BATTERY INSTALL GUIDELINES FOR ACCREDITED INSTALLERS EFFECTIVE 15 AUGUST, 2017 MANDATORY 1 NOVEMBER, 2017

Transcription

1 BATTERY INSTALL GUIDELINES FOR ACCREDITED INSTALLERS EFFECTIVE 15 AUGUST, 2017 MANDATORY 1 NOVEMBER, 2017

2 TABLE OF CONTENTS Cntents 1 PREFACE Existing Standards 7 2 SCOPE 9 3 REFERENCED DOCUMENTS 12 4 DEFINITIONS 13 5 HOW TO USE THESE GUIDELINES 16 6 BATTERY SYSTEM HAZARDS General Hazard Classificatin General Electrical Hazard General Decisive Vltage Classificatin (DVC) Battery System Shrt-Circuit Current/ Prspective Fault Current Energy Hazard Fire Hazard Explsive Gas Hazard Chemical Hazard Mechanical Hazard 23 7 INSTALLATION General Manufacturer s Instructins Safety Data Sheet (SDS) Restricted Access Envirnmental Effects External Influences Vltage Limits Prduct Standards Lcatin General 27 2

3 7.2.2 Dmestic Nn Dmestic Battery System Accmmdatin General Battery System Rm Battery System Enclsure Fenced f Sectin f Larger Rm 31 8 HAZARD REDUCTION METHODS Electrical Hazard General Pre-assembled BESS Islatin General Parallel Battery Systems Lcatin Overcurrent Prtectin General Parallel Battery Systems Lcatin Battery System Output Wiring General Parallel Battery Systems Vltage Drp Earthing General Earth Fault Alarm Equiptential Bnding Energy Hazard Fire Hazard Chemical Hazard General Safe Wrk Prcedures Persnal Prtective Equipment Explsive Gas Hazard General Ventilatin General Flded (vented) and Sealed Valve-Regulated Lead Acid Cells Rate f Ventilatin (Lead Acid) Charging Rate General Flded Lead Acid Battery Systems Sealed Valve Regulated Lead Acid Battery Systems Methd f Ventilatin General Natural Ventilatin Mechanical Ventilatin 44 3

4 Arrangement f Ventilatin Nickel Cadmium Other Battery System Chemistries Lcatin f Ignitin Surces General Exclusin Znes Scket Outlets Luminaires Other Equipment Mechanical Hazard General Mving Parts 47 9 LABELS AND SAFETY SIGNAGE Energy Strage and Battery Type UN Number Battery System Lcatin Vltage and Current Explsive Gas Hazard Chemical Hazard Energy Hazard Islatin Devices Overcurrent Devices Battery System Cables Shutdwn Prcedure Persnal Prtective Equipment COMMISSIONING AND TESTING DOCUMENTATION General System Manual MAINTENANCE 55 APPENDIX A EXAMPLE COMMISSIONING SHEET 56 APPENDIX B SIGNS 58 4

5 These guidelines have been develped by Clean Energy Cuncil. They represent latest industry best practice fr the installatin f battery systems and pre-assembled BESS. Cpyright 2017 While all care has been taken t ensure these guidelines are free frm missin and errr, n respnsibility can be taken fr the use f this infrmatin in the installatin f battery systems and pre-assembled BESS. 5

