQF Link PC software also through USB For background information on the PQF Link communication interface refer to the dedicated PQF Link manu...

Page 27: ...oad circuit rESI Stors R1 R2 6 Main earth connection point 7 IGBT inverter with DC capacitors U01 8 ESI main controller board A005 9 IGBT heat extraction fans M1 M2 10 PCB EMC neutral A003 11 PCB EMC line A002 12 PCB output inverter preload A001 13 Main power supply terminals phases underneath controller boards L1 L2 L3 14 Main power supply neutral connection not mandatory underneath controller bo...

Page 28: ... with the same type Please refer to our recommended list of spare parts The preload circuit is shown in Figure 17 2 3 4 1 5 6 Figure 17 Preload circuit main components The component identification is given in Table 12 Table 12 Preload circuit main components description Item Description Circuit diagram designation 1 Fuse preload circuit PF1 2 Fuse preload circuit PF2 3 Preload circuit resistors R1...

Page 29: ...r ESI S Hardware description 29 10 2 6 7 8 9 15 3 12 11 4 13 14 5 16 17 18 21 22 19 20 1 Figure 18 ESI main controller board The designation of the principal terminals is given in Table 13 3 4 2 1 5 Figure 19 Location of terminals ...

Page 30: ...s Spare P9 P10 P11 17 System connector control of IGBT module P12 18 Voltage selector DIP switch Not used in ESI S single voltage 19 System LED s top to bottom LED 3 ON Critical error in inverter unit considered red LED LED 3 OFF No critical error in inverter unit considered LED 2 ON ESI unit running or in startup process Armed LED 2 OFF ESI unit off and not in startup process LED 1 Blinking at re...

Page 31: ... default address setting is L L L CAN bus termination Right hand DIP switch Must be High H for the units that are at the extremity of the CAN bus maximum 2 units in a multi unit inverters typically the first one and the last one of the chain This setting is also applicable to single unit inverters Must be Low L for units in the middle of a chain The default factory setting is H Remarks a For physi...

Page 32: ... 24 h 35 C 95 F Relative humidity Max 95 non condensing Contamination levels IEC 60721 3 3 Chemical class 3C2 c Mechanical class 3S2 d Remarks a At sites over 1000m 3300ft above sea level the maximum output current must be derated by 1 every additional 100m 330ft The derating factor must be entered at commissioning b Above 40 C 104 F the maximum output current must be derated by 3 5 every addition...

Page 33: ...commended However the unit can rest on its back against a wall A spacing of 500 mm below the inverter bottom and above the inverter top is recommended Figure 20 shows a view of a typical ESI S with characteristic dimensions Figure 20 View of a typical ESI S with characteristic dimensions If an inverter system consists of more than one unit the units should be installed next to each other If it is ...

Page 34: ... is about 130 kilograms Please note that one enclosure contains always one unit In order to mount a unit on to the wall follow the steps outlined below Unpack the inverter as per Section 3 3 Set the 2 eyebolts on the top of the cubicle They will be used to lift the inverter properly Pull out the 2 fixation plates Figure 22 Figure 22 Top view of the ESI S inverter with the fixation plates 2 bolts M...

Page 35: ...he enclosure can be pushed against the rear support at the bottom also see Figure 24 Figure 24 Lower end fixation For additional units the same procedure has to be followed 5 5 Inverter noise level ESI S produce a certain level of noise when they operate The noise level depends on the operating conditions of the unit and on the rating of the inverter These values should be taken into account when ...

Page 36: ...irement Unit rating Power rating kVA Airflow requirement m h 30A 60A 20 40 520 m h 70A 100A 50 70 520 m h 120A 85 710m h Please ensure that the air used for cooling is regularly renewed and does not contain conductive particles significant amounts of dust or corrosive or otherwise harmful gases The cooling air intake temperature must not exceed 40 C under any operating condition The hot exhaust ai...

Page 37: ...n case it needs to be relocated to another enclosure follow the guidelines presented next Figure 26 Step 2 Step 1 a b Step 3 Step 4 c e Step 5 Repeat steps 3 to 5 for the bottom Mounting Bracket d Figure 26 Mechanical installation of the ESI Manager Step 1 Slide the ESI Manager a perpendicularly to the Capacitor Bank Cubicle b Step 2 Rotate the ESI Manager to insert it into the Capacitor Bank Cubi...

Page 38: ...ion Manual Energy Storage Inverter ESI S Step 5 Turn the Screw e into the Mounting Bracket and tighten until the ESI Manager is secured in place Once the ESI Manager has been installed it has to be connected electrically Cf Section 6 2 ...

Page 39: ...o such a system is only authorized after explicit approval by ABB The inverter must be connected to the network in parallel with the loads WARNING The ESI S does not incorporate protective power line fuses or main contactor Hence the customer has to ensure that the feeding cables to each inverter panel are adequately protected taking into account the inverter rating and the cable section used More...

Page 40: ...h voltage levels can still be present on the control board Respect a delay of 25 minutes after disconnecting the mains power before touching the control board 6 2 Instructions for connecting the ESI Manager to a inverter system ESI S master units are by default equipped with the ESI Manager user interface In some cases however it may be needed to remove and reconnect the ESI Manager to the control...

Page 41: ...g the test without disconnecting the abovementioned connectors may damage the inverter Use a measuring voltage of 500 Vdc The insulation resistance must be higher than 500 MΩ per enclosure 6 4 EMC considerations The inverter complies with the following EMC guidelines EN IEC 61000 6 2 Industrial level Immunity standard for industrial environments EN IEC 61000 6 4 Class A Emission standard for indus...

Page 42: ... s choice Note however that due to the high frequency output inverter of the ESI there is no radiated emission through the feeding cables Consequently there is no need for special screening of the inverter connection cables The following steps have to be followed to determine the section of the power cables feeding the inverter 1 Determine the RMS current rating of the enclosure for which the cabl...

Page 43: ...For a given installation its value can be determined using the following process Step 1 Determine in a conventional way e g using cable manufacturer s tables the cable section A mm for the RMS current Irms obtained in 1 above Step 2 Using the cable section A the cable material and the network frequency as entry points in Table 19 determine the multiplication factor X For the DC current the multipl...

Page 44: ...e previous step Conclusion one copper cable of 16 mm2 per phase is sufficient Remark The cable sizing process discussed in point 2 above only takes into account the skin effect Any further derating due to local standards and or installation conditions e g distance between cables number of cables connected in parallel have to be taken into account by the company responsible for the ESI cable connec...

Page 45: ... 290 250 0 95 238 150 300MCM 1 1 365 0 877 320 285 0 93 265 185 350MCM 1 1 415 0 844 350 325 0 908 295 240 500MCM 1 1 495 0 804 390 385 0 876 335 300 600MCM 1 1 550 0 768 420 425 0 843 358 16 6 2 0 8 160 0 997 159 120 0 999 120 25 4 2 0 8 208 0 993 205 160 0 997 160 35 2 2 0 8 256 0 987 250 192 0 994 190 50 1 1 0 2 0 8 304 0 975 290 232 0 989 229 70 2 0 2 0 8 368 0 955 350 288 0 98 282 95 3 0 2 0 ...

Page 46: ...8 406 425 0 81 346 16 6 2 0 8 160 0 996 159 120 1 120 25 4 2 0 8 208 0 99 205 160 1 160 35 2 2 0 8 256 0 981 250 192 0 99 190 50 1 1 0 2 0 8 304 0 965 293 232 0 98 228 70 2 0 2 0 8 368 0 941 346 288 0 97 280 95 3 0 2 0 8 456 0 911 415 352 0 95 336 120 4 0 2 0 8 520 0 88 457 400 0 93 374 150 300MCM 2 0 8 584 0 85 496 456 0 91 416 185 350MCM 2 0 8 664 0 817 542 520 0 89 460 240 500MCM 2 0 8 792 0 77...

Page 47: ...an alternative to fuse protection MCCB protection of appropriate sizing can also be used When the customer protection is in place the following ESI S input protection will result L1 L2 L3 To ESI S power stage To ESI S control circuit and DC bus loading circuit 2 5mm reinforced 6A 10X38 for up to 415V N Customer added protection ESI S inverter unit Note neutral connection only needed for 4 wire con...

Page 48: ...otorized DC breaker is provided as a loose item together with ESI S Installation of the same shall be as per instruction provided with the correct cable size refer to Section 6 6 Depending on the DC voltage level 750V a 4 poles or 3 poles breaker will be provided In a multi units system each inverter will have its own DC protection DC DC To ESI S power stage DC side protection provided as loose it...

