Application & Installation Guide ESS

Application &
Installation Guide
Energy Storage System
LEBE0044-01
Table of Contents
Energy Storage System

• ZA3 1-UP (Renewable Energy) • ZA7 1-UP (Renewable Energy) • ZH9 1-UP (Renewable Energy)
• ZA4 1-UP (Renewable Energy) • ZA8 1-UP (Renewable Energy) • ZHA 1-UP (Renewable Energy)
• ZA5 1-UP (Renewable Energy) • ZH7 1-UP (Renewable Energy) • ZHB 1-UP (Renewable Energy)
• ZA6 1-UP (Renewable Energy) • ZH8 1-UP (Renewable Energy)
1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.1 About This A&I Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Supportig Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.0 Site Survey, Pad Requirments, and Product Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Site Survey Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Key Site Survey Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Pad Construction and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.0 Installation Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 Torque Knob Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 General Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.0 Site Inspection and Material Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.1 Site Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Shipment Inspection and Material Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Installer Provided Material Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.0 Equipment Inspection, Handling, and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.1 Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Equipment Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Equipment Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.0 Pad Placement and Enclosure Anchoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6.1 Primary Enclosure Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2 Expanded Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.3 Power Module Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.4 Enclosure Anchoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3
Table of Contents
7.0 Mechanical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

7.1 Cathode Fan Wiring – Expanded Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2 Module Power Cable Wiring – Expanded Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.3 Module LIN Communication Wiring – Expanded Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.4 Enclosure Fan Wiring – Expanded Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.0 Scrubber Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.0 Energy Cell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

9.1 Cathode Air Supply and O2 Vent Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.2 Module LIN Communication Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.0 Power Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
11.0 SIM Card Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.0 Electrical Connections and Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

12.1 General Cable Routing Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12.2 ESS Power Cable Connections (required at all sites) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12.3 Rectifier Power Cable Connections (required at all sites) . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12.4 Ground Cable – ESS to Site Ground (required at all sites) . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
12.5 DG Control Cable – Start/Stop Signal Output (required at DG sites only) . . . . . . . . . . . . . . . . . . . 32
12.6 DG Control Cable – Run Signal Input (required at DG sites only) . . . . . . . . . . . . . . . . . . . . . . . . 33
12.7 DG Control Cable – Fail Signal Input (required at DG sites only) . . . . . . . . . . . . . . . . . . . . . . . . 33
12.8 Circuit Breaker Protection ad Total DC Charge Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12.9 DC Circuit Breaker Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
13.0 Rectifier Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

13.1 Commissioning (Start-up Guide) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 EN ER GY S TOR AGE S YSTEM

Table of Contents
14.0 ESS Initialization – “Power-up” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
15.0 Comm Control Configuration and ESS IQ Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

15.1 Factory Default Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
15.2 On-site/Remote Configuration Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
16.0 Initial Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

16.1 Energy Module Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
16.2 Power Module Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
17.0 Site Load Discharge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
18.0 Diesel Generator Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
19.0 Acceptance Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
20.0 Appendix A – Acceptance Testing Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

20.1 Product Installation and Acceptance Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
21.0 Appendix B – Telecom Pad Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-54
A P P L IC A T I O N A N D I N ST A LLATI ON GUI DE 5
Introduction
1.0 Introduction
1.1 About This A&I Guide
The Caterpillar Energy’s Energy Storage System (ESS) is a fully self-contained, advance energy storage device
serving mission-critical DC power applications. The ESS provides uninterrupted voltage support and continuous
power backup in a reliable and environmentally hardened package. This installation manual is intended to offer
the end user or installation personnel important information regarding the safe installation, commissioning, and
troubleshooting of this device. Read this manual carefully before conducting any activities on the product.
1.2 Safety Signs

Read operation instructions and precautions carefully before performing any operation to prevent unexpected
accidents. The alerts in this manual do not cover all safety precautions to be observed, but only serve as a
supplement to normal safety precautions during setup operations. Only qualified and trained personnel should
install and maintain Cat® products. Observe the related equipment precautions and special safety instructions
provided by Caterpillar during the operations on the products and equipment. This manual only lists known
safety instructions. Caterpillar bears no liability to the consequences incurred by violation of the general
safety operation requirements, or violation of the safety standards for designing, manufacturing and using
the equipment.
Safety Sign Description
Warning: Indicates a potentially hazardous situation, which if not avoided,

could result in death or serious injury.
Caution: Indicates a potentially hazardous situation, which if not avoided, could

result in minor or moderate injury. It may also be used to alert against unsafe
practices or prevent poor product performance.
Electric shock: Use extreme caution when servicing components. There is a

risk of electric shock, injury, and death. High-voltage equipment is connected
to the battery system for charging and discharging. Direct or indirect contact
through wet objects with high voltage or mains supply may result in critical
injury. Do not wear any watch, bracelet, rings and other conductive objects
during the operation. Prevent moisture entering the equipment in a damp
operation environment.
Corrosive material inside: Avoid contact with the liquid alkaline electrolyte
inside the battery cells. Direct contact with electrolyte causes severe burns
or blindness. Extreme caution should be exercised when servicing cells which
includes approved personal protective wear (goggles or face shield, long
sleeve shirt, pants, and gloves). In the event contact is made with electrolyte,
flush eyes or skin with clean water IMMEDIATELY and contact a physician.
Table 1.1 – Safety Signs

Introduction
1.3 Supporting Documents

M0066022 – Cat ESS Remote Monitoring Manual
Telecom Site Survey Document
Telecom Pad Specification – Generic
Acceptance Testing Protocol - Gen 6 – General
1.4 Acronyms
FST Field Service Tool – User interface to monitor ESS and adjust parameters
PBMS Power Battery Management System – PCB used to regulate charge and discharge current and voltage
for Power Modules
EBMS Energy Battery Management System – PCB used to regulate charge and discharge current and voltage
for Energy Modules
PIT Power and Interface Termination – PCB used inside cell to connect and disconnect electrodes
NRG “Energy” – PCB connected to system bus. Used to reduce voltage fluctuation during transitions from
charge to discharge
PCB Printed Circuit Board
APU Auxiliary Power Unit (Alternate term for ESS)
ESS Energy Storage System
NCL Non-critical Load – Telecom term for the portion of the site load that is considered “less critical” and
therefore disconnected first when battery power is limited
VRLA Valve Regulated Lead Acid
LIN Local Interconnect Network – Ribbon cable that provides a connection between the EBMS and each cell
in an Energy Module
ATS Automatic Transfer Switch – Used to transfer between AC power sources (usually Grid or DG)
DG Diesel Generator – Includes engine, generator, control module and usually the ATS
OTAC Over The Air Command – Used to read and write firmware parameters from a remote location
ESS IQ Webpage used to monitor ESS status and send OTACs
Site Survey, Pad Requirements, and Product Sizing
2.0 Site Survey, Pad Requirements, and Product Sizing

