M32 Flywheel Installation & Maintenance Manual: v1.0 September, 2017

M32 FLYWHEEL
INSTALLATION & MAINTENANCE

MANUAL
v1.0
September, 2017
ii
DISCLAIMER
The information contained herein is for informational
purposes only and is subject to change without notice.
While every precaution has been taken in the
preparation of this document, it may contain technical
inaccuracies, omissions, and typographical errors, and
Amber Kinetics, Inc. is under no obligation to update
or otherwise correct this information. Amber Kinetics,
Inc. makes no representations or warranties with
respect to the accuracy or completeness of the
contents of this document, and assumes no liability of
any kind, including the implied warranties of non-
infringement, merchantability or fitness for particular
purposes, with respect to the operation or use of
Amber Kinetics hardware, software, or other products
described herein. No license, including implied or
arising by estoppel, to any intellectual property rights
is granted by this document. Terms and limitations
applicable to the purchase or use of Amber Kinetics
products are as set forth in a signed agreement
between the parties or in Amber Kinetics Standard
Terms and Conditions of Sale.
©2017 Amber Kinetics, Inc. All rights reserved. Other
names are for informational purposes only and may be
trademarks of their respective owners.
M32 FLYWHEEL - INSTALLATION & MAINTENANCE MANUAL Copyright 2017 by Amber Kinetics. All rights reserved.
ii
Table of Contents
1 - Introduction ........................................................................... 1 4 - Testing and Commissioning .........................................31
1.1 - Features and Benefits ...............................................2 4.1 - Pre-Commissioning Steps ....................................32
1.2 - M32 Flywheel Description ......................................3 4.1.1 - Documentation Review .................................... 32
1.3 - Theory of Operation .................................................5 4.1.2 - Installation Review ............................................ 32
1.4 - Specifications & Performance ...............................6 4.2 - M32 Flywheel Spin-up ..........................................33
1.5 - Safety Features ...........................................................7 4.2.1 - Initial Startup ....................................................... 33
1.6 - About this Manual ......................................................8 4.3 - Power Cycle .............................................................34
1.6.1 - Formatting Conventions .....................................8 4.4 - Commissioning Report & Template ................35
1.6.2 - Organization ...........................................................9
1.7 - About Amber Kinetics ............................................10 5 - Maintenance .......................................................................37
1.7.1 - Support Policy ......................................................10
2 - Safety .....................................................................................11
3 - Installation ...........................................................................15
3.1 - Planning ....................................................................... 16
3.2 - Equipment & Tools ................................................. 17
3.3 - Site Preparation ....................................................... 18
3.4 - Capsule Placement ................................................. 19
3.5 - M32 Flywheel Preparation ................................... 21
3.6 - M32 Flywheel Placement .................................... 24
3.7 - Electrical Connections ......................................... 26
3.8 - Completing the Installation ................................30
Copyright 2017 by Amber Kinetics. All rights reserved. M32 FLYWHEEL - INSTALLATION & MAINTENANCE MANUAL
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1
1 - Introduction
Welcome! This chapter introduces the M32 flywheel by Amber Kinetics by
providing the following general information:
• Features and Benefits: Why the M32 flywheel compares well to batteries.
• Description: Key components of the M32 flywheel.
• Theory of Operation: How the M32 flywheel stores and discharges energy.
• Specifications: Basic mechanical and electrical specifications.
• Safety Features: How the M32 flywheel incorporates safety by design.
• About This Manual: Layout and organization of this Installation Manual.
• About Amber Kinetics: Company information.
Copyright 2017 by Amber Kinetics. All rights reserved.

2
1.1 - Features and Benefits
Amber Kinetics, Inc. was founded in 2009 to develop The M32 flywheel offers the following key benefits
and bring to market breakthrough flywheel energy- over traditional chemical batteries:
storage technology. Although flywheel storage is a • >88% round trip efficiency (DC)
mature technology, it has been limited to short-
duration discharges. • No daily cycling limitations
The M32 flywheel by Amber Kinetics is the world’s first • No degradation over time
cost-effective energy storage system that safely and • Passive air cooling, with no HVAC required
reliably provides up to four hours of continuous power
for the following applications: • Operates in hot and cold environments (-40°F to
122°F; -40°C to 50C°)
• Demand reduction
• Fast response time (<1 second)
• Energy arbitrage
• Fully-recyclable all-steel design
• T&D deferral
• Minimal operations and maintenance
• Flexible capacity
• 30-year design life
• Renewable firming
• 10-year manufacturer warranty
• Ancillary services
3
1.2 - M32 Flywheel Description
The Flywheel Module (FM) consists of the Flywheel Figure 1 displays the major components that make up
Housing that contains the primary electric and the components within and attached to the Flywheel
mechanical components of the M32 flywheel, an Housing:
Electronics Enclosure mounted on the top of the
Flywheel Housing, and a Passive Vacuum Pump that is 1 4 5
2 3
also mounted to the Flywheel Housing.
This assembly functions as a “mechanical battery.”
Like a chemical battery, it is charged by an input of DC 6
electrical energy and discharged by an output of DC
electrical energy. To charge, the DC power is inverted
to variable frequency AC power that powers a Motor/ 7
Generator to spin up a rotating mass, which stores the
electrical power as mechanical energy. To discharge, 8
this process is reversed. The rotor group operates in a
vacuum to minimize rotational losses during storage.
The M32 flywheel and Capsule are installed in an
excavated hole in the ground, and a protective 9 9
Capsule Lid is then placed on top of the Capsule to 3 4
protect the M32 flywheel and electronics from rain
and debris.
Figure 1: M32 flywheel components
Note: This drawing is intended for
general information only. It is not to
scale, and the actual appearance and/or
location of components may vary from
those shown.
Copyright 2017 by Amber Kinetics. All rights reserved. 1 - OVERVIEW