Page 49: ...erter damage For applications where predominantly 3 phase loads are present and where there is no need for neutral current filtering nor line to neutral balancing connect the inverter in 3 Wire mode For applications where predominantly single phase loads are present and where there is a need for neutral current filtering and or line to neutral balancing connect the inverter in 4 Wire mode NOTE Whe...

Page 50: ...any other control wires that may be needed e g for implementing remote control functionality When finished slide the cover over the feeding cables and the earth cable 5 Connect the earth cable Cf Section 6 5 6 Connect the three power cables to the reactor terminals Cf Figure 34 WARNING The power cables are directly connected by the customer at the line reactor terminals In order to safeguard the t...

Page 51: ... to match the networks voltages The inverter nominal voltage setting must be adapted to the actual network voltage by adjusting the tap setting of the auxiliary transformer If the tap setting for your network voltage is not available then choose a tap just above the network voltage present e g for 390V network choose 400V tap setting The auxiliary transformer is situated at the bottom right side o...

Page 52: ...e three power cables and the neutral cable Whereas the three power cables can be connected as describes in item 6 of Section 6 8 1 the neutral cable has to be connected to the neutral connection point Cf Figure 36 Figure 36 Connection of the neutral cable when using the ESI S in 4 wire mode The cable lugs for the neutral cables should comply with Maximum lug width in accordance with terminal width...

Page 53: ...ws the admitted protection scheme for regenerative loads In this case if the breaker of the load trips the ESI is isolated from the energy fed back by the drive ESI 4Q load ESI 4Q load Figure 38 Incorrect connection Figure 39 Correct connection in the case of 4Q loads in the case of 4Q loads 6 9 Connection control the DC switch The ESI S is not connected directly to the battery a DC switch has to ...

Page 54: ...ected by fuses current rating 2A The measurement has to be connected to X4 3 and X4 4 in the inverter The voltage measured is the voltage between the upstream point of the islanding contactor on phase 1 and the downstream point of the islanding contactor on phase 1 see Figure 40 Regarding the black start feature optional the external box to be installed by the customer has to be supplied by the UP...

Page 55: ...complete inverter system consisting of up to 4 inverter units is 5 VA excluding connecting cables Class 1 accuracy Primary side current rating sufficient to monitor the total line current including transient phenomena such as drive motor starts It is strongly recommended that the three CTs have the same characteristics WARNING The connection of different inverter units in an ESI S system as well a...

Page 56: ...ccuracy or better NO Section of CT cables 2 5 mm recommended Determine the length of CT cables meters L m X3 L x 0 007 x 25 10 X3 VA Select 3 identical CT s such that rating at primary X2 rating at secondary 5A Burden X3 VA Class 1 accuracy or better Determine the length m and resistance Ω m of CT cables meters L m R Ω m X4 L x R x 25 10 X4 VA Select 3 identical CT s such that rating at primary X2...

Page 57: ... so may result in CT explosion and consequent damage to the installation Once the connections to the inverter have been made the shorting links must be removed The basic rules for successful CT installation are given next Cf Figure 42 The three inverter CTs have to be positioned for closed loop control i e the CT must monitor the load current and the inverter current In some cases summation CTs ma...

Page 58: ... l K L k l K L k l ESI X21 1 X21 2 X21 3 X21 4 X21 5 X21 6 X21 7 X21 8 X21 9 L1 L2 L3 To X21 1 X21 2 To X21 4 X21 5 To X21 7 X21 8 K P1 L P2 k S1 l S2 N N Figure 42 Basic CT connection example for a single unit Figure 43 Location of the CT connection terminal X21 in the ESI S The terminal block X21 can handle control cable wiring with sections from 2 5 mm to 10 mm In addition to the 6 wire CT cabl...

Page 59: ...one unit all units have to be supplied with the CT measurement information This is done by cabling the CTs in a daisy chain fashion between the different units This is illustrated in Section 6 13 3 Note in case power quality features harmonics filtering load balancing and PF correction are not required above mentioned CT s are not needed 6 13 Electrical interconnection of ESI S enclosures This sec...

Page 60: ...N bus RJ45 cable 2 CT interconnection cable 3 DC power connection to battery DC bus Four steps have to be followed to electrically interconnect a new ESI S unit with an existing inverter They are outlined in the next four paragraphs 6 13 1 Mechanical preparation of the enclosures All cables to the ESI S unit such as power cable as well as interconnection cable between modules must pass through the...

Page 61: ...op of the control board Repeat the same procedure for any other inverters to be connected Notes In the first unit of a system the left hand RJ45 socket will always be empty In the last unit of a system the right hand RJ45 socket will always be empty During the commissioning phase a unique address has to be assigned to each unit in a system through dip switch see Chapter 8 6 13 3 CT cable interconn...

Page 62: ...information on how to connect an ESI S inverter unit to the power supply can be found in Section 6 8 Regarding the power DC connection each unit has its own connection to the battery with its own DC switch WARNING Make sure that the phase rotation of the power cable connection is clockwise at the inverter terminals and that the L1 L2 and L3 terminal in each unit is connected to the same phase for ...

Page 63: ...ding on the user requirements less or more electrical connections have to be made to it Figure 48 shows the rear side layout of the ESI Manager In order to get access to the rear side of the ESI Manager remove the ESI S top cover Cf guidelines in Section 3 4 Figure 48 Rear side layout of the ESI Manager user interface When looking at the ESI Manager from the rear on the left side can be found a 15...

Page 64: ...approach is used such as is the case for the internal communication and ESI Manager power supply WARNING Before cabling any of the circuits discussed below switch off the power supply to the inverter When the inverter has already been installed on site this is done by opening the protection system located just upstream of the inverter and opening the auxiliary fuse box present in the inverter Wait...

Page 65: ... Digital input 1 15 24Vdc Remarks a Left hand terminal block when looking from rear counting from top to bottom b Acceptable power supply range 15Vdc 24 Vdc driving current 13mA 24Vdc Figure 50 Implementation of remote control functionality on Digital Input 1 of the ESI Manager WARNING If a function is assigned to a digital input the same function must never be assigned to the other digital input ...

Page 66: ...ell above the inverter safe operation level for a certain time In that case the inverter will disconnect from the network reporting a network over voltage When the network voltage returns to a normal level however the inverter will reconnect to the network and continue filtering providing that the same problem does not occur systematically 2 Internal error conditions These are error conditions tha...

Page 67: ...n error disappears When closed before remains closed When closed before opens when error disappears When open before remains open Figure 51 shows an example of an alarm contact cabling scheme using the NC alarm contact Using this scheme the bulb B will be on when the power supply to the inverter is interrupted or the inverter trips due to an error Otherwise the bulb will be off 15 16 a 17 a ESI Ma...

Page 68: ...he digital input will be low when the inverter is disconnected from the supply OR the inverter trips due to an error OR the external 24 Vdc power supply fails The voltage applied to the external digital input is high when the inverter is connected to the supply and is not in error AND the external 24 Vdc power supply is in working order 15 a 16 a 17 Alarm outputs NO NC 24 Vdc external supply Remar...

Page 69: ... In that case the desired function can be assigned to a programmable alarm which can be monitored be assigned to a digital output This type of alarm has to be cabled on the 8 pin terminal block situated at the top right corner when looking at the ESI Manager from the rear Cf Figure 48 The digital output contacts have a common point cabled on contacts 1 and 2 and are of the NO type normally open Th...

Page 70: ...ptably low Vrms_min 90 Vnominal One of the phases of the supply is missing Vrms_min 60 Vnominal Network imbalance unacceptably high Vimbalance 2 Frequency variation unacceptably high Frequency variation 20 s ESI S DC bus voltage unacceptably high Vdc 105 Vdc_max_allowed for each capacitor stack ESI S internal preload error DC capacitor voltage rise too low in preload phase or the DC capacitors cou...

Page 71: ...r In order to obtain full redundancy with inverters consisting of more than one master unit the digital outputs of all the units in a multi master arrangement have to set up and cabled in the same way The cabling scheme is given in Figure 54 Once the cabling has been finished The auxiliary fuse box may be closed The inverter top cover may be replaced including the connection of the ESI Manager to ...