2.1 Site Survey Requirements
Prior to installation of this equipment at an existing “live” site, a thorough site survey must be carried out.
Caterpillar provides a thorough template for all relevant site information; see the Telecom Site Survey for the
complete details. There is a wide array of site configurations and rectifier equipment used internationally and
understanding site specifics and/or restrictions will promote a more seamless integration.
While a thorough site survey should be completed prior to Installation and Commissioning, it is important to verify
the following items before actual installation as some may have changed since the last record.
2.2 Key Site Survey Information

Key Site Survey Information at Installation
Item Description
Verify rectifier parameters such as float voltage, charge current, battery
Rectifier Configuration
capacity, etc. can be changed on-site/remotely. See Table 12.1.
Assess total site load and compare with ESS size. A 20% allowance should be
DC Site Load given for fluctuations in site load.
(Site load x 1.2 should be < or = ESS capacity.)
Rectifier Capacity Verify rectifier capacity > DC Site Load + ESS Charge Power Requirement.
Table 2.1 – Key Site Survey Information
It is important to verify the items referenced above to ensure proper charge and discharge function of the Cat
equipment. In general:
• The rectifier configuration needs to be modified to allow sufficient current from the rectifier for the ESS. An
improperly configured rectifier can result in poor charge performance and possible rectifier oscillation.
• The site load cannot exceed the capacity/size of the Cat equipment. An improperly sized ESS can cause an
unsupported event due to high current demand.
• The rectifier capacity needs to match the total charge load of the ESS plus the total site load. A rectifier with
limited capacity can result in poor charge performance and possible rectifier oscillation.
2.3 Pad Construction and Guidelines

Reference Appendix B for the minimum pad requirements related to physical dimensions, material composition as
well as conduit specifications and cable exit/entry requirements.
Note: D
ifferent geographical areas often have different requirements for pad construction, location, etc. Contact
your local account manager for specific guidelines for a particular region. In some cases there are
complete engineering documents generated for specific regions that can be made available.

Installation Tools
3.0 Installation Tools

3.1 Torque Knob and Accessories
Caterpillar has specified a critical torque requirement for the cell power connections and module power
connections. The torque knob and accessories are listed in the table below and are available from Caterpillar.
Part Number Description
Clutch-type torque knob, preset, 22 in-lbs., silver body, red I.D. ring, with 1/4 in hex female
488-9145
adaptor kit
N/A 1/4 in square drive metric socket, 6-point standard, 7 mm size, 7/8 in overall length, chrome finish
N/A Screw-holding hex insert bit, 1/4 in hex shank, 3 mm hex size, 1 in length
N/A Bit adapter, insert, 1/4 in hex male, 1/4 in square male, 1 in length
Table 3.1 – Torque Tool and Accessories
3.2 General Hand Tools
A basic set of tools are recommended for a quick and effective installation of the Cat equipment. In general, tools
needed for assembly are common hand tools and can be readily procured at any local hardware store. A list of
the recommended tools is listed below:
N/A Plastic cable tie, 8 inch (208 mm) LG, 0.14 in (3.55 mm) wide, nylon 6.6
N/A Multi-fold paper towels
N/A Gloves; 6 mil, Nitrile powder free
N/A Deionized water, in 5 liter jug
N/A Safety goggles
N/A Field tool – 40A/400A AC & DMM function (AC/DC, Ohm)
N/A Field tool – 1/4 in drive click torque wrench, 20-200 inch/lb
N/A Field tool – 1/4 in driver socket bit adapter – Hx3
N/A Field tool – WIHA torque handle adjustable 7.5-20 in-lbs
N/A Field tool – adapter for WIHA torque handle to fit 1/4" hex bits
N/A Field tool – adapter for WIHA torque handle to fit 1/4 in square drive socket
N/A Field tool – torque setting tool for wiha torque handle
N/A Dieless mechanical compression tool, for copper or aluminum conductor, 8-4/0 AWG (8.4-120 mm2)
488-9148 USB-CAN adapter with 500V optical isolation
Field tool – clutch-type torque knob, preset, 22 in-lbs, silver body, red I.D. ring, with 1/4 in hex
488-9145
female adaptor kit
N/A Field tool – bit adapter, insert, 1/4 in hex male, 1/4 in square male, 1 in length
N/A Screw-holding hex insert bit, 1/4 in hex shank, 3 mm hex size, 1 in length
N/A Field tool – 1/4 in square drive metric socket, 6-point standard, 7 mm size
N/A Field tool – 17 mm 3/8 in drive 6 pt socket
Installation Tools

N/A Enclosure door key – 5 mm double bit 1/4 turn
N/A Field tool – socket 13 mm 6 point 3/8 in drive (for enclosure bolts)
N/A Field tool – socket drive extension 3/8 in 10 in length
N/A Field tool – reversible ratchet wrench 3/8 in drive
Table 3.2 Installation Tools

Site Inspection and Material Inventory
4.0 Site Inspection and Material Inventory

4.1 Site Inspection
The items in this section should be completed before the Cat ESS is installed on the pad or any cables are
connected to the system. This serves to provide a quality check for site work accuracy performed by the civil and
electrical contractor.
1. Verify site load, to be supported by ESS, is less than ESS capacity.
2. Verify cable entry position on pad.
3. Verify all doors have adequate clearance.
4. Verify grounding cable routed from Cat ESS to site ground.
5. Verify positive and negative battery cables from Cat ESS to DC power source (i.e. rectifier).
6. If DG present, verify signal wire is installed from Cat ESS to DG controller for DG Start/Stop.
7. If DG present, verify signal wire is installed from Cat ESS to DG controller for DG Run/Fail.
8. Verify all cables have sufficient length for routing up and into the Cat ESS.
9. Confirm battery cable length from ESS to rectifier does not exceed 35 meters.
4.2 Shipment Inspection and Material Inventory