4
The M32 flywheel components are as follows • Motor/Generator (8): Converts electrical energy to
(numbers correspond to the callouts in Figure 1 on the mechanical energy when the Flywheel Rotor is
preceding image): charging, and vice-versa when the Flywheel Rotor
is discharging. The Motor/Generator also contains
• Flywheel Housing (1): Vacuum vessel that houses
the current-carrying conductors that route power
the components numbered 2 through 9.
to and from the Electronics Enclosure (5).
• Passive Vacuum Pump (2): of molecule-adsorbing
• Feet (9): Support the Flywheel Housing (1) and
desiccants that maintain the appropriate vacuum
other components.
environment within the Flywheel Housing (1).
• Capsule (not shown): Encloses the M32 flywheel
• Bearing Caps (3): Cover and provide access to the
and other components within the excavated hole.
upper and lower Bearings (4). There is also a jack
screw underneath the lower Bearing Cap that • Capsule Lid (not shown): Covers the Capsule to
protects the Bearings during flywheel shipment. prevent rain and debris from falling into the
You will remove the lower Bearing Cap and adjust Capsule.
this jack screw during installation.
• Bearings (4): Support the Flywheel Rotor (7).
• Electronics Enclosure (5): Houses a number of
electronic components, including the electrical
powertrain, instrumentation, communications, and
control.
• Offloader (6): Electromagnet that reduces loads on
the Bearings (4) by providing a lifting force for the
Flywheel (7).
• Flywheel Rotor (7): Rotating mass that stores
mechanical energy for conversion into electricity.
5
1.3 - Theory of Operation
The M32 flywheel stores kinetic energy in a massive

rotating disk. The amount of energy stored is defined Multiple M32 flywheels can be connected in parallel to
by the equation E ½Jω2, where: meet desired power and energy requirements. The
• J is the moment of inertia (related to the mass and inverter in each M32 flywheel connects to a common
size of the disk) DC bus, as shown in Figure 2.
• ω is the rotational speed. +/- DC current
The rotational speed of the M32 flywheel accurately
characterizes the state of charge of the system, and
this speed will vary slowly between its minimum and
maximum limits over the course of a 4-hour charge or M/G Flywheel
discharge period. Unlike batteries, the M32 flywheel
exhibits no capacity fade over time.
As described in “M32 Flywheel Description” on page 3,
the Motor/Generator assembly within the M32
flywheel converts the kinetic energy of the Flywheel
Rotor to and from electrical energy. This 3-phase
Figure 2: Connecting multiple M32 flywheels
electric component is driven by a Pulse Width
Modulation (PWM) voltage-source inverter within the A third-party grid-tie inverter (not shown) interfaces
Electronics Enclosure. Both the Motor/Generator between the DC bus and the AC line. A single central
assembly and M32 flywheel inverter are capable of grid-tie inverter can serve many parallel M32
providing both positive and negative watts to the flywheels. Please contact Amber Kinetics as described
Flywheel Rotor, which allows the M32 flywheel to in “Support Policy” on page 10 for information on grid-
accurately track any continuously variable charge/ tie inverter requirements.
discharge profile that falls within its maximum power
and energy ratings.

6
1.4 - Specifications & Performance
These tables provide basic mechanical, environmental, Electrical

and electrical specifications for the M32 flywheel.
Power 8 kW (minimum)
Mechanical
Energy 32 kWh
Weight 10,500lbs
(4,763kg) Full-power response <1 second
time
Size (height/diameter) 52”x54”
(132cm x 137cm) Discharge duration 4 hrs (minimum)
Efficiency (round trip) >88%*
Installation either above or
below grade Average self-discharge <60W
Seismic rating 4 USUBC Station power (120 Vac) 44 W (coasting)
108W (charge/discharge)
Daily cycling limit none
AC input/output 480Vac, 3-phase
Design life 30 years
DC input/output 800Vdc nominal;
Standard warranty 10 years
adjustable to 700 Vdc
Environmental DC current 10A (nominal)
Temperature (storage) -40°F to 140°F 13A (maximum)
(-40°C to 60°C) Fuse 30A DC
Temperature (operating) -40°F to 122°F *excludes self-discharge
(-40°C to 50°C)
Humidity 100% condensing
Greenhouse gases zero emissions
7
1.5 - Safety Features
Amber Kinetics has developed a comprehensive, five- • Testing: Finished rotors are
step approach to flywheel safety. Our methodology scanned for both surface and bulk
encompasses the entire spectrum from design to defects. Each rotor is then spun
manufacturing, testing, installation, and operation: beyond its maximum rated
operating RPM before being
• Design: Each M32 flywheel is
placed into service.
designed using conservative peak
stress and cyclic fatigue margins • Installation: As a redundant safety
that are consistent with aerospace measure, M32 flywheels are
engineering standards. installed either below grade or
behind surrounding earth berms.
Please contact Amber Kinetics for
• Manufacturing: The material used
assistance with above-ground
for the Flywheel Rotor is produced
installations, if needed.
using a commercially proven
manufacturing process that yields • Operation: Each M32 flywheel is
the cleanest, highest-grade steel monitored 24/7/365 by a health
available. monitoring system.