Page 72: ...oltage RMS lower than preset value Supply voltage imbalance higher than preset value Ground current level higher than preset value IGBT Temperature higher than preset value Control board temperature higher than preset value Remark All warning levels can be changed by the user Any of the six digital outputs can be used to cable warning functionality A maximum of 3 warnings can be assigned to the di...

Page 73: ... The active inverter features main and auxiliary control setup modes This implies that two different compensation characteristics can be defined e g one for the day and one for the night or one for normal network operation and one for backup generator operation With the ESI Manager a set up can be made to either use always the main or the auxiliary settings In addition the possibility exists to sw...

Page 74: ...ager settings WARNING If a function is assigned to a digital input the same function must never be assigned to the other digital input Otherwise the inverter may behave erratically Table 30 Inverter behavior as a function of the ESI Manager settings for main auxiliary switching ESI Manager setup for digital input Vlow applied to digital input Vhigh applied to digital input Activ Main Auxiliary set...

Page 75: ...inverter system in which more than one master system is present the digital inputs of all masters have to be set up and cabled in the same way to obtain full redundancy Two connection approaches exist The first approach is to use one digital input for the start function and the second digital input for the stop function Table 31 shows the ESI Manager setup for the input considered and the resultin...

Page 76: ... start function and the stop function This leaves the other digital input available for the implementation of other functions Table 32 shows the ESI Manager setup for the input considered and the resulting effect when applying voltage to this input Table 32 Inverter behavior as a function of the ESI Manager settings for local start stop and using 1 digital input ESI Manager setup for digital input...

Page 77: ... start stop buttons the remote control has priority over the local start stop buttons When the local start stop command has to be given deactivate first the remote control functionality by navigating with the ESI Manager to the digital input setup menu and setting the digital input associated with the remote control to Disabled Note that in a multi unit inverter system in which more than one maste...

Page 78: ... our in house communication software called PQF Link rs232 Using any communication system supporting the Modbus TCP protocol Using any communication system supporting the Modbus RTU protocol For communication over Modbus TCP the computer can be connected through the Ethernet port using standard cable RJ45 For communication over Modbus RTU we need a RS485 Modbus adapter as shown in Figure 67 This a...

Page 79: ...Inverter ESI S Electrical design and installation 79 6 15 2 Connection of the Modbus adapter For the connection setup of the Modbus adapter please refer to the document 2GCS212013A0050 RS 485 Installation and Start up guide ...

Page 80: ...at the rear of the ESI Manager Refer to Section 6 14 for guidelines on how to do this Figure 59 Front view of the ESI Manager user interface 7 2 ESI Manager user interface description The ESI Manager is based on a touch screen user interface hence there are no hardware buttons used All user actions like moving from one to another menu or data entry are done directly by touching the soft buttons or...

Page 81: ...eral master units in parallel in a single inverter the ESI Manager on the Master unit has all the menus and options active The ESI Manager s on the Slave unit s have different screens in the sense that certain items menu buttons etc are non active and may appear greyed In case the maser unit fails and the next unit in the order takes over as new master due to redundancy feature of ESI the menu of ...

Page 82: ...will remain Ack Fault In the fault clearing process the complete inverter system will be shut down The inverter can be restarted after the fault clearing process has ended Not present the unit considered has been excluded of the normal inverter operation due to either fault or the unit is not present Master An alarm icon showing when the ESI Manager s alarm contact has been activated Cf Figure 59 ...

Page 83: ...the original appearance If a digital output is Disabled the default icon is shown Example Table 36 Digital outputs status icons Icons ESI Manager setting for digital output Output relay closes when Auxil ON Auxil OFF The auxiliary power is present in the main inverter enclosure and the main controller is communicating with the ESI Manager ESI running ESI not running The active inverter is on IGBTs...

Page 84: ...ted Pg alarm 2 The programmable alarm 2 is activated Pg alarm 3 The programmable alarm 3 is activated Warning 1 The programmable warning 1 is activated c Warning 2 The programmable warning 2 is activated c Warning 3 The programmable warning 3 is activated c Battery charging The ESS is discharging or charging the battery Connected to grid The ESS is connected to grid or islanded Following are the d...

Page 85: ...tate of charge Battery voltage Max cell voltage Min cell voltage Battery current Battery ambient temp Average cell temp Max cell temperature Min cell temperature Max charge current Max disch current ESI user State of charge Battery voltage Max cell voltage Min cell voltage Battery current Battery ambient temp Average cell temp Max cell temperature Min cell temperature Max charge current Max disch ...

Page 86: ...t current 3W or 4W Auto CT detection Man CT settings ESI Battery P Control Battery limitations Low Volt Ride Thr Black Start Derating User Main harmonics Main PFC Bal Inverter mode T Commissioning Installation set Network charact Inverter charact CT Installation Derating Start Stop set Clock Password Installation lock Battery operation Go to islanding state P Set Point Q Set Point Set language Use...

Page 87: ...he top of the screen Figure 63 Sub menu Measurements Please note that Sometimes the complete item list in a menu cannot be shown on the display This is indicated by a small symbol that appear s at the bottom right see Figure 64 Pressing this button takes the menu to the next screen where more items are available to choose from Figure 64 Illustration of arrow symbol on the ESI Manager display Somet...

Page 88: ...e menu structure and allows selecting the measurements and data as reported by different units in a multi unit inverter system Figure 66 Illustration of different menu item types The next sections discuss the four main submenus of the Welcome screen Remark This manual uses a directory structure convention to indicate a submenu The main Welcome screen is referenced as Welcome Example Welcome Measur...

Page 89: ...elp on the Voltage button is requested in the menu System Values following help will appear 7 5 The ESI Manager behavior during inverter initialization During powering up the inverter or after a system reset the inverter is initialized This includes initialization of the ESI Manager also Depending on the type of reset the initialization process of the ESI Manager results in following message displ...

Page 90: ...s are changed or a fault is acknowledged by the user the inverter resets and the following messages are displayed on the screen Please wait Resetting system Table 38 gives an overview of the initialization steps for common reset conditions Table 38 Overview of common reset conditions and corresponding ESI Manager initialization steps Reset condition after ESI Manager initialization steps Applying ...

Page 91: ...ord is a four digit number which is set by default to 1234 Entering the password is done by choosing the right value numeric keyboard which appears on the screen The password can be changed in the menu Welcome Settings Installation set Change Password Entering the new password is done the same way and confirming the password by re entering the same If hardware and software lock are combined the ha...

Page 92: ...alidation phase b In multi master inverter units this function is available on the master unit that has the control over the system In a multi unit system the ESI start stop and fault acknowledgement menu will only switch to the ACK FAULT message when the complete inverter system is shut down If one of the units of a multi unit system is shut down due to a fault this fault can be acknowledged and ...

Page 93: ...ts menu This menu allows monitoring a variety of variables e g voltage current in a variety of formats e g RMS values spectra time domain waveforms Its submenus are discussed next In multi unit inverters several parameters are measured by the individual units In order to consult measurements from a specific unit select the unit with the Select Unit option where available The order of the unit is d...

Page 94: ...al harmonic distortion of all the line currents I1 A RMS value of the fundamental component of all the line currents ESI Irms A RMS value of all the inverter currents including neutral current for 4 wire configuration P W kW MW Active power in the network at the location of the CTs P 0 Load absorbing active power P 0 Load generating active power Q var kvar Mvar Reactive power in the network at the...

Page 95: ...ported by the BMS Maximum battery current A Maximum charge and discharge currents allowed by the BMS On the display the parameters are organized in such a way that a maximum of information is obtained without having to scroll down The user may customize the display to his particular needs To do this follow the steps given below Select the measured parameter that has to be moved The selected parame...

Page 96: ...g edge zero crossing of the voltage V L1 N 4 W mode or V L1 L2 3 W mode Figure 69 Time domain waveform of line voltage displayed by the ESI Manager 3 W mode example 7 8 2 1 3 Spectrum The network voltage spectrum for all phases in chart format Figure 70 The spectral components up to the 49th order are expressed as a of the fundamental component with absolute values also shown in the top right corn...

Page 97: ...e 71 Both the absolute values and the of the fundamental component values are shown for each spectral component up to the 49th rank Figure 71 Spectrum of the network voltage in table format displayed by the ESI Manager 4 W mode example Following parameters are displayed in the sub menu Voltages itself in a tabular form The network frequency The network imbalance The inverter DC bus voltage of the ...