The Cat equipment will be shipped from the factory with all necessary components to assemble the equipment.
Inspect all packages for damage prior to installation; do not complete installation with damaged components.
Caterpillar offers several configurations for the ESS for different sized loads. See below for a list of ESS sections
and determine the applicable inventory required.
Quantity with
Quantity Quantity Quantity with
Cat Part Power Module
Description per Energy per Power Expansion
Number Electronics
Module Module Cabinet
Panel
4932662 Energy Cell Assembly 18 – – –
4885813 Power cell 32V 1100 Whr – 1 – –
4885799 Cell interconnect, copper BUS 16 – – –
4885807 M4 Belleville washer (cells) 36 – – –
4889109 M4 x 12 mm screw (cells) 36 – – –
N/A M8 flat washer (enclosure) – – 28 14
N/A M8 x 16 mm bolt (enclosure) – – 14 14
N/A M8 nut (enclosure) – – 14 –
Table 4.1 Installation Components Shipped From Factory
*Any model having 4 or more energy modules will ship with two separate enclosures.
**Breaker size selection from Table 12.1
Site Inspection and Material Inventory
4.3 Installer Provided Material Inventory

In general, the installation contractor is expected to provide the materials found in Table 4.2.
Cat Part Number Description Quantity

Compression lug, aluminum: for positive and negative connections
N/A As Required
to rectifier and grounding cable terminations
DC breaker: to function as disconnect and provide circuit
N/A protection for the ESS. Usually mounted inside rectifier cabinet. As Required
See Table 12.1 for size requirement.
Wire bundle, 22 AWG, 2 conductor, copper, PVC insulation,
N/A As Required
300 VAC: for DG control cables (DG sites only).
Cable, aluminum, single conductor, 1/0AWG, 600V:
N/A As Required
for cabinet grounding cable.
N/A 12 mm anchor bolt and hardware 4
Table 4.2 – Installer Provided Material
Aluminum conductor is specified for the positive and negative cables connecting the Cat ESS to the rectifier.
Equivalent copper conductor may be utilized if necessary, but as an increased deterrent to theft it is
recommended to use Aluminum conductors and the supporting materials specified in Table 4.2. For instructions
on power cable termination and mechanical interface to the ESS see Section 12.

Equipment Inspection, Handling, and Unpacking
5.0 Equipment Inspection, Handling, and Unpacking

5.1 Equipment Inspection
Inspect all material after delivery to the site to ensure no damage to any of the components. If there is any
damage to the components, review with project coordinator before moving forward with the installation.
Document and report all findings.
5.2 Equipment Handling

If the enclosure must be rotated horizontally to transport from the delivery vehicle to the pad, the electronics
panel should be on the TOP. Applying pressure to the electronics panel to transport the enclosure could damage
electronic components inside. Take care to recognize which side has the electronics panel door before rotating
the enclosure from the vertical position.
In general, cells must be kept level and upright at all times during transportation.
5.3 Equipment Unpacking

All components will be shipped with protective material to prevent damage during shipment. These shipping
materials will need to be removed and disposed of properly. Take care not to nick or scrape the protective paint
coating on the cabinet.
After the equipment is unpacked, the material inventory listed in Section 4.2 should be accounted for.
Pad Placement and Enclosure Anchoring
6.0 Pad Placement and Enclosure Anchoring

Once the site inspection and material inventory is complete the Cat ESS enclosure can be moved to the pad
location and anchored.
6.1 Primary Enclosure Placement

1. Set the primary enclosure in place so that the cable entry holes align with cable conduit location on the pad.
Figure 6.1 – ESS Conduit Locations
2. Open the electronics panel door. See Figure 6.2.

3. Remove the cable entry plenum from the enclosure by removing 4 screws (two screws outside the electronics
panel door, two screws inside).
Figure 6.2 – Cable Entry Plenum Removal

4. Slide the enclosure over the conduit holes.
5. Verify there is clearance to open all doors of the enclosure.
Figure 6.3 – ESS Door Clearances
6.2 Expanded Enclosures

If the site load requires 4 or more energy modules, two enclosures are required. Follow the steps below to join and
torque the two enclosures together.
1. Verify blanking plate is installed ONLY on the expansion enclosure. If blanking plate is installed on primary
enclosure, remove it and install on expansion enclosure.
2. Place expansion enclosure so alignment pins match with the holes in the primary enclosure.
3. Slide the two enclosures together keeping the pins aligned and avoiding damage to the rubber interface seal.
4. Inspect the rubber seal for proper sealing.
5. Install 14 joining bolts, washers, and nuts around the interface seal and torque to 80 in-lbs (+/- 4 in-lbs).
Figure 6.4 – Enclosure Mating Pins and Blanking Plate
6.3 Power Module Enclosure

If the model includes power modules, the power module enclosure will arrive already connected to the primary
energy module enclosure.
6.4 Enclosure Anchoring

Once the enclosure(s) are located above the conduits and joining bolts are torqued, the enclosure(s) must be anchored
to the concrete. A total of 4 anchor bolts are required for this step. If a double enclosure is installed, only the outside
4 corners should be anchored. See figure below. Follow the steps below to anchor the enclosures to the concrete.
1. Remove anchor bolt cover plates at bottom of cabinet.
2. Use 12 mm masonry bit to drill anchor holes into the concrete at each corner of the cabinet. Use the four
outermost holes only, see red highlight in Figure 6.5.
Figure 6.5 – Anchor Bolt Locations for Double Cabinet (left) and Single Cabinet (right)
3. Remove debris from hole and install anchor bolts (10 mm x 80 mm) and tighten to manufacturer’s recommended
specification.
Figure 6.6 – Anchor Bolt Location

4. Install anchor bolt cover plates.

Mechanical Assembly
7.0 Mechanical Assembly

If a double enclosure is being used, there are several cables and harnesses that must be routed through the
Expansion Enclosure before cells are installed.
7.1 Cathode Fan Wiring – Expanded Enclosure

1. Uncoil the cathode fan extension harness located in the primary enclosure.
2. Route the cathode fan extension harness through the cable tray in in each module of the expansion enclosure
(according to Figure 7.1). Be careful to route the longer leg of the harness to the cathode fan for cells 1-9.
Figure 7.1 – Cathode Fan Extension Harness Wire Routing
7.2 Module Power Cable Wiring – Expanded Enclosure

1. For each module, route the positive and negative power cables from the expansion enclosure through the cable
tray and then through the hole in the primary enclosure leading to the electronics panel.
2. Secure the cables with a zip-tie and verify the terminals can reach cell 1 and cell 18 terminals.
7.3 Module LIN Communication Wiring – Expanded Enclosure