8
1.6 - About this Manual
This section describes the formatting conventions and Interface elements such as document titles, fields,
information contained in this manual. windows, tabs, buttons, commands, options, and icons
appear in bold text.
1.6.1 - Formatting Conventions WARNING: WARNINGS INDICATE THE
POSSIBILITY OF DEATH OR SERIOUS
This manual uses several formatting conventions to BODILY INJURY, INCLUDING
present information of special importance. ELECTROCUTION HAZARDS.
Lists of items, points to consider, or procedures that
do not need to be performed in a specific order CAUTION: CAUTIONS INDICATE THE
appear in bullet format: POSSIBILTY OF EQUIPMENT DAMAGE
AND/OR DATA LOSS.
• Item 1
• Item 2
Procedures that must be followed in a specific order Note: Notes provide helpful information.
appear in numbered steps:
1. Perform this step first.
2. Perform this step second.
Specific keyboard keys are depicted in square
brackets and are capitalized, for example: [ESC]. If
more than one key should be pressed simultaneously,
the notation will appear as [KEY1]+[KEY 2], for
example [ALT]+[F4].
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1.6.2 - Organization
This manual contains the following chapters:
1 - Introduction: Introduces the M32 flywheel by
describing its key features, components, operation,
specifications, and safety features.
2 - Safety: Provides important safety information that
must be followed when installing, commissioning,
operating, and maintaining the M32 flywheel.
3 - Installation: Detailed installation procedures that
include site planning and preparation, physical
installation, and the various electrical and monitoring
connections.
4 - Testing and Commissioning: Describes how to test
the M32 flywheel and commission it for regular
service.
5 - Maintenance: Contains scheduled maintenance
procedures that will maximize the operating life of
your M32 flywheel(s).

10
1.7 - About Amber Kinetics
Amber Kinetics, Inc. was founded in anticipation of the

enormous worldwide demand for competitively
priced, safe, environmentally sustainable, multi-hour
energy storage. Our mission is to accelerate global
adoption of energy storage by commercializing our
advanced, cost-disruptive flywheel technology to
provide a lower cost and higher performing
alternative to fossil fuel generation.
1.7.1 - Support Policy

Amber Kinetics support is available via either phone or
email Monday to Friday from 8:00AM to 5:00PM
Pacific time (holidays excluded).
You may contact Amber Kinetics via the following
methods:
Address 32920 Alvarado Niles Blvd
Suite 250
Union City, CA 94587
Phone* (510)-474-1000
Email support@amberkinetics.com
11
2 - Safety
This chapter contains important safety guidelines and advice that are intended
to help ensure a safe installation and operating environment. These directions
must be considered in addition to both standard and site-specific safety best
practices.
The order in which these guidelines appears is not intended to express or
imply any priority or relative importance.