Page 98: ...Figure 69 All waveforms are synchronized with the rising edge zero crossing of the voltage V L1 N 4 W mode or V L1 L2 3 W mode 7 8 2 2 3 Spectrum The line current spectrum for all phases 3 W mode and the neutral current spectrum 4 W mode in chart format The chart layout is similar to the one of the voltages Figure 70 7 8 2 2 4 Harmonic table The line current spectrum for all phases 3 W mode and th...

Page 99: ...ses 3 W mode and the neutral current spectrum 4 W mode in table format for the unit selected with the Select unit option The table layout is similar to the one of the voltages Figure 71 but only absolute current values are shown 7 8 2 4 Total inverter currents Refer to Table 40 for an explanation of the parameters ESI Irms in table format for the complete inverter system 7 8 2 4 1 Waveforms The in...

Page 100: ...values for the individual units can be obtained in the Inverter currents menu 7 8 2 5 Powers The power in the system at the location of the CTs Refer to Table 40 for an explanation of the parameters Active power P Reactive power Q Apparent power S Power factor PF Displacement power factor cos ϕ The power in the system at the location of the IGBT s inverter unit measurements Refer to Table 40 for a...

Page 101: ... Select unit option Temperature of the hottest IGBT T IGBT max in a multi unit system Temperature of the control board T Control of the unit selected by the Select unit option Temperature of the hottest control board T control max in a multi unit system Temperature recorded by the optional temperature probes up to 8 probes can be connected on each ESI Manager 7 8 2 7 Battery information The batter...

Page 102: ... can be used with the logging function are voltages Vrms THDV currents Irms Power P Q S frequency and temperature T IGBT and Tcontrol along with temperatures recorded by the probes max 8 probes possible All information about temperature are specific to the probe connected to the ESI Manager where the probe is connected Refer to Table 40 for an explanation of the parameters For the frequency minimu...

Page 103: ...ioning level which allows the commissioning engineer to set up the equipment according to the customer s installation Typical parameters that need to be entered are the network voltage and frequency the CT parameters and a derating factor that needs to be applied when the installation is at great height above sea level or in conditions where excessive ambient temperatures are present At the commis...

Page 104: ...pports six languages English French Note In inverter systems consisting of more than one master the ESI Manager of the master that has the control over the system has full functionality and the ESI Managers of the other master units have limited functionality In practice the functions that are not enabled on these units are locked and a symbol will appear These functions are set up in the real mas...

Page 105: ...the power set points in kW and kvar The set points will be applied soon as the button OK is hit An internal reactive power control is available in Welcome Settings Customer set Main settings This control requires external CT s in order to measure the reactive power and correct the cos φ accordingly 7 9 2 The Customer settings menu The customer settings menu is intended to be used by people that ar...

Page 106: ...ion or one set for day settings and one set for night settings Both main and auxiliary settings windows have the same setup possibilities i e Definition of the filter mode Selection of the harmonics with setting of curve levels Selection of reactive power compensation with balancing functionality Deselection of all harmonics The inverter has to be informed about whether the main window settings or...

Page 107: ... magnitudes reach the residual level permitted by the user filtering to Curve Produce or absorb reactive power including load balancing The user can put the emphasis on one of the above effects by selecting the filtering mode Table 42 shows the three available modes Table 42 Available inverter modes Highest priority level Lowest priority level Mode 1 Active power set point filtering to curve Maxim...

Page 108: ...c order The flexibility of the ESI control is such that a specific curve level may be defined for each selected harmonic Filtered current Remaining supply current Before filtering After filtering Permitted residual level into the supply curve setting Supply current for harmonic order n Figure 74 Invertering to curve for harmonic order n The default inverter mode is Mode 3 7 9 2 1 2 Selecting the h...

Page 109: ...onic order all harmonics from 2nd to 49th order are listed but only those harmonics which are not already chosen appears selectable and those which are already in the pre selected list appear greyed Once a new harmonic order is selected the table automatically gets sorted in ascending order In order to remove any harmonic order from this list one has to touch that row and then from the dropdown me...

Page 110: ...is required to correct the problem 7 9 2 1 4 Selecting the reactive power compensation and balancing options For setting up the inverter s main reactive power and balancing mode go to Welcome Settings Customer set Main settings Main PFC Bal For setting up the inverter s auxiliary reactive power and balancing mode go to Welcome Settings Customer set Auxiliary settings Aux PFC Bal The active inverte...

Page 111: ... regardless of the value set for the target cos ϕ Fixed inductive power step with a rating of x kvar no load balancing required a PFC type Static ind Q static x kvar The inverter will absorb x kvar reactive inductive power regardless of the value set for the target cos ϕ Remarks a When load balancing is required set the Balance load flag to the desired mode The following modes are available depend...

Page 112: ...mic compensation 7 9 2 2 Temp unit This menu provides two temperature units Celsius and Fahrenheit User can choose the unit Celsius or Fahrenheit for all temperature measurements or settings 7 9 2 3 Activate menu The Activate function is used to select the setting Main or Aux with respect to harmonics PF Load balancing If the main is selected by the user in this menu the inverter operated as per t...

Page 113: ...ts and 1 alarm contact with two complementary outputs These contacts can be used to provide data to the inverter e g remote control signals and get data out of the inverter e g inverter status information alarm information etc This section discusses the ESI Manager setup for controlling all the digital I O and creating warnings and alarms 7 9 2 4 1 Alarms and warnings Programmable alarms and warni...

Page 114: ...ings levels 7 9 2 4 2 Set up of the digital inputs of the ESI Manager For setting up the digital inputs go to Welcome Settings Customer set Digital Inputs 7 9 2 4 3 Set up of the digital outputs of the ESI Manager For setting up the digital output go to Welcome Settings Customer set Digital outputs ...

Page 115: ...ingly 7 9 3 The Commissioning menu WARNING The commissioning menu is intended to be used by qualified commissioning engineers that are authorized to change the inverter s core installation settings and to set up the user s requirements In multi master units these functions need to be set up only in the master with the lowest hardware ID setting The complete commissioning procedure must be executed...

Page 116: ...cteristics and the inverter synchro mode go to Welcome Settings Commissioning Network charact The network characteristics include The nominal supply voltage This value has to be set up according to the nominal value of the grid voltage WARNING For ESI S inverter the hardware is by default set for operation at voltages in the range 380 415V When the inverter is used in networkswith voltages in the ...

Page 117: ...eristics menu the inverter system will be automatically reset after which the new values will be taken into account The inverter needs to be stopped before the network characteristics menu can be accessed Attempting to access the menu while the inverter is running will result in a fault message being displayed When involuntarily entering the menu walk through the menu by pressing the button or fol...

Page 118: ...gly WARNING Setting up a wrong inverter configuration possible in case of ESI S range may lead to inverter malfunction This should only be done by experienced commissioning engineers When entering the Inverter characteristics window first the connection mode has to be defined 3 W choose this mode when only the phases are connected In this case the inverter can inverter harmonics that are flowing b...

Page 119: ...nu walk through the menu This way the menu can be quit without modifying any values 7 9 3 3 Setting up the current transformer ratios and position The ratio of the current transformers connected to the inverter units has to be entered into the inverter system For single master units this has to be done only for that master For inverter systems consisting of more than one unit this has to be done f...

Page 120: ...or personal safety reasons close the inverter cover before launching the CT detection procedure Also ensure that the inverter CT terminals X21 are not shorted When engaging the automatic CT detection procedure the inverter will execute the following steps Deselect harmonics and reactive power balancing settings previously entered by the customer Display a warning message to wait for the identifica...

Page 121: ...his column refers to the physical location of the CT connected to the input shown in the first column Line 1 CT connected in phase 1 L1 R U with correct orientation Line1 CT connected in phase 1 L1 R U with inversed orientation Line 2 CT connected in phase 2 L2 S V with correct orientation Line 2 CT connected in phase 2 L2 S V with inversed orientation Line 3 CT connected in phase 3 L3 T W with co...

Page 122: ...detection ratio results presentation Text on ESI Manager display Meaning Ratio found Ratio found for the CT in the considered phase E g 200 means a CT of 1000 5 CT Ratio L1 a Ratio that will be used by the inverter for the CT physically connected in phase 1 L1 R U of the installation CT Ratio L2 a Ratio that will be used by the inverter for the CT physically connected in phase 2 L2 S V of the inst...

Page 123: ...ll be ended The unsuccessful CT detection attempt is recorded in the event logging window Conditions under which the automatic CT identification process may give unsatisfactory results include The use of CTs with extremely high ratio s 20000 5 This will result in an error message indicating inconsistent CT positions In this the ratio of the summation CTs that may be present should be included The ...