The module LIN communication harness is slightly complicated to route and care should be taken to avoid damage
to the nodes of the harness when pulling through the enclosure. In general, the module LIN communication harness
will follow the pattern shown in Figure 7.2 and can be broken into 3 steps:
1. Route from expansion enclosure to primary enclosure through the separating wall.
2. Route through cable tray to electronics Bay.
3. Route through electronics Bay to IPM.
Figure 7.2 – Module LIN Communication Harness (Top View)
Mechanical Assembly
Follow the steps outlined below for instructions on the specific steps and relevant images.
1. Uncoil the module LIN communication harness (long) from the expansion enclosure.
2. Route the harness into the primary enclosure through the holes shown in Figure 7.3 and Figure 7.4.
Figure 7.3 – Module LIN Communication Harness Routing – Primary Enclosure Entry (Cells 1-9)
Figure 7.4 – Module LIN Communication Harness Routing – Primary Enclosure Entry (Cells 10-18)
3. Once both sides of the module LIN communication harness are inside the primary enclosure, route the two pieces
through the cable tray.
4. Next, route both ends of the LIN cable into the electronics panel.
5. Connect one end to J6 and one end to J8 of the EBMS for that module. Either end may be connected to either
J6 or J8.

Mechanical Assembly
7.4 Enclosure Fan Wiring – Expanded Enclosure

1. Uncoil the enclosure fan extension harness located in the middle cable tray in the primary cabinet.
2. Route the enclosure fan extension harness into the expansion enclosure.
3. Route the enclosure fan extension harness through the middle cable tray (energy module 5) in the expansion
enclosure.
4. Route the harness through the hole and to the enclosure door. Secure with zip ties.
5. Fasten the bundle of cables to the door near the center fan plenum.
6. Route the connector labeled “Fan 4” to the top fan.
7. Route the connector labeled “Fan 5” to the middle fan.
8. Route the connector labeled “Fan 6” to the bottom fan.
9. Connect each fan to the appropriate leg of the harness.
Scrubber Installation
8.0 Scrubber Installation

The following section defines the instructions to install the CO2 scrubber kit. It should be noted that there is one
CO2 Scrubber for every nine (9) cells in a module. This means that for every module there will be two (2) CO2
Scrubbers installed. Install one scrubber next to cell 9 and one next to cell 10.
The system will ship with the CO2 scrubber cartridges, 2 per box, inside the cabinet. Before any cells are installed
in the system the CO2 scrubber cartridges should be installed in every module.
Figure 8.1 – Cabinet with CO2 Scrubber Cartridges Inside
1. Remove the CO2 scrubber cartridges from the packaging.

2. Remove red tapered plug from grommet and plug from scrubber tube as shown in Figure 8.2.
Figure 8.2 – Plug Removal

3. Place the scrubber cartridge inside the cabinet to align with the cathode fan adapter and CO2 scrubber piping.
Figure 8.3 – Cathode Fan Adapter and Scrubber Piping
4. Remove the zip-ties securing the adapter and align the scrubber cartridge.
5. Insert the long PVC pipe into the rear grommet. Secure screw on the top middle manifold as shown in Figure 8.4
as inserting the PVC pipe may have loosened the screw. Torque to 3 in-lbs.
Figure 8.4 – Torque Set Screw on Middle Manifold
6. Loosen the set screw on the front tube attached to the scrubber cartridge.
7. Install the cathode fan adapter onto the front tube of the CO2 scrubber. Seat the adapter completely onto the
scrubber. Torque the set screw to 3 in-lbs.
8. Secure screw on the top front manifold shown in Figure 8.5 as the installation may have loosened the screw.
Torque to 3 in-lbs.
Figure 8.5 – Torque Set Screw on Front Manifold
9. Ensure the cathode fan power plug is connected properly to the harness as shown in Figure 8.6.
Figure 8.6 – Cathode Fan Power Plug

Energy Cell Installation
9.0 Energy Cell Installation

Note: R
ead this entire section prior to beginning the first step to gain familiarity with the entire cell placement
process, including the requirement to have personal protection gear available prior to beginning installation.
Cells contain a water-based Potassium Hydroxide (KOH) electrolyte. Direct contact with this liquid will cause
skin irritation and burns and blindness if not addressed immediately. Any personnel handling cells must wear
personal protection including approved eye protection and gloves. If KOH comes in contact with skin, rinse
immediately with water for 30 seconds. If KOH comes in contact with eyes, rinse IMMEDIATELY with water for
one minute. KOH can cause permanent blindness within 15 seconds if untreated.
1. When removing individual cells from the shipping containers, be cautious not to tilt boxes or cells during
handling. Cells are of a flooded type that will spill electrolyte if tipped on their side or turned upside down.
2. Remove cell from shipping container and inspect for any leaks, swelling, or damage that may have occurred
during shipping. Document and report any issues discovered to the Project Coordinator. Depending on the
severity of damage the cell may have to be replaced. Consult Cat DSN on whether the cell should be installed
or returned to factory. Use a clean towel to remove any debris or grease from cell positive and negative
terminals.
3. Place all cells in the enclosure.
Figure 9.1 – Module and Cell Physical Orientation
Very Important: U
se the torque wrench specified by Caterpillar to torque the 3 mm hex cap screw to 22 in-lbs on
cell connectors. Incorrect torque setting may result in a high resistance connection capable of
producing sufficient heat to permanently damage battery components.
4. After all cells are installed in the module, connect black module cable labeled “Cell 1 (-)” from EBMS module
negative to the negative side of Cell 1. Place cable lug on top of cell, then insert screw with washer (washer on
top of cable lug) according to Figure 9.2. Torque to 22 in-lbs.
5. Connect red cable labeled “Cell 18 (+)” from EBMS Module Positive to positive side of cell 18. Place lug on top of
cell, then insert screw with washer according to Figure 9.2. Torque to 22 in-lbs.
6. Connect cell interconnect cable from Cell 9 (+) to Cell 10 (-). Place lug on top of cell, then insert screw with
washer according to Figure 9.2. Torque to 22 in-lbs.
4885799 – Cell Interconnect (x 1)
4889109 – M4 x 12 Cap Screws (x 2)
4885807 – M4 Belleville Washer (x 2)
Figure 9.2 – Energy Cell Hardware Installation and Belleville Washer Orientation
7. Install cell connectors between all cells as shown in Figure 9.2. Start with position 1 (+) and cell 2 (-). Place
connector on top of cell, and then insert screws with washers (see Figure 9.2) through each end of the
connector. Torque to 22 in-lbs. There are 16 inter-connects per module.
8. After all cells are installed it is recommended to re-torque all module cell interconnections to ensure all have
been tightened and a good connection is made.
9.1 Cathode Air Supply and O2 Vent Connections
Cells may become pressurized during shipping. In order to control the pressure release, apply pressure to the
Shipping Cap while pulling out the slider. Clean any electrolyte with a paper towel.
1. Pull back on the slider for the shipping cap. Be sure to apply pressure to the cap while sliding back as the cell
may be pressurized.
2. Remove shipping cap from Module 1 Cell 1 and install the cathode air port cap. See Figure 9.3 for reference.
Lock the cap in place by pushing the slider forward.