12
WARNING: THIS MANUAL IS FOR USE • This manual is an integral part of the M32 flywheel
BY QUALIFIED PERSONNEL ONLY. product. It contains important instructions that
QUALIFIED PERSONNEL ARE THOSE must be followed when installing, commissioning,
WHO HAVE RECEIVED TRAINING AND and maintaining the M32 flywheel. Read this entire
HAVE DEMONSTRATED SKILLS AND manual, paying particular attention to all
KNOWLEDGE IN THE INSTALLATION, WARNING, CAUTION, and Note callouts, before
COMMISSIONING, AND OPERATION OF installing or commissioning the M32 flywheel. Keep
THE M32 FLYWHEEL, AND WHO ARE this manual and all other documentation in a
TRAINED IN MITIGATING HAZARDS convenient place for future reference.
INVOLVED IN INSTALLING AND • Read all of the instructions for all grid-tie
OPERATING HIGH-POWER inverter(s), computers, routers/switches, and all
ELECTRICAL DEVICES. other components used in every installation,
paying particular attention to all safety-related
WARNING: FAILURE TO FOLLOW THE information.
INSTRUCTIONS CONTAINED IN THIS
MANUAL AND ANY OTHER M32 • This manual does not and is not intended to
FLYWHEEL DOCUMENTATION, AND/ replace any local, state, provincial, federal, or
OR TO FOLLOW STANDARD AND SITE- national laws, regulations, or codes applicable to
SPECIFIC BEST PRACTICES CAN the installation and use of the M32 flywheel,
CAUSE SERIOUS INJURY OR DEATH including without limitation applicable electrical
FROM A VARIETY OF ELECTRICAL safety codes. All phases of M32 flywheel
AND NON-ELECTRICAL HAZARDS. installation, commissioning, and operation must
comply with all applicable codes and regulations
CAUTION: FAILURE TO FOLLOW ALL for the installation site,
OF THE SAFETY INSTRUCTIONS IN • All US electrical installations must be performed by
THIS CHAPTER, MANUAL, AND OTHER an authorized electrician in compliance with both
APPLICABLE DOCUMENTATION CAN National Electrical Code ANSI/NFPA 70 and OSHA
RESULT IN EQUIPMENT DAMAGE AND requirements, in addition to all local jurisdiction
CAN VOID YOUR WARRANTY OR requirements.
WARRANTIES.
13
• The M32 flywheel weighs approximately 10,000lbs • Be sure to use safety lockout devices on all
(~4,550kg). The Capsule weighs approximately affected circuit breaker(s) and/or power shut-
1,200lbs (~550kg). The Capsule Lid weighs off(s) when working on the M32 flywheel or
approximately 400lbs (~200kg). Always use an associated components to prevent accidental
appropriately rated crane/hoist along with power-on and death from electrical shock,
appropriately rated equipment (such as straps, • The M32 flywheel contains no user-serviceable
chains, shackles, and/or hooks) when hoisting any parts. Under no circumstances should you open the
of these components. Flywheel Housing or perform any other servicing or
• Remain well clear of any component during any repair aside from that explicitly described in this
hoisting operation to prevent serious injury or manual. Always contact Amber Kinetics for any
death in the event of any hoist failure. Never use maintenance or repair that is not described in this
any body part to position or align the components, manual.
such as when lowering the M32 flywheel and • Only use the M32 flywheel in accordance with the
Capsule into the hole, Instead, use one or more
information provided in this manual, any other M32
tagline(s) while remaining well clear of the documentation, and all locally applicable standards
components. and directives. Any other use or application may
• The installation hole and protruding Capsule pose cause death, personal injury, and/or property
various tripping and/or falling hazards. Remain damage.
clear of all installation holes and be aware of your • Altering the M32 flywheel, such as (but not limited
surroundings at all times. to) modifications or conversions, is only permitted
• The M32 flywheel produces hazardous voltages with the express written permission of Amber
and currents when the wheel is spinning at any Kinetics, Inc. Unauthorized alterations will void all
speed, even when the utility grid and/or other guarantee and warranty claims and will usually void
power sources are lost or disconnected. the operation permit. In no event shall Amber
Kinetics be held liable for any damage caused by
• All wiring and connections may have hazardous
such changes.
voltages and currents at any time. Only qualified
and authorized personnel may install and/or • The M32 flywheel can continue to spin for up to 15
maintain the M32 flywheel and associated days following removal of DC power. Contact
components. Amber Kinetics for assistance before approaching
any M32 flywheel while it is still spinning.
Copyright 2017 by Amber Kinetics. All rights reserved. 2 - SAFETY

14
15
3 - Installation
This chapter describes the installation procedure for the M32 flywheel. This
process begins with planning the installation, gathering the needed equipment
and tools, and then preparing the site. Next, the M32 flywheel is installed in the
ground and electrical connections are made. Finally, a vacuum pump is
connected to the M32 flywheel(s) to ensure a proper level of vacuum inside
the Flywheel Housing, and the site-wide wiring is completed.

16
3.1 - Planning
When planning a multi-M32 flywheel installation: • Each block of M32 flywheels consists of two rows.
• The total DC capacity will be 8kw times the number • Figure 3 displays the minimum clearance
of M32 flywheels in the installation. requirements between individual M32 flywheels,
blocks, and the site perimeter.
Not to scale 15' (180")
... ...
Site perimeter
36" 36"
... ...
Block A 36" Block B 36"
10'
(120")
10'
WARNING: THE SITE MUST NOT HAVE ANY BURIED GAS OR WATER LINES.
(120")
... ...
15' (180") 15' (180")
36" 36"
... ...
Block C 36" Block D 36"
15' (180")
Figure 3: Clearance requirements at a multi-M32 flywheel site
17
3.2 - Equipment & Tools
The following equipment and tools are required in • Magnetized 1.5” (~39mm) socket provided by
order to install the M32 flywheel: Amber Kinetics.
• Auger with a diameter between 78” (~200cm) and • 3/8” (9.5mm) hex wrench.
84” (~215cm) that is capable of boring a hole • 1.5” (~39mm) low-profile open-ended wrench.
approximately 70” (~178cm) deep.
• Handheld Load Cell Reader (AK 700-0015-00).
• Crane or forklift rated to a minimum of 6 tons
(5,500kg) or more, in accordance with local • Latex-free gloves.
requirements: • Denatured alcohol.
- M32 flywheel and Capsule: Approximately • Lint-free wipes.
11,200lbs (~5,100kg).
• Basic hand tools.
- M32 flywheel without Capsule: Approximately
10,000lbs (~4,550kg).
- Capsule Lid: Approximately 400lbs (~200kg).
• Lifting straps with shackles (three required).
• One or more tagline(s) and/or magnetic
manipulator bars for aligning and positioning the
M32 flywheel and Capsule during installation.
• Shovels and/or other handheld earthmoving tools,
as appropriate for the installation site.
• Socket torque wrench rated to at least 150 foot-
pounds (210Nm).
• 7’ (~213cm) extension.
Copyright 2017 by Amber Kinetics. All rights reserved. 3 - INSTALLATION