Page 124: ...n the right phase but inversed enter Line 1 for the CT connected to the inverter CT terminals X21 4 5 Input 2 in which line phase is it installed Line 1 Line 2 Line 3 does the CT cabling have the good orientation Line x or not Line x Remark If the CT installation is correct enter Line 2 If the CT is installed in the right phase but inversed enter Line 2 for the CT connected to the inverter CT term...

Page 125: ...n the other units Section 8 6 gives guidelines on how to identify the position of the CTs in case the automatic CT detection procedure cannot be used or is unsuccessful Refer to Section 6 9 and Section 6 12 for more information on the selection and the installation of the current transformers 7 9 3 4 Setting up the inverter rating parameter ESI battery menu allows the customer to set the type of a...

Page 126: ...r entering the rating parameter go to Welcome Settings Commissioning Derating The permissible ambient conditions for ESI operation are laid out in Table 15 If the inverter is installed at locations higher than 1000 m 3300 ft above sea level the maximum inverter output current must be derated by 1 every additional 100m 330ft ...

Page 127: ...fter approving the new rating value the inverter will reset and the new value will be taken into account In practice this implies that the output current of the unit will be limited to the inverter nominal current times the entered rating factor E g a rating factor of 50 implies that the maximum RMS inverter current is half the nominal inverter current Pressing will result in the original value be...

Page 128: ...on on the main and auxiliary inverter settings the inverter mode the harmonics selection table and reactive power setup possibilities A more complete user set up process can be done at the customer settings level cf Section 7 9 2 In order to interrupt the set up process press repeatedly until the stop message appears It should be noted that any parameters entered before the procedure is stopped wi...

Page 129: ...nded that all the temperature probes are connected to the ESI Manager installed on the unit assigned the Master status In case of failure of Master unit the next unit assumes the role of Master however the temperature probe connection needs to be physically shifted to the new Master unit and commissioning of probes be redone on the new ESI Manager for the probes to function properly 7 9 4 The Inst...

Page 130: ... an overview of the installation settings More specifically the following settings can be read Settings for the nominal voltage frequency and synchro mode Welcome Settings Installation set Network charact Inverter characteristics Welcome Settings Installation set Inverter charact CT installation settings Welcome Settings Installation set CT Installation Rating setting Welcome Settings Installation...

Page 131: ...ull redundancy The standby function when enabled puts the inverter in standby a preset time after the load requirement disappears In this condition the IGBTs stop switching while the main contactor remains closed inverter remains connected to the network This way the inverter losses become virtually zero The inverter will resume normal operation a preset time after the load requirement comes back ...

Page 132: ...ions need to be set up in each master unit in order to obtain full redundancy The auto restart function when enabled ensures that the inverter restarts automatically after a power outage if the inverter was on before the power outage occurs A time delay can be programmed to define how long after the power returns the inverter will restart When the auto restart function is disabled the inverter wil...

Page 133: ... is set up for the time zone GMT 1 7 9 4 4 Setting Password For setting up the password go to Welcome Settings Installation set Password A password setting allows the user to set a software lock of the settings Once set and the installation are locked the crucial parameters cannot be changed unless the software lock is removed A customer can choose a 4 digit password of his choice to activate the ...

Page 134: ...irst With correct password entered the installation gets a software lock and changing of key parameters is prohibited The software lock can be disabled after checking the Installation Unlocked check box This checkbox can be used only after entering the right password 7 9 5 Set Language This menu allows the user to choose one of the two languages English French available in the ESI Manager The defa...

Page 135: ... network conditions Where applicable the different units in an inverter system can be selected to get more detailed information on parameters of the individual unit The ESI monitoring menu can also be used to check the status of individual units of a multi inverter system If required errors in individual units can be reset The items of the ESI Monitoring menu are discussed next 7 10 1 The Status o...

Page 136: ...ut down The inverter can be restarted after the fault clearing process has ended Not present The unit considered has been excluded of the normal inverter operation due to either The unit is physically not present The unit is physically present but the control board power is not present 7 10 2 The Inverter load menu The inverter load menu shows bar graphs expressed in indicating the inverter load w...

Page 137: ...Table 48 Table 48 Item explanation of the event window Item Explanation 1 Event number 0 199 The smaller the number the more recent the event 2 Event type Table 49 gives an overview of the possible event types 3 Date and time at which the event occurred 4 If the event reported is a fault which is considered critical by the system a Critical indication will appear on the screen 5 Fault description ...

Page 138: ...reported by the DSP relate predominantly to the inverter interacting with the installation Table 50 gives an overview of the faults that can be reported by the DSP controller The list is in alphabetical order Table 50 Overview of the faults that can be reported by the DSP controller DSP fault message Description Bad CT connection The automatic CT detection procedure has encountered a problem durin...

Page 139: ...h Unbalanced supply The supply imbalance is out of range Under voltage RMS The RMS value of the supply voltage is lower than the acceptable minimum value Unstable mains frequ The network frequency is varying too fast Wrong phase rotation The inverter is fed by a supply system which has the wrong phase rotation SPI Timeout Internal system error Global BESS fault The system encountered an issue duri...

Page 140: ...if the BMS is not answering at the startup of the system power is supplied to the control BMS cont trip Trip of the DC contactor For guidelines on how to troubleshoot and solve the reported problems refer to Chapter 11 For multi unit inverters this data can be obtained for each individual unit Internal system errors are most likely due to faulty hardware and thus the only solution may be to exchan...

Page 141: ...ble warnings refer to Section 7 9 2 4 and the list of possible warning in the detailed manuals Table 52 shows an overview of the warning messages that will be displayed and the corresponding warning condition For multi master inverters this data can be obtained for each individual unit Table 52 Warning messages that can be displayed by the ESI Manager and corresponding warning conditions Warning c...

Page 142: ... parameter indicates the total operating time of the inverter inverter on The Fan operation parameter indicates the total operating time of the fans cooling the inverter The reset fan operation button resets the number of fan operation and should be used after a fan is replaced For multi master inverters this data can be obtained for each individual unit If a problem exists an external interventio...

Page 143: ... allows the touch screen to be configured and Communication setting to be performed 7 11 1 Manufacturer setting This menu gives basic data on the inverter Basic manufacturer settings such as inverter type maximum voltage rating and inverter serial number These settings can be accessed in Welcome User Interface Manufacturer set 7 11 2 About ESI ...

Page 144: ...unit 7 11 3 Screen configuration These settings can be accessed in Welcome User Interface Screen Config Two main buttons Touch Screen Cal and Backlighting allows the user to calibrate the touch screen and adjust the backlighting to the optimal level The touch screen calibration is normally not needed in a reasonable use of the screen and in standard environmental conditions To prevent loss of the ...

Page 145: ...ations methods In this main menu it includes the settings for Modbus and Ethernet and the MAC and IP addresses More information regarding the Modbus USB and TCP IP protocol and programming please refer to manual 2GCS239011A0070_ESI Manager communication with Modbus RTU Modbus TCP and PQF Link protocols When the communication is unlocked see Figure 76 the user can change parameter setting of the in...

Page 146: ... e g Modbus or TCP IP based with help of PQF Link software In other words locking the communication is equivalent to using the hardware lock in the back side of the ESI Manager Figure 77 Communication locked 7 11 4 1 Modbus RTU The slave address is the one used by the Modbus master to address the ESI through Modbus Baud rate Parity Stop bit shall match exactly the communication settings of the Mod...

Page 147: ...pter is an optional device for the inverters which enables the connection of the ESI Manager to a RS485 Modbus system The controller is considered as a slave unit in the Modbus network Refer to the 2GCS214013A0050 RS485 adapter User guide for more information on the RS485 Modbus Adapter 7 11 4 2 MAC address ...

Page 148: ...SI IP address mask address and gateway IP address Depending on the DHCP status the displayed data may be different The below screens give the result for the above Example 1 and 2 Example 1 The below screen shows the actual IP address fixed with DHCP disabled Example 2 The below screen shows the actual settings resulting from the automatic IP address resolution with DHCP enabled ...

Page 149: ...ateway or Ethernet LAN set DHCP to enable Some examples are given below Example 1 The below screen shows the default settings to connect directly to a PC note that the PC need to be configured accordingly with a fixed IP address of 192 168 1 40 Subnet mask of 255 255 255 0 DHCP disabled Figure 78 ESI TCP IP protocol setting Example 2 The below screen shows the default settings to connect to an Eth...