Figure 9.3 – Energy Cell Cathode Air Supply Connection
Very Important: B
e sure that the cathode air supply cap is securely in place and not tilted in the fitting. Also,
confirm that the hoses are not kinked.
3. Repeat for all cells and store shipping caps for use when cells are removed.
9.2 Module LIN Communication Connections

1. Plug LIN ribbon cable connector into cell 1 as shown in Figure 20. There is a keying feature on the connector to
ensure the proper orientation.
2. Repeat for all cells.
Figure 9.4 – Energy Cell LIN Connections
Power Module Installation
10.0 Power Module Installation
Do not place the Power Cells near a flame or heat source.

Heating this product may result in an accident or device failure due to leakage, smoking, fire, rupture, or electric
shock. Do not use or store the product in high temperatures (greater than 55°C).
Do not allow the Power Cell to come in contact with any liquid.
Wetting or immersing the product may result in an accident or device failure due to leakage, heating, smoking,
fire, rupture or electric shock. Use and store the product in dry conditions only.
Do not drop the Power Cell. Do not allow impacts with other objects. Do not allow the housing to be punctured.
Internal damage may occur due to impact from dropping, etc. It may cause an accident or device failure due to
leakage, heating, smoking, fire, rupture or electric shock. Handle the Power Cells with care.
Do not touch or allow any tool to contact the battery terminals (+ and -).
The Power Cell terminals will discharge if a circuit is made between them. The Power Cell has a potential
difference of 36V DC (max) between (+) and (-) terminals. Beware of electric shock.
Do not short the battery module’s charging and discharging terminal (+ and -).
Short circuit of the battery module may result in a very high discharge current. Keep the Power Cell terminal
cover installed to protect the terminals (except when connecting/disconnecting the wiring).
To begin power module installation:

1. Remove power module access panel by using a 13 mm socket to loosen the 4 bolts inside the holes indicated
in Figure 10.1. Swing the panel open a few inches, then slide it to the right. This will allow it to detach from
the enclosure.

Figure 10.1 – Power Module Access Panel Removal
2. Remove one Power Cell from shipping box.

3. Insert the Power Cell partially into the top slot as shown in Figure 10.2.
Figure 10.2 – Power Cell Installation
4. Be sure that the terminals face toward the electronics panel (to the left).
5. Remove the power cell terminal cover to expose the positive and negative connections.
6. Locate the power cell terminal screws (shipped in a small plastic bag with the cell).
7. Connect the positive power cable (coming from the Power Module 1 Fuse) to the terminal marked (+) on the
power cell (the top terminal).
8. Torque the screw to 50 in-lbs.
9. Connect the negative power cable (coming from the PBMS) to the terminal marked (-) on the power cell
(the bottom terminal).
10. Torque the screw to 50 in-lbs.
11. Connect the power cell communication Wire (coming from the BMU) to the power cell. The connection point
is located between the power terminals. See Figure 10.2.
12. Install the power cell terminal cover back onto the cell as shown in Figure 10.3.
Note: The cover may not close completely over the negative terminal. This is normal.
Figure 10.3 – Power Cell Terminal Cover Installation
13. Slide the completely into the slot.

14. Repeat steps to install remaining power modules.
15. When all power modules are complete, install power module access panel. Torque panel bolts (x4) to
80 in-lbs.

SIM Card Installation
11.0 SIM Card Installation

The ESS requires a SIM card for GPRS communication. If an alternative SIM card is required, or the ESS did not
ship with a SIM card installed, follow the steps below to remove/install a SIM card.
1. Find the GPRS modem located in the electronics panel (See Figure 12.1).
2. Press the yellow button on the side of the modem and slide out the SIM card tray.
3. Install the SIM card in the designated slot following the orientation shown in the SIM card tray. Be sure to seat
completely in the tray.
4. Slide the SIM card tray into the slot and press to install completely.
5. If the card tray does not slide in easily with the SIM card in place, the small tabs on the edge of the card may
need to be shaved slightly.
Electrical Connections and Termination
12.0 Electrical Connections and Termination

The ESS requires positive and negative cable connections to the rectifier battery output and cabinet connection
to site ground. At sites where the Cat ESS will be integrated with a DG controller, additional connections are
required: a DG Start/Stop connection to the DG controller, a DG Fail signal connection, and a DG Run signal
connection.
12.1 General Cable Routing Guidelines

1. Run cables in buried conduit following local building standards.
2. The cable entry plenum to the Cat ESS is designed for cables to enter from the bottom. Cables and conduit
should NOT be visible at any point between cabinets.
3. Figure 12.1 shows the locations of the battery positive and negative terminals, grounding stud, and conduit
glands.
Figure 12.1 – Electronics Panel ESS Connection Locations

The use of stainless steel hardware is outlined in the sections that follow. In these instances, both copper and
aluminum components will be mated. Stainless steel hardware is required for all connections to allow for
varying rates of thermal expansion of the different materials.
12.2 ESS Power Cable Connections (required at all sites)

The four large cable glands at the bottom of the electronics panel are designated for the positive and negative
power cables from the rectifier. The table below shows power cable sizing for each ESS model. The terminal lugs
are designed to accommodate aluminum or copper power cables. Aluminum cable is recommended to minimize
theft value. When using aluminum cable, the end of the cable must be coated with No-Oxide grease to protect the
terminal from corrosion. Torque the compression screws to 120 in-lbs.
Aluminum Cable Requirements Copper Cable Requirements

Maximum
Model Size Size
Quantity Quantity Current (Amps)
(AWG) (AWG)
(ES6H0.75) 1/0 1 1/0 1 27
(ES12H1.5) 1/0 1 1/0 1 53
(ES18H2.25) 1/0 1 1/0 1 79
(ES24H3.0) 1/0 2 1/0 1 105
(ES30H3.75) 1/0 2 1/0 1 131
(ES36H4.5) 1/0 2 1/0 2 157
(ES14H3.5) 1/0 2 1/0 1 107
(ES20H4.25) 1/0 2 1/0 2 133
(ES27H6.0) 2/0 2 1/0 2 186
(ES34H7.75) -* -* 1/0 2 239
(ES40H8.5) -* -* 2/0 2 265
Table 12.1 – Cable Size, Cable Quantity, and Maximum Current up to 50°C
*ES34H7.75 and ES40H8.5 models require copper cable. The terminal lugs on the bus bars can only accommodate a
maximum wire size of 2/0 AWG.
12.3 Rectifier Power Cable Connections (required at all sites)