18
3.3 - Site Preparation
To prepare the site: • The bottom of the hole must be leveled to a

maximum slope of no more than 1%.
• The Capsule that contains the M32 flywheel is
approximately 82” (~208cm) tall and 70” (~178cm) CAUTION: UNEVEN AND/OR
in diameter. IMPROPERLY COMPACTED GROUND,
• Adequate drainage must be provided in AND/OR SLOPES IN EXCESS OF 1%
accordance with site conditions and local CAN CAUSE SETTLING OR OTHER
requirements. MOVEMENT THAT CAN REDUCE
BEARING LIFE.
• The hole must allow sufficient clearance to allow
free placement of the Capsule with adequate room • When installing multiple M32 flywheels, be sure to
to provide and compact backfill. An auger diameter plan the sequence of drilling holes and installing
of between 78” (~200cm) and 84” (~215cm) is units so as to preserve equipment and personnel
recommended. When in doubt, a slightly larger access without creating undue tripping/falling
hole is preferable to a slightly smaller one. hazards.
• The Capsule must protrude 12” (~31cm) from the
ground, plus or minus 3” (~7cm). Thus, the hole
must be approximately 70” (~178cm) deep.
• The ground surface must be leveled and smoothed
to ensure proper Capsule ground clearance on all
sides.
• The bottom of the hole must be smooth enough to
provide even support across the entire base of the
Capsule and must be compressed to ensure that
the soil can support a uniform load of
approximately 3.5 pounds per square inch (~0.25kg
per square centimeter) without settling.
19
3.4 - Capsule Placement
To install the Capsule: 4. Connect the three lifting straps and shackles to the
M32 flywheel lifting points, as shown in Figure 5.
1. Read all of the safety instructions in “Safety” on
Connect the other ends of the straps to the crane
page 11, as well as all of the instructions for the
or forklift, and then hoist the M32 flywheel and
other installation components and tools.
Capsule into the hole. If needed, use one or more
2. Prepare the site and bore/prepare the installation tagline(s) and/or manipulator(s) to align and
hole as described in “Site Preparation” on page 18. center the M32 flywheel and Capsule inside the
See Figure 4, below. hole. Do not disconnect the hoist.
Figure 4: Augered installation hole Figure 5: M32 flywheel and Capsule with lift points
3. If the M32 flywheel shipped inside and bolted to WARNING: REMAIN WELL CLEAR OF
the Capsule, then proceed to Step 4. If the M32 THE M32 FLYWHEEL AND CAPSULE
flywheel shipped separately from the Capsule, then WHILE THE HOIST IS IN PROGRESS.
skip to Step 7.

20
5. Use the torque wrench with the extension and 1.5” 8. Backfill the gap between the Capsule and sides of
(~39mm) magnetized socket provided by Amber the hole, being sure to compact the soil as much as
Kinetics to remove the three nuts securing the M32 possible (see Figure 7). During backfilling:
flywheel to the Capsule (see Figure 6), and then lift - Leave room to allow electrical conduit
the M32 flywheel out of the Capsule. installation.
- Be careful to avoid spilling dirt or debris into the
Capsule. If dirt or debris does fall into the
Capsule, then clean out the Capsule as
thoroughly as possible.
Figure 6: Nuts securing the M32 flywheel

6. Skip to Step 8.
7. Hoist only the Capsule into the hole. If needed, use
one or more tagline(s) and/or manipulator(s) to
align and center the Capsule inside the hole. Figure 7: Backfilling around the Capsule
9. Proceed to “M32 Flywheel Preparation” on page 21
21
3.5 - M32 Flywheel Preparation
The M32 flywheel includes a jack screw located WARNING: REMAIN WELL CLEAR OF
beneath the lower Bearing Cap. This jack screw raises THE M32 FLYWHEEL AND CAPSULE
the Flywheel Rotor off of its shipping support posts. If WHILE THE HOIST IS IN PROGRESS.
the M32 flywheel is being installed for the first time,
then the jack screw will need to be adjusted using the
procedure described in this section. 2. Connect the Handheld Load Cell Reader to the
To adjust the jack screw: serial port on the upper Bearing Cap (see Figure 9),
and then power it on. It should read 0lbs.
1. If the M32 flywheel is in the Capsule, then use the
torque wrench with the extension and 1.5” (~39mm)
magnetized socket provided by Amber Kinetics to
remove the three nuts securing the M32 flywheel to
the Capsule (see Figure 8), and then lift the M32
flywheel out of the Capsule.
Figure 9: Serial port on upper Bearing Cap
Figure 8: Nuts securing the M32 flywheel

22
3. Remove the six (6) bolts securing the lower 5. Loosen the locknut (A) securing the jack screw (B)
Bearing Cap using a 3/8” (9.5mm) Allen wrench. to the M32 flywheel using the 1.5” (~39mm) open-
ended wrench.
Figure 10: Hex bolts securing the lower Bearing Cap

Figure 11: Bearing Cap (left) and jack screw (right)
WARNING: ENSURE THAT THE M32
FLYWHEEL IS PROPERLY SUPPORTED 6. Using the socket torque wrench with a 1.5”
TO PREVENT A FALL OR OTHER (~39mm) socket, turn the jack screw (B) clockwise
UNEXPECTED MOVEMENT. until the Handheld Load Cell Reader indicates
120lbs (+/- 10lbs).
CAUTION: ALL VACUUM SEAL 7. Turn the jack screw (B) counterclockwise 1/2 turn,
COMPONENTS MUST BE KEPT CLEAN and then verify that the Handheld Load Cell Reader
AND FREE OF DAMAGE. FURTHER, is now indicating 50lbs (+/- 5lns).
ALL SURFACES MUST BE CLEANED
8. Record the load displayed on the Handheld Load
BEFORE REASSEMBLY.
Cell Reader in Box 9 (Final Load) of the Offloader
4. Place the lower Bearing Cap inside a clean plastic Gap Worksheet (document number 55-0004-00).
bag or other storage.
23
9. Use the 1.5” (~39mm) open-ended wrench to fully 11. Remove the lower Bearing Cap from storage, and
tighten the locknut (A), thereby securing the jack then remove the O-ring seal from the groove in the
screw (B) in place. Torque to 70 foot-pounds cap.
(95Nm).
Figure 13: Removing the O-ring seal