Page 150: ...o initialize it with these parameters Ethernet TCP IP TCP IP connections can be indifferently initiated locally or remotely The TCP port used by default is 4250 The connection to the ESI Manager is an RJ45 Cat5e Ethernet cable The ESI Manager can be connected directly to a LAN or through Internet USB The USB interface is used to present the ESI Manager as a serial interface on its USB port The com...

Page 151: ...torage Inverter ESI S The ESI Manager user interface 151 Caution The USB connection to the ESI Manager is not isolated It is mandatory to connect the protective EARTH connection when using the USB 7 11 4 4 IP address ...

Page 152: ...ddress and when the inverter is reset the new IP address is copied in the window under menu IP address Figure 79 Ethernet settings If the DHCP client is enabled see Figure 79 the customer s system automatically assigns an IP address to the ESI Manager which is visible in the window under menu IP address In this case the IP address in the window under Menu Ethernet Setting Menu still remains what t...

Page 153: ...he Modbus option has been installed please refer to the document 2GCS212013A0050 RS 485 Installation and Start up guide for more information on this item The commissioning procedure consists of 9 steps that should be strictly followed Table 53 Steps to follow to commission the inverter Steps Actions Step 1 Visual and installation check Step 2 Setting the address of each unit in a multi unit invert...

Page 154: ...result in severe damage to the inverter and or battery WARNING Make sure that the inverter is installed at a location where no conductive dust is present Conductive dust when distributed in the inverter panel may lead to equipment failure Check that the mechanical and electrical installation fulfils the requirements described in Chapter 5 and Chapter 6 of this manual Pay attention to the ambient t...

Page 155: ...owest address must be assigned to the master unit that is considered as the main controlling unit When the main master unit is faulty the master unit with the next lowest address will become the main controlling unit In order to set the address of each unit in a system the DIP switch module on the control board has to be set accordingly Figure 80 shows the location of the DIP switch on the control...

Page 156: ...system not being able to start up and go in error Bad Ratings When a system consists of more than one unit attention has to be paid to the proper termination of the communication bus between the different units This communication bus is depicted in the below Figure 81 by the black lines interconnecting the different units Control board in the previous unit Control board in the next unit From previ...

Page 157: ...perate on networks where the supply voltage is up to 10 higher inclusive of harmonics but not transients or lower than the voltage range it is set up for Since operation at the upper limits of voltage and temperature may reduce its life expectancy the ESI S should not be connected to systems for which it is known that the overvoltage will be sustained indefinitely The voltage phase rotation at the...

Page 158: ...rect the installation should be corrected before applying power to the inverter to avoid potential inverter malfunctioning and or damage 8 5 Step 4 Basic commissioning parameters set up using ESI Manager In order to set up the basic commissioning parameters with the ESI Manager navigate to Welcome Settings Commissioning Cf Section 7 9 3 An overview of the main menus of the ESI Manager is given in ...

Page 159: ...w to enter the derating value refer to Section 7 9 3 5 The battery limitations According to the specification of the battery limitations can be set in the inverter control These limitations are concerning the voltage battery and cell temperature battery and cell and current battery Remarks Although the user requirements can be set up from the commissioning window this should not be done before the...

Page 160: ... the units of a system have to be supplied with the same CT information daisy chain principle with return path as shown in Figure 47 All shorting links in the CT path have been removed i e on the CTs on the inverter CT terminal X21 CT shorting links are provided with the ESI S for servicing purposes but they are not installed by default on the X21 terminal The CT settings can be detected with the ...

Page 161: ...its terminals which can lead to physical danger or destruction of the CT 8 6 2 1 ESI connection diagram Figure 82 shows the standard connection diagram for the ESI Cf Section 7 9 2 It must be noted that L1 L2 and L3 rotation must be clockwise The CTs must be on the supply line side of the ESI The CT monitoring a phase must be connected to the inverter CT terminal dedicated to the same phase One se...

Page 162: ...llation manually is to use the waveform displays of the ESI Manager In this it should be noted that all waveforms displayed are synchronized on the rising edge zero crossing of the voltage V L1 N Note however that this approach requires some experience 8 6 2 3 Checking the correct connection of the CTs with a two channel scopemeter The first channel of the scopemeter must be connected to the phase...

Page 163: ... extrapolate the fundamental component as it is the most important one Figure 85 Remark If the earthing of the system is bad the phase to ground voltage may appear like a much distorted waveform In this case it is better to measure the phase to phase voltage move the black clamp to the phase L2 and subtract 30 on the measured phase shift Figure 85 Extrapolation of the fundamental component from a ...

Page 164: ...he same operations as those described in the previous paragraph must be repeated with the phase L2 Figure 87 and phase L3 Figure 88 For a balanced load which is usually the case in most of the three phase systems the phase shift should be approximately the same for all the three phases L1 L2 L3 Load side Supply side K L I k K L I k K L I k ESI L1 L2 L3 Positive direction Ch1 Ch2 N N X21 1 X21 2 X2...

Page 165: ...rules are taken it is possible to use the two channel scopemeter in order to see if the current measured through the CT is matching the real current in the bus Connect the current probes as shown on Figure 89 The two traces must be in phase and of the same shape the magnitude could be different as the gains are different if the wiring is correct L1 L2 L3 Load side Supply side K L I k K L I k K L I...

Page 166: ...the system such as the Master Controller System Verify that all battery information is received by the inverter The battery voltage reported on the ESI Manager information coming from the master controller is matching the real battery voltage The protection of the battery is closed The battery is ready to start Before switching the inverter ON ensure that all features have been deselected For dese...

Page 167: ...mation and then it will start The main contactor should close within 30 seconds One second after closing the IGBTs will start and the inverter will charge the DC capacitors in order to reach the battery voltage Once it reach it the inverter will close the DC contactor and will be connected to the battery without power flow The START indication in the start stop menu changes in a STOP indication on...

Page 168: ...11 for troubleshooting the problem When harmonic load is not present the inverter can be tested by generating static reactive power Initially a low value can be set which can then be gradually increased to the nominal inverter rating For setting up the inverter s main reactive power feature go to Welcome Settings Customer set Main settings Main PFC Bal For setting up the inverter s auxiliary harmo...

Page 169: ...c After this process the inverter will launch the filtering process for the component considered If during the network identification process for a given harmonic a special problematic condition is encountered the system puts the component in standby In that case the harmonic selected is not filtering for the time being Special network conditions include extremely high impedance of the supply netw...

Page 170: ...5 indicates the harmonics recommended to be deselected for different types of detuned banks Table 55 Recommended harmonics to be deselected for different detuned bank types Detuned bank type Harmonics recommended to be deselected 5 67 2 3 4 6 2 3 4 7 2 3 14 2 For other types of detuned bank please contact your ABB Service provider to evaluate the resonance frequency and the harmonics that are reco...

Page 171: ...ncy of the passive inverter If these harmonics are selected the SDP function may stop filtering these harmonics temporarily resulting in a reduced overall filtering performance In installations where 2 non compatible masters are connected to the same CT respect the following guidelines for best performance 1 Select different harmonics on both units 2 If 1 above is not possible put one inverter in ...

Page 172: ... W Unit ratings serial number b Rating A Serial number Article code b Unit 1 M Unit 2 M S d Unit 3 M S d Unit 4 M S d Software version c ESI Manager software µcontroller software DSP software Installation location Remarks a Read from main identification tag located on the master enclosure b Read on identification tag located at the outside of each enclosure c After the inverter has been commission...

Page 173: ...verter from the supply disconnection recommended by upstream protection If inverter connected to the supply before wait for 25 minutes to discharge DC capacitors Remove the right side of the protective cover of the inverter Ensure that the left side of the protective cover is in place Disconnect ESI Manager if required Open auxiliary circuit fuse protection box DC capacitor voltage low enough to o...

Page 174: ...aster units running as slave Program equipment b Network characteristics Supply voltage V Supply frequency Hz Synchro mode should normally not be changed default value is Single ph inverter ratings Connection mode 3 wire or 4 wire Battery limitations are set according to the battery specification CT position and ratio for first unit Automatic detection feature used YES NO Inverter terminal Input 1...