6 1 PREFACE The installatin f grid-cnnected energy systems - including batteries, is a relatively new and emerging field, and ne in which there is a lack f definitive standards. There are existing standards fr the design and installatin f statinary battery systems (refer Existing Standards belw). Hwever, such standards were prepared fr use with traditinal lead acid and nickel cadmium battery chemistries, and d nt address recent prduct innvatins and ther develpments. Such develpments include: Battery chemistries ther than lead acid and nickel cadmium, such as: Lithium (eg. lithium irn phsphate, lithium ferr phsphate, etc), Flw (eg. zinc brmine, vanadium redx flw, etc); and, Hybrid in (eg. aqueus) Intercnnected pwer cnversin equipment (such as multi-mde inverters), which can result in energy strage being cntinually cnnected t the grid netwrk, and may include phtvltaic r ther energy surces Availability f pre-assembled integrated battery energy strage systems, manufactured as cmplete packages. Such systems include battery strage, inverters and ther cntrl equipment int a single assembly, with pre-engineered cnnectins This dcument prvides guidance t designers and installers f energy strage and must be read in cnjunctin with existing relevant standards, cdes, netwrk service prvider rules and ther such requirements. These guidelines, referencing Australian and internatinal standards, apply t energy strage perating at bth: Extra-lw vltage (ELV); and, Lw vltage (LV). Additinally, these guidelines apply t the fllwing energy system types: Grid-cnnected; and, Stand-alne. Fr further infrmatin n applicability refer t: 2 SCOPE 6 BATTERY SYSTEM HAZARDS General 6

7 1.1 Existing Standards There are several existing Australian Standards cvering installatin f statinary batteries in buildings. Whilst these standards have sme cmmn cntent, their scpe and applicability vary as fllws: Standard Scpe Ntes AS Guide t the installatin, maintenance, testing and replacement f secndary batteries in buildings AS Electrical installatins - Secndary batteries installed in buildings AS Secndary batteries fr use with standalne pwer systems Installatin and maintenance This standard cvers practices fr the installatin, maintenance, testing and replacement f lead acid and alkaline (eg. nickelcadmium) secndary batteries installed in r n buildings. The scpe includes batteries with a nminal vltage f at least 24VDC and a capacity exceeding 10A.h (at the 1 hr rate.) This standard cvers the installatin (including layut) and maintenance, f lead acid and alkaline (eg. nickelcadmium) secndary batteries installed in r n buildings, structures r premises. The scpe includes batteries with a nminal vltage f at least 24VDC and a capacity exceeding 10A.h (at the 1 hr rate.) This Standard cvers the installatin, maintenance, testing and replacement f secndary batteries, having nminal vltages nt exceeding 115 VDC, fr use with stand-alne systems. Stand-alne systems are thse that are nt cnnected t the pwer distributin systems f an electricity supply authrity. This Standard applies t all battery chemistries, including lead-acid and nickel-cadmium. T be read in cnjunctin with AS Electrical installatins - Secndary batteries installed in buildings T be read in cnjunctin with AS Guide t the installatin, maintenance, testing and replacement f secndary batteries in buildings This standard is referenced by AS/ NZS Standalne pwer systems system design, safety & installatin 7

8 Standard Scpe Ntes AS/ NZS Stand-alne pwer systems system design, safety & installatin AS/ NZS Grid cnnectin f energy systems via inverters - Installatin requirements This standard sets ut design, safety and installatin requirements fr stand-alne pwer systems used fr the supply f extralw (ELV) and/ r lw vltage (LV) electric pwer t an electrical lad. This standard specifies the electrical and general safety requirements fr inverter energy systems cnnected t the grid at lw vltage. This standard includes requirements fr cnnectin f an inverter t an energy surce including battery strage. Such requirements include cnnectins, cabling, vercurrent prtectin and islatin devices. This standard references AS Secndary batteries fr use with stand-alne pwer systems Installatin and maintenance - 8

9 2 SCOPE This dcument applies t the installatin f battery systems up t the terminals f pwer cnversin equipment (PCE), such as inverters, charge cntrllers, etc. That is, the scpe includes the fllwing: Battery Battery Enclsure Cabling Switchgear (Prtectin & Islatin Devices) Auxiliary Equipment (eg. Battery Management System (BMS), and ther equipment required by the manufacturer) Additinally, this dcument cvers the installatin f pre-assembled integrated battery energy strage systems (BESS) which includes the battery system, cabling, switchgear, pwer cnversin equipment and auxiliary equipment. The scpe f this dcument als includes installatin f battery systems/ pre-assembled BESS as fllws: A nminal vltage 12VDC Rated capacity f 1kWh and 200 kwh C10 rating fr lead acid batteries 0.1C fr lithium chemistries Manufacturer s specified energy capacity, fr ther chemistries Refer t Figure 1, Figure 2, Figure 3 and Figure 4 fr examples f the scpe f these guidelines. The scpe des nt include the fllwing: Telecmmunicatin Equipment Electric Vehicles Prtable Equipment Sites with critical pwer supply requirements (eg. acute care hspitals, distributr sub-statin supprt, etc) 9