When connecting positive aluminum cable to rectifier bus positive, use an Aluminum compression lug with factory
pre-filled No-Oxide. Crimp lugs to cable ends following lug manufacturer’s instructions.
A manual circuit breaker must be installed between the rectifier battery bus and the negative power cable. This
will offer protection if a short occurs in the ESS circuit; and will offer a means to isolate the ESS for service.
12.4 Ground Cable – ESS to Site Ground (required at all sites)

1. Use 53.4 mm2 (1/0 AWG) aluminum cable to connect ESS grounding terminal to site grounding ring.
2. There is a grounding stud provided in the cable entry plenum at the bottom of the cabinet as shown in
Figure 12.1.
12.5 D
G Control Cable – Start/Stop Signal Output
(required at DG sites only)
1. The Cat ESS provides a dry contact output to signal the DG controller to start the DG when the ESS is at low
capacity. Pins 11, 12, and 13 on the site interface terminal block on comm control G6.1-ME provide connection
points for this signal. See Figure 12.2.
Figure 12.2 – Comm Control G6.1-ME Site Interface Locations
2. When the ESS determines that the DG should start, pins 11 and 12 will be shorted. Similarly, pins 12 and 13 will
open when the DG should start. See Figure 25.
3. This output is designed to connect to the “Remote Start” or “Simulated Mains” input at the DG controller. The
controller may need to be configured to respond to this input.
4. The Start/Stop output is designed to work in conjunction with a contact that monitors the Grid AC power.
• S ome DG controllers have this logic built in (usually included in the “Simulated Mains” function). If this option
is not available, a relay is needed.
• T he relay coil should be activated by AC voltage at the grid input to the ATS.
• If a closed circuit signals the DG controller to start the DG, connect the NC output of the relay in series with
TB pins 11 and 12.
• If an open circuit signals the DG controller to start the DG, connect the NO output of the relay in parallel with
TB pins 12 and 13.
• F or 3-phase applications, 3 relays will be needed.
5. There are two cable glands (smaller size) at the bottom of the electronics panel dedicated for the DG Control
Cables.

12.6 DG Control Cable – Run Signal Input (required at DG sites only)

The ESS uses a binary input at TB pins 1 and 2 to monitor DG state. The pins being shorted, signals that the DG is
providing AC power to the site. The pins being open, signals that the DG is not providing power. See Figure 12.1.
1. If there is a DG Run signal output available from the DG controller, it can be connected to TB pins 1 and 2
using two conductor 0.20 mm2 (22 AWG) wire. Be sure that the terminals are shorted when the DG is providing
AC power.
2. If the output is not available from the DG Controller, a relay will need to be installed. The relay coil should be
activated when there is AC power present at the DG input to the ATS. Connect the normally open output of the
relay to TB pins 1 and 2.
12.7 DG Control Cable – Fail Signal Input (required at DG sites only)

The Cat ESS uses a binary input at TB pins 3 and 4 to monitor a DG fail alarm. The pins being shorted, signals that
the DG has failed. See Figure 12.1.
Connect the DG Fail Signal to TB pins 3 and 4 using two conductor 0.20 mm2 (22 AWG) wire. Be sure that the
terminals are shorted when the DG controller sends the fail signal.
12.8 Circuit Breaker Protection and Total DC Charge Load

In order to properly install the Cat system, it is critical to adhere to industry electrical standards for both the cable
and DC breaker sizing to ensure a safe and reliable operation. The Cat ESS is required to have circuit breaker
protection on the DC output of the rectifier. Table 12.1 outlines the maximum current rating for each ESS model.
12.9 DC Circuit Breaker Installation

Once the appropriate size breaker is determined, it is necessary to install the breaker in the rectifier cabinet. This
will allow any service team to disconnect the Cat ESS from the power bus. If there is an existing DC circuit breaker
installed for lead acid batteries it may be sufficient to use that breaker as the lead acid batteries will be removed.
Check with the project coordinator before utilizing an existing breaker. In addition, verify the breaker size and ESS
charge requirements described in Table 12.1.
Rectifier Configuration
13.0 Rectifier Configuration

Cat ESSs may require some rectifier parameters to be changed in order to operate correctly. The procedure to
change these parameters varies depending on rectifier model. In general, the following changes are necessary:
1. Low voltage battery disconnect must be disabled. The Cat ESS does not require protection from low voltage
discharge. If LVBD is not disabled, a site visit will be required to reset the LVBD contactor if it is opened due to
low battery voltage.
2. Rectifier float voltage should be set to 54.5 VDC.
3. Battery capacity (accumulator capacity) and maximum charge current should be adjusted to allow for the
maximum charge current required for the ESS. The bus current required to charge the ESS varies depending on
ESS model and circuit breaker configuration (see Table 12.1).
13.1 Commissioning (Start-up Guide)

There are two methods to perform the ESS start-up: On-site (using FST) and remote (using the ESS IQ web
interface to send over the air commands). Both methods require personnel to be on site to switch on the modules
and to operate breakers during the process. The on-site method requires use of the field service tool and trained
personnel to carry out the start-up. The remote method does not require use of the FST but requires trained
personnel to send over the air commands.