Page 175: ...lcome Settings Customer set Alarms 8 11 4 Testing with load Before starting the inverter OK NOK Set the power target to zero Deselect all harmonics and reactive power balancing a Start the inverter b Fans start running While the inverter is running c Charge and discharge the battery If harmonic load is present select for example the 11th harmonic Check the line current Irms 11th harmonic level and...

Page 176: ...Bal Auxiliary settings Aux PFC Bal PFC type PFC type Disabled Disabled Static ind Static ind Q static kvar Q static kvar Static cap Static cap Q static kvar Q static kvar Dyn ind Dyn ind Target cos ϕ Target cos ϕ Dyn cap Dyn cap Target cos ϕ Target cos ϕ Balance load Balance load Disabled Disabled L L L L Harmonics Main settings Main PFC Bal Auxiliary settings Aux PFC Bal 1 1 2 2 3 3 4 4 5 5 6 6 7...

Page 177: ...og alarm 3 V min warn Alarm delay V max warn Alarm rst del Imbalance Ground fault Prog warnings Prog warn 1 Prog warn 2 Prog warn 3 Warning delay Warn rst del Digital Inputs Digital Outputs Dig In 1 Dig Out 1 Dig In 2 Dig Out 2 Dig Out 3 Dig Out 4 Dig Out 5 Dig Out 6 Start Stop set Communication Stdbystatus Protocol Standby level Modbus Stdbydel off Baud rate Standby hyst Parity Stdbydel con Stop ...

Page 178: ...torage Inverters ESI Issued by Commissioning report Date Page 7 of 7 178 Commissioning instructions Manual Power Quality Inverter ESI S 8 11 6 Comments Commissioning Engineer Customer s representative Name Signature Date ...

Page 179: ...tics and manufacturer data Inverter behavior on faults retrieving error information Note that in the context of this manual the ESI Manager is used to operate the inverter Background information on the ESI Manager can be found in Chapter 7 Alternative ways to operate the inverter are Using the optional PQF Link software Refer to the PQF Link installation and user s guide for more information on th...

Page 180: ...e inverter start stop menu ESI item in the list In this menu the START indication should be visible Press The system will ask confirmation and then it will start The main AC contactor should close within 30 seconds and one second after closing the IGBTs will start The inverter will increase its DC voltage in order to reach the battery voltage then it will close the DC contactor This operation may ...

Page 181: ...s given in Section 6 14 1 and Section 7 9 2 4 If the hardware lock and or the Communication lock has have been engaged the inverter cannot be started nor stopped In order to see which lock s has have been engaged push when the start stop menu is highlighted A message will appear to indicate which lock s has have to be disengaged If authorized disengage the relevant lock The hardware lock can be di...

Page 182: ...tors voltage check the closure of the inverter AC contactor the start of fan and the starting of the IGBTs If harmonics mitigation feature is activated the network identification may be done after the start up sequence has finished This network identification will always be done when harmonic components were selected and the supply to the inverter was removed before or when new harmonic components...

Page 183: ...r repeatedly until the Welcome screen is displayed Highlight the inverter start stop menu ESI item in the list In this menu the STOP indication should be present Press The inverter will ask confirmation and then it will stop The main contactor will open The STOP indication in the start stop menu changes in a START indication once the inverter is stopped Remarks If the start stop menu reads ACK FAU...

Page 184: ...e menu Welcome User interface Communication by ticking the check box More information on the Communication lock is available in the document 2GCS212013A0050 RS 485 Installation and Start up guide The stop sequence conducted when a stop command is given can be derived from the following flow chart System is running Stop request Stop IGBT s Open the DC contactor Controller running DC capacitors char...

Page 185: ... 1 Circle 2 Circle 3 Circle 1 Circle 2 Circle 3 Figure 94 PQ diagram As shown in Chapter 8 the target of the active power can be or in kW on the AC side or in kW on the DC side To set the active power target on the ESI manager Press on the ESI Manager repeatedly until the Welcome screen is displayed Press the inverter Settings menu In this menu press on Battery operation In this menu the window sh...

Page 186: ...r generators such as wind turbines solar panels as shown on Figure 95 The island is physically disconnected thanks to a switch from the supply This avoid any issue when the supply is back because both voltages are not synchronized Loads Three phase Single phase Generation Wind turbines Solar panels ESS Supply 1 2 Island Figure 95 Island setup Item Description 1 AC voltage measurement 2 Islanding c...

Page 187: ...g mode Leaving the islanding mode 9 3 3 2 Going to the islanding mode When the unit connected to the network grid the ESS is charging or discharging the battery based on the request If the user requests to switch to the islanding mode it can be done on the ESI Manager Press on the ESI Manager repeatedly until the Welcome screen is displayed Press the inverter Settings menu In this menu press on BE...

Page 188: ... SOC and the min SOC set during the commissioning the system stops Max min voltages battery and cell if the battery reach the limits set during the commissioning the system stops Max min temperatures battery and cell if the battery reach the limits set during the commissioning the system stops 9 3 3 4 Resynchronization of the island If the user or the main controller system is requesting to leave ...

Page 189: ...main AC contactor should close within 30 seconds and one second after closing the IGBTs will start The inverter will increase its DC voltage in order to reach the battery voltage then it will close the DC contactor This operation may take up to 30 sec After this operation the system is ready to charge or discharge the battery The START indication in the start stop menu changes in a STOP indication...

Page 190: ...settings menu Welcome Settings Installation set These advanced functions include the autorestart function after power outage the standby function to switch off the IGBTs when the load requirement is low the system clock setup the software lock activation and password setup for inverter protection purposes Refer to Section 7 9 4 for detailed information on these topics It is recommended that the ad...

Page 191: ...nverter behavior on fault retrieving error information Under normal conditions the inverter is either running or stopped and the ESI item in the ESI Manager Welcome screen shows the message START or STOP In this case if the inverter is stopped it can be started and if it is running it can be stopped The start and stop commands will be stored in the event log accessible in Welcome ESI Monitoring Ev...

Page 192: ...disappears the user may decide to give an inverter stop command This is done by highlighting the ESI ACK FAULT item in the Welcome menu and selecting After this the Armed indicator will be OFF The green and red LED on the main controller board Cf Table 13 item 18 LEDs 2 and 3 will be OFF too Stop briefly without opening the main contactor and continue to run when the error has disappeared This is ...

Page 193: ...If the inverter is in remote control operation and the message ACK FAULT is present on the ESI Manager the fault can be acknowledged by sending a STOP command by remote control low signal Alternatively the remote control functionality can be disabled by disabling the corresponding digital input functionality Then the fault can be acknowledged locally Refer to Chapter 11 for advanced troubleshootin...

Page 194: ...no circumstances close the DC and AC contactor manually Failure to adhere to this guideline may result in physical injury and or in inverter damage 10 2 Maintenance intervals Table 56 lists the routine maintenance intervals Depending on the operating and ambient conditions the intervals of Table 56 may have to be reduced Announced intervals assume that the equipment is operating under ABB approved...

Page 195: ...ing its output current due to temperature problems By default the T Limit indicator is assigned to digital output 6 of the ESI Manager Make a note of the ESI operation hours Welcome ESI monitoring ESI operation and the fan operation hours Welcome ESI Monitoring Fan operation For units up to 60A if the fan operation indicator shows a multiple of 40000 hours it is recommended that the fan be replace...

Page 196: ...hat the AC and DC contactor can move freely If bad fuses are found upstream or in the unit replace them If the fuse in one phase is bad it is good practice to change the fuses of all phases More information on the fuses to use is given in Section 6 7 and in Chapter 12 10 3 6Step 6 Check the tightness of the electrical and mechanical connections Ensure that all electrical connections are properly f...

Page 197: ... follow the instructions below Cf Figure 96 Ensure that the power to the inverter is switched off upstream Wait for at least 25 minutes to allow for the DC capacitors to discharge Remove the cover on the right hand side of the ESI S and disconnect the fan terminals at the bottom of the inverter next to the IGBT bridge for the fan in and on the top right of the PCB for the fan out Remove the screws...

Page 198: ...he DC capacitors must be reformed re aged before use Without reforming the DC capacitors may be damaged at start up Stocked or non operational units should be reformed once a year The method described here assumes that the inverter is stocked in a clean and dry environment To reform the capacitors Switch on the power supply to the inverter without starting the inverter for about 2 hours Verify wit...

Page 199: ... Unit ratings serial number b Rating A Serial number Article code b Unit 1 M Unit 2 M S d Unit 3 M S d Unit 4 M S d Software version c ESI Manager software µcontroller software DSP software Installation location Remarks a Read from main identification tag located on the master enclosure b Read on identification tag located at the outside of each enclosure c After the inverter has been commissioned...