Figure 12: Tightening the locknut 12. Inspect the O-ring seal to ensure that it is intact;
10. Don a pair of latex-free gloves, and then use lint- replace if damaged or broken.
free wipes and denatured alcohol to thoroughly 13. Clean the O-ring seal and the surface of the
clean the area of the Flywheel Housing where the Bearing Cap using lint-free wipes and denatured
lower Bearing Cap will go. alcohol, and then replace the O-ring seal in the
groove.
14. Lift the lower Bearing Cap into position against the
Flywheel Housing, being sure that the bolt holes
are aligned.
15. Insert and hand-tighten the six (6) bolts, being sure
to use all 6 washers and hex bolts. Tighten until
snug, and then fully tighten them using a 3/8”
(9.5mm) Allen wrench in a star pattern.

24
3.6 - M32 Flywheel Placement
To place the M32 flywheel inside the Capsule: 4. Use the torque wrench with the extension and 1.5”
(~39mm) magnetized socket provided by Amber
1. Connect the three lifting straps and shackles to the
Kinetics to replace the three nuts that secure the
M32 flywheel lifting points, as shown in Figure 5.
M32 flywheel to the Capsule. Torque each nut to 50
Connect the other ends of the straps to the crane
foot-pounds (70Nm), and then finish-torque each
or forklift.
nut to 150 foot-pounds (210Nm).
2. Slowly lower the M32 flywheel into the Capsule,
using the tagline(s) and/or magnetic
manipulator(s) to align it over the three bolts at the
bottom of the Capsule.
CAUTION: MOVE THE M32 FLYWHEEL
SLOWLY TO AVOID JOSTLING OR
IMPACT.
3. Disconnect the hoist.
Figure 14: Securing the M32 flywheel in the Capsule
25
5. Connect a vacuum pump to the KT40 flange, and

then open the valve (conduit not shown for clarity).
Figure 15: KT40 flange and vacuum valve

Note: Your vacuum valve configuration
on your M32 flywheel may vary from that
shown in Figure 21.
6. Run the vacuum pump for at least 2 hours

(120 minutes).
Note: If desired, you may save time by
working on the electrical connections
while the vacuum pump is operating.
7. Tun off the pump, close the valve, and then

disconnect the pump from the flange.

26
3.7 - Electrical Connections
To make the electrical connections to the M32 Note: Conduit must be a watertight type
flywheel: approved for use in your local
1. Run the following conduits and wiring to the M32 jurisdiction. The specific conduit type
flywheel and secure them to the Electronics and routing (such as above- or below-
Enclosure using watertight connectors: grade) is beyond the scope of this
manual.
- Connect a 1” flex conduit to the bottom port of
the Electronics Enclosure. This conduit will
contain one red and one black copper wire (size
14-8AWG), and one bare grounding copper
wire, size 14-4AWG.
- Connect a 3/4” flex conduit to the middle port
of the Electronics Enclosure. This conduit will
contain one white, one black, and one green
copper wire, size 22-12AWG.
- Connect a 1 1/4” flex conduit to the top port of
the Electronics Enclosure. This conduit will
contain:
> Either one fiber-optic, or one Cat6a Ethernet
Figure 16: Flex conduits connected to
cable. Ethernet. See Step 7, below.
Electronics Enclosure
> Either one Cat6a Ethernet cable or one USB
cable. See Step 8, below.
27
2. Remove the top of the Electronics Enclosure by 4. Connect the DC wires as follows:
removing the four cotter pins (one on each side),
- Black wire to the negative (-) terminal.
releasing the four latches, and then lifting the top
out of the way. - Red wire to the positive (+) terminal.
- Bare wire to the grounding lug on the
Electronics Enclosure.
Figure 17: Cotter pins and latches on Electronics

Enclosure
3. Lift the upper electronics tray up to gain access to Figure 18: DC connections (lower tray)
connect the DC wires to the terminals on the lower 5. Lower the upper electronics tray back into
electronics tray. position.

28
6. Connect the AC wires as follows: 7. Connect a fiber-optic cable to the fiber-to-Ethernet

transceiver (color may vary from that shown).
- White wire to the neutral (N) terminal.
Alternatively, you may connect a Cat6a Ethernet
- Black wire to the hot/line (L) terminal. cable directly to the white Ethernet cable that is
- Green wire to the ground (G) terminal. normally connected to the of the top of the
transceiver using a Cat6 RJ45 coupler.
- Bare or green wire from the ground (G) terminal
to the grounding lug on the Electronics
Enclosure.
Figure 20: Fiber-optic connection
Figure 19: AC connections (upper tray)
29
8. Connect a Cat6a Ethernet cable to the Ethernet-to- 10. Connect the M32 flywheel(s) to the following
USB adapter (color may vary from that shown). components, and complete all external connections
Alternatively, you may connect a USB cable to those components:
directly to the black USB cable that is normally - Grid-tie inverter
connected to the opposite side of the converter
using a female-to-female USB coupler. - DC Balance Load (if needed)
- Industrial PC
- Ethernet switch/router
Figure 22 depicts the wiring diagram for a generic
site; your specific site may vary.
M32 480 VAC