10 Figure 1 Scpe f these guidelines: The battery system including cabling up t PCE terminals Figure 2 Scpe f these guidelines: Installatin f pre-assembled integrated battery energy strage systems (pre-assembled BESS) 10

11 Figure 3 Scpe f these guidelines: Installatin f pre-assembled integrated battery energy strage systems (pre-assembled BESS) Figure 4 Scpe f these guidelines: Installatin f pre-assembled integrated battery energy strage systems (pre-assembled BESS) 11

12 3 REFERENCED DOCUMENTS AS Structural design actins - Earthquake actins in Australia AS 1319 Safety signs fr the ccupatinal envirnment AS Swimming pl safety - Safety barriers fr swimming pls AS Guide t the installatin, maintenance, testing and replacement f secndary batteries in buildings Vented cells AS Guide t the installatin, maintenance, testing and replacement f secndary batteries in buildings Sealed cells AS/ NZS 3000 Electrical installatins (knwn as the Australian/New Zealand Wiring Rules) AS Electrical installatins - Secndary batteries installed in buildings - Vented cells AS Electrical installatins - Secndary batteries installed in buildings - Sealed cells AS Secndary batteries fr use with stand-alne pwer systems - Installatin and maintenance AS/ NZS Stand-alne pwer systems - Safety and installatin AS/ NZS Stand-alne pwer systems - System design AS/ NZS Grid cnnectin f energy systems via inverters Installatin requirements AS/ NZS Grid cnnectin f energy systems via inverters Inverter requirements AS/ NZS Electric cables - Plymeric insulated - Fr wrking vltages up t and including 0.6/1 (1.2) kv AS/ NZS Electric cables - Plymeric insulated - Fr wrking vltages up t and including 450/750 V AS Infrmatin technlgy equipment - Safety - General requirements AS Uninterruptible pwer systems (UPS) - General and safety requirements fr UPS used in peratr access areas AS Uninterruptible pwer systems (UPS) - General and safety requirements fr UPS used in restricted access lcatins NZS 4219 Seismic perfrmance f engineering systems in buildings IEC Safety Of Pwer Cnverters Fr Use In Phtvltaic Pwer Systems - Part 1: General Requirements IEC Safety Of Pwer Cnverters Fr Use In Phtvltaic Pwer Systems - Part 2: Particular Requirements Fr Inverters IEC Secndary cells and batteries cntaining alkaline r ther nn-acid electrlytes - Safety requirements fr secndary lithium cells and batteries, fr use in industrial applicatins 12