ESS Initialization – “Power-up”
14.0 ESS Initialization – “Power-up”

It is recommended to double check all power and signal connections prior to powering on the unit. At this point
the NOC must be notified that the equipment is being powered on. The ESS can be monitored remotely during the
initial charge and discharge portions of the test, however if the location is prone to poor network connectivity it
is recommended to utilize the 4889148 CAN adapter and the field service tool for battery monitoring and control.
Follow the steps in this section for the initialization of the ESS.
1. Confirm all system boards and battery breaker are switched off.
2. If using the FST, connect the CAN adapter DB-9 to the ESS in the electronics panel (Figure 12.1) and then
connect the USB to a laptop.
3. Switch on the DC circuit breaker at the rectifier to power on the ESS.
4. Switch on the communications control board. Heartbeat LED should be blinking. All other boards should remain
off at this time.
5. Verify all enclosure fans are on.
6. Verify with a clamp meter (on the negative battery cable), or via remote monitoring that the bus current is
between 1 and 3 amps. If not in this range, shut down the ESS and contact NOC for next steps.
7. Open the FST and confirm the battery ID/serial number in the menu bar of the program and system level data
(bus voltage, bus current, system power, etc.).
Comm Control Configuration and ESS IQ Verification
15.0 Comm Control Configuration and ESS IQ Verification

15.1 Factory Default Configuration
The Cat ESS will come with a default configuration in the communications control board. Configuration
parameters include battery ID/serial number, number of modules, hardware type, and network settings, etc.
15.2 On-Site/Remote Configuration Changes

If any configuration parameters need to be modified, do it at this time. The steps listed in this section can be done
using ESS IQ OTAC remotely ONLY if there is a connection to the ESS IQ server. If the cellular provider is not
available in the area, or another cellular provider is desired it must be programmed with the FST.
1. Open the FST, and click on the “Config” button. This will open a screen which allows configuration of modules
and comm control parameters.
2. Click the “Read” button to read the existing configuration from the ESS. This will allow the user to modify only
the needed parameters and will prevent the need for generating a brand new configuration.
Comm Control Parameter Default Value
Hardware Type* Comm. Control Gen6
Serial number of ESS as shown on product label
Example:
APU ID*
If Cat APU ID (on the product label inside the electronics
panel door) is ZH700005, enter APU ID: 00005
Number of Energy Modules* 1-6 depending on configuration
Number of Power Modules* 0-6 depending on configuration
Model Model Number of Number of Power
ID Number Energy Modules Modules
ZA3 (FE10) ES6H0.75 1 0
ZA4 (FE20) ES12H1.5 2 0
ZA5 (FE30) ES18H2.25 3 0
ZA6 (FE40) ES24H3.0 4 0
Model ID ZA7 (FE50) ES30H3.75 5 0
ZA8 (FE60) ES36H4.5 6 0
ZH7 (FE22) ES14H3.5 2 2
ZH8 (FE32) ES20H4.25 3 2
ZH9 (FE43) ES27H6.0 4 3
ZHA (FE54) ES34H7.75 5 4
ZHB (FE64) ES40H8.5 6 4
Number of Cells per Module* 18 (always use this setting)
Cellular Provider* Select appropriate carrier
DG Profile DG disabled (enable only if DG control wiring is connected)
Door Sensors Enable only if door sensors are installed.
Table 15.1 – Comm Control Default Parameters
*Required for all ESSs
3. Enter the appropriate parameters (see example in Figure 15.1). Be sure all required parameters listed in
Table 15.1 are filled out. Then click write in the bottom of the window. (If using ESS IQ OTAC use the “Write
Comm Config Param” and select the appropriate parameter from the drop down menu.)

Comm Control Configuration and ESS IQ Verification
Figure 15.1 – FST Comm Configuration Window

4. A confirmation message will appear when the new configuration is successfully written to the Communications
Control Board. Click “Ok” and close the config parameters window.
5. Once programming is complete, the Communications Control Board will reboot and will take up to two minutes
to re-initialize.
6. Once initialization is complete, the modem LED should be blinking red every 1-2 seconds, then green once
every 6 minutes (for periodic data). If using the FST, observe the ESS IQ Connection status (green when
connected) in the system level data section as shown in Figure 15.2.
Figure 15.2 – FST ESS IQ Connection Status Success
7. Notify the NOC that the ESS is now sending data to ESS IQ.
Initial Charge
16.0 Initial Charge

The steps listed in this section can be done with or without the use of the FST. If performing the initial charge
test remotely, the NOC will need to perform the verification for each module. After completing the Comm Control
Configuration and ESS IQ Verification, follow the steps in this section to begin the initial charge.
Note: T he system is equipped with a power limiting mode as well as a sequential charge mode. If the rectifier
capacity is not sufficient to charge all modules at the maximum current, the system will automatically
reduce the charge current set point and attempt to reach a stable state. If the system cannot reach a stable
state in charge, the modules will begin to charge sequentially.
If at any point during this procedure, a cell or module enters a fault state, click the “Faults” button to view details.
Contact NOC for troubleshooting assistance.
16.1 Energy Module Start-up

1. Switch on the power switch for EBMS Module 1. See the system diagram on the electronics panel door for
module locations. (The energy modules are not in sequential order from top to bottom.)
2. In the Module Commands section of the FST, select Module E1. From the command drop down menu select
Address Cells, click Execute. When initially turned on the EBMS will report a Fault-LIN, execute the ‘Address
Cells’ command and wait 30 seconds. Module should reboot and begin initialization. If module remains in fault,
check all cell connections for the ribbon cable.
3. Confirm either in the FST or in ESS IQ that data is reporting for Module 1. The module number in the “Active
Modules” area will turn green (see Figure 16.1). Since the modules have hardware based addressing it is
necessary to verify data is reporting for the physical location of the module.
Figure 16.1 – FST Module Communication (Energy Module 1)

Initial Charge
4. Under “Module Data” select the appropriate module.

5. Confirm module current reaches a stable value between 12A and 28A.
6. Click the “Cell Level” tab at the top left of the display area.
7. Confirm all cells enter “Charge.” See Figure 16.1.
Note: cells may enter discharge temporarily while searching for the appropriate charge current.
8. Confirm all cell voltages are 2.2V (+/- 0.3V) and that module voltage is 40.5V (+/- 4.0V).
9. Repeat steps 1 through 7 for all energy modules. Verify data is reporting for each.
16.2 Power Module Start-up

1. Switch on the power switch for PBMS Module 1. See the System diagram on the electronics panel door for
module locations.
2. Confirm either in the FST or in ESS IQ that data is reporting for Power Module 1 (see Figure 16.2). Since the
modules have hardware based addressing it is necessary to verify data is reporting for the physical location of
the module.
Figure 16.2 – FST Module Communication (Power Module 1)
Initial Charge
3. Confirm the power module state is “Charge.”