Grid
Flywheel (3-phase)
Inverter WYE
#1
Figure 21: Cat6a Ethernet connection M32 DC

120 VAC
Flywheel Balance
AC In
9. If applicable, repeat Steps 1-9 for the other M32 #2 LEGEND Load
flywheel(s) in the installation. DC+
... DC-
GND
SCADA*
RS485 Industrial
LAN PC 120 VAC
M32 USB AC In
Flywheel *DNP3 over TCP/IP
n
Ethernet 120 VAC
router AC In
Figure 22: General site wiring

30
3.8 - Completing the Installation
To complete the installation: 3. Connect a lifting strap and shackle to the lifting
point at the top of the Capsule Lid. Connect the
1. Visually inspect the M32 flywheel and Capsule to
other end of the strap to the crane or forklift, and
ensure that no tools or other debris remain in the
then hoist the Capsule Lid up and over the
Capsule.
protruding Capsule. If needed, use one or more
2. Complete backfilling around the Capsule(s), taking tagline(s) and/or manipulator(s) to center the
care not to allow dirt or other debris to fall inside Capsule Lid as you gently lower it into position,
the Capsule(s). being sure not to damage any conduits or wiring.
Figure 23: Capsule Lid in position over the Capsule

WARNING: REMAIN WELL CLEAR OF
THE CAPSULE LID WHILE THE HOIST
IS IN PROGRESS.
31
4 - Testing and
Commissioning
These steps are intended to verify that the M32 flywheel is ready for
commissioning, and that proper documentation exists.

32
4.1 - Pre-Commissioning Steps
The M32 flywheel commissioning process begins with 4.1.2 - Installation Review
reviewing the documentation and ensuring that the
required power and communications are available to Review “Installation” on page 15, and verify that all
the M32 flywheel(s) at the site. steps have been completed. Conduct a visual
inspection of the installed M32 flywheel(s), paying
particular attention to the following:
4.1.1 - Documentation Review
• Each M32 flywheel is properly secured to its
Review the manufacturing traveler for the M32 Capsule.
flywheel, which includes all of the following
• All electrical and communications connections to
documents:
the M32 flywheel(s) have been completed in
• 55-0001-00 Flywheel Unit Traveler accordance with the instructions in this manual.
• 55-0006-00 Offloader Assembly Traveler • There is no debris in the Capsule(s).
• 55-0004-00 Offloader Gap Worksheet • Station power and network communications are
• 55-0003-00 Stator Assembly Traveler available to the M32 flywheel(s).
• 55-0002-00 Rotor Assembly Traveler WARNING: DO NOT ENERGIZE THE DC

BUS AT THIS TIME.
• Rotor NDT Inspection Certificate
Verify that every document included in the traveler is
present and complete, and that all manufacturing test
steps are completed as “PASS.”
33
4.2 - M32 Flywheel Spin-up
The M32 flywheel spin-up process consists of 3. Wait for the automated spin-up routine to
energizing the DC bus, bringing the M32 flywheel up complete.
to minimum operating speed, verifying that resonance This process is managed by the SCADA system and
frequency and amplitude measurements are within will take several hours to complete. Once the
limits, and then adding the startup report to the flywheel spin-up is complete, the flywheel status
documentation package for the M32 flywheel. indicator will read Active.
Note: The M32 flywheel will require 4. Repeat this procedure for any other M32
approximately two hours to reach flywheel(s) in the array.
minimum operating speed, which
represents a zero-charge state. The array will be ready to accept power commands
when all of the M32 flywheels are Active.
4.2.1 - Initial Startup

To spin up the M32 flywheel:
1. Connect the designated support computer to the
Ethernet switch/router, and then launch a web
browser.
The browser will automatically connect to the
Amber Kinetics SCADA software.
2. Click the Spinup button next to the flywheel
control section of the interface.
Copyright 2017 by Amber Kinetics. All rights reserved. 4 - TESTING AND COMMISSIONING
34
4.3 - Power Cycle
Perform the automated power test cycle while logging • Full power charge to 50% SoC
the M32 flywheel data, and then add the data log to • Self-discharge test at 50% SoC
the unit documentation package. The power test cycle
consists of: • Full power charge to 100% SoC, hold for 15 minutes
• Self-discharge test at 0% SoC • Self-discharge test at 100% SoC
• Full power discharge to 0% SoC
Figure 24: Sample data log
35
4.4 - Commissioning Report & Template
The commissioning technician must prepare and sign

a Commissioning Report using the template on the
following page. This report documents the results
from:
• Pre-commissioning
• Electronics initialization
• M32 flywheel spin up
• Power cycle tests
• Any notes
Any test(s) that do not meet the criteria lists on the
Commissioning Report must be reported as FAILED,
and a corrective action must be generated to resolve
the issue(s).
WARNING: FAILURE TO CORRECT ALL
FAILED TEST(S) MAY CREATE AN
ELEVATED RISK OF DEATH OR
SERIOUS INJURY.
CAUTION: FAILURE TO CORRECT ALL