13 4 DEFINITIONS Where pssible, terms and definitins have been derived frm AS/ NZS 3000, AS/NZ 5033, AS 4777, [DR] AS/ NZS 5139, ther relevant standards, cdes r industry terminlgy. Sme terms have been adapted in line with industry and market develpments r translated int plain language; and, sme terms are unique t this dcument. Adjacent Within three meters, where each item is fully visible frm bth lcatins Arc Flash An electrical explsin r discharge, which ccurs between electrified cnductrs during a fault r shrt circuit cnditin Authrised persn A persn in charge f the premises, r the licenced electrician/ cntractr/ accredited persn, r ther such persn appinted r selected by the persn in charge f the premises t perfrm certain duties Battery A unit cnsisting f ne r mre energy strage cells cnnected in series, parallel r bth Battery Cell A basic functinal unit f a battery generally cntaining electrdes, electrlyte, terminals, etc. Battery Energy Strage System (BESS) A system cnsisting f pwer cnversin equipment (PCE), battery system (s), switchgear and ther such equipment. A BESS may be manufactured as a cmplete package where all abve cmpnents are integrated int a single assembly with pre-engineered cnnectins (referred t as a Preassembled BESS in this dcument.) Battery enclsure An enclsure cntaining a battery r batteries suitable fr the installatin lcatin and assciated cmpnents Battery management system (BMS) An electrnic device which safely manages a battery/ battery system by ensuring it is within its safe perating parameters. Such parameters generally include vercharge, vercurrent, ver discharge, verheating, etc. Battery mdule One r mre batteries linked tgether, generally incrprating electrnics fr mnitring, cycling and/ r prtectin Battery system A system cmprising ne r mre cells, mdules r battery systems. It may include a battery management system (BMS), auxiliary equipment and ther supprting equipment. It des nt include pwer cnversin equipment (PCE). Bunding/ bunds A physical system fr the retentin f ptentially hazardus substances, eg. electrlyte Cmbustible material a material that, in the frm in which it is used and under the cnditins anticipated, will ignite and burn Cntact, direct Cntact with a cnductr/ cnductive parts that is live in nrmal service Cntact, indirect Cntact with a cnductr/ cnductive parts that is nt nrmally live but has becme live under fault cnditins (eg. due t a breakdwn f insulatin) Damp situatin A situatin in which misture is either permanently r intermittently present t the extent t impair the effectiveness and safety f an electrical installatin Dwelling, dmestic An Australian r New Zealand building as specified in the Natinal Cnstructin Cde (NCC) under Australian building classificatins, as fllws: 13

14 Class 1, examples include: Detached huse Terrace huse Twn huse Villa unit Barding huse/ guest huse/ hstel (subject t specified cnditins refer t clause 1.3.2(b) f the Natinal Cnstructin Cde 2015, Vlume 2) Class 2, examples include: A building cntaining 2 r mre sle-ccupancy units each being a separate dwelling such as an apartment blck Class 10, examples include: A nn-habitable building being a private garage, carprt, shed, etc Nte that AS/ NZS 5033:2014 includes Class 3 as a dmestic dwelling. Hwever, this dcument and AS/ NZS des nt include Class 3 as a dmestic dwelling. Dwelling, nn-dmestic An Australian r New Zealand building as specified in the Natinal Cnstructin Cde (NCC) under Australian building classificatins, that is nt Class 1, Class 2 r Class 10. Nte that AS/ NZS 5033:2014 includes Class 3 as a dmestic dwelling. Hwever, this dcument and AS/ NZS des nt include Class 3 as a dmestic dwelling. Fire resistance level (FRL) as defined in the Natinal Cnstructin Cde (NCC), is the grading perid in minutes fr three criteria: structural adequacy, integrity and insulatin Material Safety Data Sheet (MSDS) See Safety Data Sheet (SDS) Prt (f PCE) Access t a device (eg. inverter) where electrmagnetic energy r signals may be supplied r received Pwer cnversin Equipment (PCE) An electrical device that cnverts ne kind f electrical pwer frm a vltage r current surce int anther with respect t vltage, current and frequency (eg. inverters, charge cntrllers, etc) Readily available capable f being reached fr inspectin, maintenance r repairs (withut having t dismantle structural parts, cupbards, benches, etc) Readily accessible capable f being reached quickly withut having t remve bstructins, use f elevatin equipment (eg. ladder); and nt mre than 2 metres abve the grund/ flr/ platfrm Restricted access (t battery system/ pre-assembled BESS) - Access restricted, t authrised persns, t the fllwing: DC islatin devices DC vercurrent devices DC cabling (between batteries/ battery mdules and DC vercurrent devices) Live parts (eg. PCE input terminals, battery cell terminals, DC busbars, etc) Access can be restricted: By a barrier, such as: 14