4. Confirm the power module current reaches a stable value between 4.0A and 40.0A.
5. Confirm the power module voltage is 28.0V (+/- 4V).
6. Repeat steps 1-5 for all power modules. Verify data is reporting for each. See Figure 16.3.
Figure 16.3 – FST All Modules Charging

Site Load Discharge Test
17.0 Site Load Discharge Test

Once the unit has reached full capacity and all modules are in “Idle” state, the ESS can be tested with the site
load. Click the “Faults” button to confirm no faults have occurred during charge. At this point all previously
existing batteries should be switched off and “locked-out” from operation. The Cat ESS is not designed to work
in parallel with VRLA batteries. It is recommended to monitor the bus voltage during this time and restore the AC
power if it drops below 48.0V at any time. Follow the steps in this section to complete the site load discharge test.
1. Switch off all phases of the AC breaker.
1. Confirm bus voltage is between 48.0V and 52.5V.
2. The ESS should discharge and provide power to the site load. The system is designed to discharge the power
modules first. You will notice that the energy modules’ current is approximately zero.
3. Confirm the values in the following steps using Figure 17.1.
Figure 17.1 – Power Module Discharge Test
5. Confirm system power does not exceed the ESS rated capacity (750 watts per energy module).
6. Confirm system state is NCL and module states are “Disch.”
7. Confirm the power modules are discharging at approximately equal currents.
8. Click “Energy Module Test” button.
9. Wait 10 seconds then confirm current for all energy modules is within +/- 1.0A of the other energy modules.
See Figure 17.2.
Note: If modules are at different SOC, the module with higher SOC will likely discharge at a higher current.
10. Confirm all energy cells are in “Discharge” state.
Site Load Discharge Test
Figure 17.2 – Energy Module Discharge Test
11. Confirm bus voltage is at least 48V.

12. Allow the system to discharge for about 10-20 minutes and then switch on the AC breaker.
13. Confirm all modules and cells return to charge as outlined in Figure 16.3.

Diesel Generator Control Test
18.0 Diesel Generator Control Test

If there is a diesel generator connected to the ESS, a functional test can be done to confirm connections
and settings.
1. Confirm the ESS has been configured to operate with a DG. See Section 15.
2. Confirm the ESS is in “Ready” state.
3. Switch off the main AC breaker to the site.
4. Confirm the ESS is supporting the site load.
5. Test the DG start function by either:
• Clicking the “DG On” button in the FST, or
• Sending an OTA command to turn on the DG.
Note: O
nly when the Comm is configured with DG Enabled, the DG On/Off buttons will appear in the FST. See
Figure 18.1.
Figure 18.1 – DG On/Off Buttons
6. When the DG controller start delay time has been met, the DG will start and begin providing power to the
rectifier.
7. Confirm that all modules begin charging and that DG is able to support the ESS charging load.
8. Switch on the main AC breaker to the site.
9. Confirm that the DG turns off (may be a cool down period).
10. Confirm that the ESS begins charging.
Note: T he ESS has a feature called “Minimum Charge Time.” It recognizes if the DG has been run during the last
outage. If so, the DG will automatically be started as soon as the grid turns off. The default minimum charge
time is set to 4 hours (adjustable). This can be overridden by clicking the “DG Off” button on the FST or by
sending an OTA Command to turn off the DG.
Acceptance Test Procedure
19.0 Acceptance Test Procedure

Following the initial charge, full charge, and site load discharge tests, the ESS can now be considered
“In-Service” as outlined by document M0066022 Cat ESS Remote Monitoring Manual. This process will verify all
cells have fully charged without fault and that no other faults exist on the system.
Caterpillar has outlined an Acceptance Test Procedure/Protocol that can be used to qualify all aspects of the Cat
equipment and site integration. Reference document “Acceptance Testing Protocol - Gen6 – General” for this
form (located in Appendix A). It can be used to submit to the client for integration acceptance.

Appendix A – Acceptance Testing Protocol
20.0 Appendix A – Acceptance Testing Protocol

20.1 Product Installation and Acceptance Authorization
Appendix B – Telecom Pad Specification
21.0 Appendix B – Telecom Pad Specification





Notes
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Application &amp; Installation Guide ESS

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Copyright:

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Application &amp; Installation Guide ESS

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Application &

Energy Storage System

Energy Storage System

2.0 Site Survey, Pad Requirments, and Product Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.0 Installation Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.0 Site Inspection and Material Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.0 Equipment Inspection, Handling, and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6.0 Pad Placement and Enclosure Anchoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7.0 Mechanical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

8.0 Scrubber Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

9.0 Energy Cell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

10.0 Power Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

11.0 SIM Card Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

12.0 Electrical Connections and Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

13.0 Rectifier Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4 EN ER GY S TOR AGE S YSTEM

14.0 ESS Initialization – “Power-up” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

15.0 Comm Control Configuration and ESS IQ Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

16.0 Initial Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

17.0 Site Load Discharge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

18.0 Diesel Generator Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

19.0 Acceptance Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

20.0 Appendix A – Acceptance Testing Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

21.0 Appendix B – Telecom Pad Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-54

1.2 Safety Signs

Safety Sign Description

Warning: Indicates a potentially hazardous situation, which if not avoided,

Caution: Indicates a potentially hazardous situation, which if not avoided, could

Electric shock: Use extreme caution when servicing components. There is a

Table 1.1 – Safety Signs

6 EN ER GY S TOR AGE S YSTEM

1.3 Supporting Documents

2.0 Site Survey, Pad Requirements, and Product Sizing

2.2 Key Site Survey Information

Table 2.1 – Key Site Survey Information

2.3 Pad Construction and Guidelines

8 EN ER GY S TOR AGE S YSTEM

3.0 Installation Tools

Part Number Description

10 EN ER GY S TOR AGE S YSTEM

4.0 Site Inspection and Material Inventory

4.2 Shipment Inspection and Material Inventory

4.3 Installer Provided Material Inventory

Cat Part Number Description Quantity

12 EN ER GY S TOR AGE S YSTEM

5.0 Equipment Inspection, Handling, and Unpacking

5.2 Equipment Handling

5.3 Equipment Unpacking

6.0 Pad Placement and Enclosure Anchoring

6.1 Primary Enclosure Placement

Figure 6.1 – ESS Conduit Locations

2. Open the electronics panel door. See Figure 6.2.

Figure 6.2 – Cable Entry Plenum Removal

14 EN ER GY S TOR AGE S YSTEM

4. Slide the enclosure over the conduit holes.

5. Verify there is clearance to open all doors of the enclosure.

Figure 6.3 – ESS Door Clearances

6.2 Expanded Enclosures

Figure 6.4 – Enclosure Mating Pins and Blanking Plate

6.3 Power Module Enclosure

6.4 Enclosure Anchoring

Figure 6.6 – Anchor Bolt Location

16 EN ER GY S TOR AGE S YSTEM

7.0 Mechanical Assembly

Application & Installation Guide ESS

Application & Installation Guide ESS