FAILED TEST(S) MAY CAUSE
PREMATURE WEAR AND/OR DAMAGE
TO THE M32 FLYWHEEL AND/OR
OTHER SITE COMPONENTS.
Copyright 2017 by Amber Kinetics. All rights reserved. 4 - TESTING AND COMMISSIONING
COMMISSIONING REPORT TEMPLATE
M32 Flywheel serial number: ______________________________________
Pre-Commissioning Criteria Value PASS/ Date Initials

FAIL
Mfg. documentation complete? Pass/Fail
Visual inspection Pass/Fail
Electronics Initialization Criteria Value PASS/ Date Initials

FAIL
Unit installation identification Pass/Fail
Unit software revision Revision #
Self-diagnostic text Pass/Fail
Spin Up Criteria Value PASS/ Date Initials

FAIL
Spin-up complete Pass/Fail
Maximum resonant frequency <2400rpm
Maximum resonant amplitude <0.7g
Power Cycle Criteria Value PASS/ Date Initials

FAIL
Self discharge at 0% SoC <100 W
Minimum charge efficiency >92%
Minimum discharge efficiency >92%
Notes
37
5 - Maintenance
This chapter describes the regular maintenance required to keep the M32
flywheel in optimal operating condition.

38
Perform the following maintenance for each M32

flywheel at the site:
Time Procedure
At least once per quarter (every 90 days) Inspect the perimeter of the M32 flywheel cover for
weeds, trash, and/or other debris that might be
blocking the ventilation inlet, and remove if present.
Every 10 years after initial installation Contact a certified Amber Kinetics service provider to
replace the upper and lower Bearings.
39
Copyright 2017 by Amber Kinetics. All rights reserved. 5 - MAINTENANCE

M32 FLYWHEEL
INSTALLATION & OPERATION
MANUAL
v1.0
September 2017
©2017 Amber Kinetcs, Inc. All rights reserved.

M32 Flywheel Installation & Maintenance Manual: v1.0 September, 2017

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M32 FLYWHEEL

INSTALLATION & MAINTENANCE

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Copyright 2017 by Amber Kinetics. All rights reserved.

1.1 - Features and Benefits

1.2 - M32 Flywheel Description

Copyright 2017 by Amber Kinetics. All rights reserved. 1 - OVERVIEW

1.3 - Theory of Operation

The M32 flywheel stores kinetic energy in a massive

Copyright 2017 by Amber Kinetics. All rights reserved. 1 - OVERVIEW

1.4 - Specifications & Performance

These tables provide basic mechanical, environmental, Electrical

1.5 - Safety Features

Copyright 2017 by Amber Kinetics. All rights reserved. 1 - OVERVIEW

1.6 - About this Manual

Copyright 2017 by Amber Kinetics. All rights reserved. 1 - OVERVIEW

1.7 - About Amber Kinetics

Amber Kinetics, Inc. was founded in anticipation of the

1.7.1 - Support Policy

Copyright 2017 by Amber Kinetics. All rights reserved.

Copyright 2017 by Amber Kinetics. All rights reserved. 2 - SAFETY

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Copyright 2017 by Amber Kinetics. All rights reserved.

Not to scale 15' (180")

Figure 3: Clearance requirements at a multi-M32 flywheel site

3.2 - Equipment & Tools

Copyright 2017 by Amber Kinetics. All rights reserved. 3 - INSTALLATION

3.3 - Site Preparation

To prepare the site: • The bottom of the hole must be leveled to a

3.4 - Capsule Placement

Copyright 2017 by Amber Kinetics. All rights reserved. 3 - INSTALLATION

Figure 6: Nuts securing the M32 flywheel

3.5 - M32 Flywheel Preparation

Figure 9: Serial port on upper Bearing Cap

Figure 8: Nuts securing the M32 flywheel

Copyright 2017 by Amber Kinetics. All rights reserved. 3 - INSTALLATION

Figure 10: Hex bolts securing the lower Bearing Cap

Figure 13: Removing the O-ring seal

Copyright 2017 by Amber Kinetics. All rights reserved. 3 - INSTALLATION

3.6 - M32 Flywheel Placement

3. Disconnect the hoist.

Figure 14: Securing the M32 flywheel in the Capsule

5. Connect a vacuum pump to the KT40 flange, and

Figure 15: KT40 flange and vacuum valve

6. Run the vacuum pump for at least 2 hours

7. Tun off the pump, close the valve, and then

Copyright 2017 by Amber Kinetics. All rights reserved. 3 - INSTALLATION

3.7 - Electrical Connections

Figure 17: Cotter pins and latches on Electronics

Copyright 2017 by Amber Kinetics. All rights reserved. 3 - INSTALLATION

6. Connect the AC wires as follows: 7. Connect a fiber-optic cable to the fiber-to-Ethernet

Figure 20: Fiber-optic connection

Figure 19: AC connections (upper tray)

M32 480 VAC

Figure 21: Cat6a Ethernet connection M32 DC

Figure 22: General site wiring

Copyright 2017 by Amber Kinetics. All rights reserved. 3 - INSTALLATION

3.8 - Completing the Installation

Figure 23: Capsule Lid in position over the Capsule

Copyright 2017 by Amber Kinetics. All rights reserved.

4.1 - Pre-Commissioning Steps

• 55-0002-00 Rotor Assembly Traveler WARNING: DO NOT ENERGIZE THE DC

4.2 - M32 Flywheel Spin-up