15 A perimeter fence/ barrier/ dr t a dedicated rm with access nly via a padlcked/ equivalently secured gate/ dr; r, Enclsure (where the relevant parts are fully enclsed and are nly accessible with the use f a tl (eg. screwdriver, key, etc) By lcatin (eg. where there is n ready means f access) Nte that restricted access is nt required t DC battery cabling between batteries/ battery mdule vercurrent and PCE. Hwever, the general cable installatin requirements f AS/ NZS 3000 shall apply. Risk assessment - A risk assessment builds knwledge and understanding abut hazards and risks that have been identified s that infrmed decisins can be taken abut cntrlling them. Safe wrk prcedures a part f a risk management prcess which utlines hazards, risks and cntrl measures t be applied t ensure an activity is cnducted in a way that satisfactrily reduces the risk f injury Statinary batteries permanently installed batteries, nt in use fr a prtable applicatin Safety Data Sheet (SDS) a dcument that prvides critical infrmatin abut hazardus materials. Typically such infrmatin includes the chemical s identity and ingredients, health and physical hazards, safe handling and strage prcedures, emergency prcedures and dispsal cnsideratins. 15

16 5 HOW TO USE THESE GUIDELINES The purpse f this dcument is t prvide guidance t battery installers and prmte: Best practice Cmpliance with existing standards Familiarity with the methdlgy f the frthcming standard AS/ NZS Electrical Installatins - Safety f battery systems fr use with pwer cnversin equipment System: Safety Reliability Perfrmance T fully understand the prceeding clauses the fllwing terms shuld be reviewed by referring t 4 DEFINITIONS: Battery system Battery energy strage system (BESS) Restricted access Dwelling Dmestic Nn-dmestic Readily available T cmply with the requirements f this dcument, the fllwing shuld ccur: 1. Apply the clauses f 7 INSTALLATION: 7.1 General 7.2 Lcatin 7.3 Battery System Accmmdatin 2. Determine the hazards applicable t the battery system/ pre-assembled BESS accrding t the table in 6 BATTERY SYSTEM HAZARDS General 3. Apply the risk reductin methds specific t the battery system/ pre-assembled BESS in accrdance with 8 HAZARD REDUCTION METHODS Nte: Only the risk reductin methds applicable t the battery system/ pre-assembled BESS need be applied. Fr example, where a battery installer intends t install a hybrid in chemistry and where an explsive gas hazard is nt fund t be present, the risk reductin methds fund in 8 HAZARD REDUCTION METHODS Explsive Gas Hazard need nt apply 4. Apply the requirements f: 9 LABELS AND SAFETY SIGNAGE 16

17 10 COMMISSIONING AND TESTING 11 DOCUMENTATION 17

18 6 BATTERY SYSTEM HAZARDS 6.1 General There are numerus hazards assciated with battery systems/ pre-assembled BESS, such as: Electrical Energy Fire Chemical Explsive Gas Mechanical The fllwing sectins discuss the nature f each hazard. Where a hazard is identified, as per the chemistry and verall battery system/ BESS design, risk reductin methds shall be applied t eliminate r reduce these risks t prtect persns, prperty and livestck frm: Electric shck Fire Physical injury Risk reductin methds are specified in: 7 INSTALLATION 8 HAZARD REDUCTION METHODS 6.2 Hazard Classificatin General The fllwing table displays hazards that apply t specific battery chemistry types. Where a chemistry is nt listed, a risk assessment shall be undertaken t determine which hazards apply t the specific battery system and the relevant risk reductin methds shall be applied. In all cases, as per Safety Data Sheet (SDS), the installatin f all battery systems and preassembled BESS shall be in accrdance with the SDS applicable t the chemistry. 18