Page 200: ...r on digital output monitor on digital output 6 by default Y N If answer if Y to any of the two questions above check inverter cooling ESI operation hours Fan operation hours If fan operation hours are multiple of 40000 hrs for units up to 60A and of 35000 hrs 27000 hrs for units with higher ratings exchange fan Event logging window Abnormal events present Y N If Y describe them in the comments se...

Page 201: ...ections fixations if necessary Correct the outstanding problems Reclose the auxiliary fuse box and refit the inverter protective cover Reclose the inverter upstream protection Restart the system ESI Manager booting DC capacitors charging Start the inverter Fan s start s running If major servicing work has been done follow the commissioning instructions to start the inverter 10 7 3 Special service ...

Page 202: ...nergy Storage Inverters ESI Issued by Servicing report Date Page 4 of 4 202 Maintenance instructions Manual Power Quality Inverter ESI S 10 7 4Comments Service Engineer Customer s representative Name Signature Date ...

Page 203: ...emoved These tests must be carried out only by authorized and qualified personnel in accordance with the local regulations Apply the safety guidelines that are presented in Chapter 2 Failure to adhere with the safety guidelines may result in lethal physical injury 11 2 Fault treatment procedure All faults that occur are stored in the inverter event log and are analyzed by the inverter controller T...

Page 204: ...ger will switch on after a programmable delay and the Armed indicator will be ON If it takes a long time before the fault disappears the user may decide to give a inverter stop command This is done by highlighting the ESI ACK FAULT item in the Welcome menu and selecting After this the Armed indicator will be OFF Stop briefly without opening the contactors and continue running when the error has di...

Page 205: ...erter ESI S Troubleshooting guide 205 Green LED is LED2 on the main controller board and is Armed indicator on PQF Manager Red LED is LED3 on the main controller board Figure 98 ESI error treatment procedure in flowchart format ...

Page 206: ...arts for normal and dedicated inverter servicing Ref Description Order code Recommended quantity 1 Spare fuses for auxiliary circuit 2GCA100465A0420 3 2 Spare fuses for pre load circuit 2GCA113178A0420 2 3 ESI Manager controller 2GCA294781A0079 1 4 Assy cooling fan in ESI S 30 100A 2GCA294292A0075 1 5 Assy cooling fan in ESI S 120 A 2GCA294290A0075 1 6 Assy cooling fan out ESI S 30 60A 2GCA294201A...

Page 207: ...t tracing Table 59 Power supply problems Symptom Cause What to do No display on ESI Manager All the indicator LEDs on the electronic cards LEDs remain OFF The inverter auxiliaries is are not energized or no power supplied to the inverter Check if the protection fuses disconnector feeding the inverter are OK Check if the auxiliary fuse box is closed and the fuses are OK Check the mains and auxiliar...

Page 208: ...lving the problem the fault has to be acknowledged and the inverter has to be restarted manually One of the two controller LEDs 1 4 on the main controller board is not blinking while the other one is One of the controllers is not starting up properly Eventually the red LED 3 will switch on Check the inverter event log to analyze the critical errors Refer to Table 61 to know what to do in order to ...

Page 209: ... phase Disable all features Deselect the high frequency components to free DC bus resources and to see if the problem persists DC overvoltage HW The DC hardware overvoltage protection has been triggered Check the connection between the DC voltage measurement connectors P6 5 and P6 7 and the DC capacitors Check flat cable connections between the Control Board and the IGBT module Analyze network vol...

Page 210: ... IGBT module Verify flat cable connection between the Control board and the IGBTs Ensure that the Control board power supply is around 24 V If significantly lower check the 24 V power supply and the wiring between this supply and the Control board IGBT temporary The IGBT modules report a transient error that could be automatically cleared by the system This error can be due to peak overcurrent or ...

Page 211: ... not solve the problem contact your ABB service provider No synchronization The system cannot synchronize on to the network The supply frequency has changed too much or too fast No low voltage measured during inverter initialization Wrong frequency set up Measure the network frequency and its variation and check if they are within limits Check the phase rotation only in case of modification at the...

Page 212: ...o the checks discussed for the Loss of phase fault Check the earthing of the unit Overcurrent RMS The system has detected RMS overcurrent in the inverter Verify that the inverter CTs are properly installed and are not shorted Verify that the unit current ratings and order programmed at the commissioning stage corresponds to the rating and order physically present Verify the inverter cooling system...

Page 213: ... The supply network imbalance is out of range Measure the three line voltages and check if they are within limits including the imbalance limit Measure the line voltages e g voltmeter and compare them with the line voltages given by the inverter ESI Manager or PQF Link Ensure that the AC voltage is properly measured Do the checks discussed for the Loss of phase fault Check the earth of the unit Un...

Page 214: ...ter current Remark If the problem persists contact your ABB service provider Provide him with all the relevant information i e Inverter serial number and type status of the control LEDs Error messages displayed and inverter behavior Table 62 Fault messages reported by the µcontroller of the inverter and troubleshooting tips Fault message Cause What to do Com Problem RS 232 Communication problem be...

Page 215: ...measurement board Several units same id Two or more units in an inverter system have the same CAN_ID Check the CAN_ID of the different units in the set of inverters each unit has to have one unique CAN_ID on the DIP switch S5 1 to S5 3 Reset the inverter by switching off and on the power If the problem persists contact your ABB representative The controller card must probably be replaced Com Probl...

Page 216: ...Inverter is sent Remark If the problem persists contact your ABB service provider Provide him with all the relevant information i e Inverter serial number and type status of the control LEDs Error messages displayed and inverter behavior Table 63 Other inverter indications and behavior with corresponding troubleshooting tips Symptom Cause State What to do The inverter is working at 100 of its nomi...

Page 217: ... is operating in Mode 3 If the problem persists contact your ABB representative Two master units are fed from the same CTs The setup guidelines for this installation setup have not been implemented Interconnect the units with an RJ 45 cable If this is not possible Select different harmonics on both inverters If not possible ensure that one inverter is operating in Mode 1 and the other inverter is ...

Page 218: ...ee a list of most recent critical errors Look in the inverter event log for more information on which errors have occurred Refer to the Table 61 and Table 62 for more information on these errors and for guidelines on how to troubleshoot them Remark If the problems persist contact your ABB service provider Provide him with all the relevant information i e inverter serial number and type status of t...

Page 219: ...0 C 104 F for derating refer to Table 15 Recommended maximum average temperature over 24 h 35 C 95 F Relative humidity Max 95 non condensing Contamination levels IEC 60721 3 3 Chemical class 3C2 for more information refer to Table 15 Mechanical class 3S2 for more information refer to Table 15 Vibration IEC 60068 2 6 Max 0 3mm 2 9Hz Max 1m s2 9 200Hz Shock IEC 60068 2 27 Max 40m s 22ms Inverter ins...

Page 220: ...Auxiliary circuit voltage 230 Vrms Neutral connection systems if any IT TT TNC and TNS Earth current protection type and sensitivity must be chosen appropriately Environment class 2 Compliance with standards IEEE 1547 pending General construction aspects EN 61439 1 ed 2 0 EMC immunity EN IEC 61000 6 2 Industrial level EMC emissions EN IEC 61000 6 4 Inverter characteristics RMS output current per p...

Page 221: ...ency Better than 97 of inverter rating typically Reaction time 500 s Response time P and Q 200 500 ms 40 ms typically 10 90 filtered Reactive power Static dynamic Power factor programmable from 0 6 inductive to 0 6 capacitive Load balancing Off Phase to phase phase to neutral if neutral present both if neutral present Setting possibilities Main and auxiliary settings functionality Three possible i...

Page 222: ... earth resistance 1 MΩ inverter unit Noise intensity at one meter 30A 60A 65 3 dBA typically 70A 100A 68 4 dBA typically 120A 70 9 dBA typically Communication Through ESI Manager display Through Modbus RTU with optional RS485 Modbus Adapter Through Modbus TCP with Ethernet Through dedicated optional software PQF link with USB Ethernet Programming Through ESI Manager display Through USB Ethernet wi...

Page 223: ...f this document without prior notice With regard to purchase orders the agreed particulars shall prevail ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document We reserve all rights in this document and in the subject matter and illustrations contained therein Any reproduction disclosure to third parties or utilization of its content...