19 Battery Hazard Lead Acid Nickel Alkaline Lithium Flw Hybrid In Electrical Energy Fire Nte 1 Nte 1 Nte 1 N/A N/A Chemical/ Txic Gas Explsive Gas N/A Nte 2 N/A Mechanical This table has been adapted frm [DR] AS/ NZS Electrical installatins - Safety f battery systems fr use with pwer cnversin equipment. Ntes: 1 - Lead acid, nickel alkaline and lithium chemistry types may represent a fire hazard. As per Safety Data Sheet (SDS), the SDS shall be cnsulted t determine if a fire hazard is present. In all cases, fire hazard risk reductin installatin methds shuld be cnducted in accrdance with 8 HAZARD REDUCTION METHODS Fire Hazard - especially where the chemistry type may change t a mre hazardus type ver the life f the BESS. 2 - Typically, lithium chemistry types d nt emit explsive gas during nrmal wrking cnditins. Hwever, sme may release hydrgen under fault cnditins (eg. lithium manganese). T determine if a lithium chemistry represents an explsive gas hazard the SDS shall be cnsulted as per Safety Data Sheet (SDS) Electrical Hazard General The electrical risks assciated with battery systems are dependent n the vltage f the battery system and ther cnnected equipment such as earthing, prtectin devices, etc Decisive Vltage Classificatin (DVC) Decisive Vltage Classificatin (DVC), as defined in IEC 62109, infrms the level f electric shck hazard. It als infrms the designer/ installer n safety measures required fr electrical prtectin, enclsures and interlcks. Table 1 Summary f Decisive Vltage Classificatin (DVC) Ranges prvides a summary f DVC levels. DVC refers t the vltage level and the degree f separatin f the relevant battery prt frm the grid r ther energy surce. It is the highest vltage that ccurs cntinuusly between tw live parts during wrst case cnditins. 19

20 Where a battery system is within the DVC A (eg. 48V) range and is cnnected t a PCE prt als within the DVC A range, it is cnsidered relatively safe with respect t an electric shck hazard (althugh ther types f hazards may be present). Hwever, where a battery system is within the DVC A (eg. 48V) range and is cnnected t a PCE prt classified as DVC C (fr example, a nn-separated inverter cnnected t the grid) the entire battery system wuld be classified as DVC C. The applicable DVC is always the highest classificatin f the equipment within, and cnnected t, a battery system, which may be greater than the vltage at the battery terminals. Ntes: Decisive Vltage Classificatin (DVC) Table 1 Summary f Decisive Vltage Classificatin (DVC) Ranges Limits f Wrking Vltage (V) AC Vltage U ACL r.m.s. AC Vltage U ACPL peak A B C > 50 >71 >120 DC Vltage U DCL mean Under fault cnditins, DVC-A circuits are permitted t have vltages up t the DVC-B limits fr a maximum f 0.2s Fr DC vltages greater than extra lw vltage (120V ripple free) and nt exceeding 1,500V, AS/ NZS 3000 defines this as lw vltage Where a battery system has a nminal vltage f 48VDC (DVC-A) but exceeds 60VDC (but nt exceeding 120VDC) under charging including bst cnditins, it wuld be classified as DVC-B Battery System Shrt-Circuit Current/ Prspective Fault Current The prspective shrt circuit/ fault current may be significant in a battery system. This cnditin ccurs where the impedance between cnductrs is almst zer and vercurrent prtectin des nt perate. This figure is imprtant fr selectin f vercurrent prtectin, cabling, etc. The shrt circuit/ prspective fault current shuld be btained frm the battery system manufacturer. Alternately, the fault current may be calculated, based upn the internal resistance f the battery system, by using the frmula in AS , clause Energy Hazard An energy, r arc flash, hazard ccurs where there is a release f energy caused by electrified cnductrs when there is insufficient islatin r insulatin t withstand the applied vltage. Under such cnditins, electrical energy is transferred int ther frms f energy including heat, light and sund. 20

21 The severity f any such energy hazard depends n: Vltage Current Duratin f event Prximity t the hazard; and, Obstructins near the hazard Such a hazard may ccur under the fllwing scenaris: Accidental cntact between battery terminals with a cnductive tl such as an uninsulated scket wrench, spanner, etc A dead shrt within cnnected PCEs A build-up f cnductive material acrss cnductrs such as fluid, metal shavings, etc Damage t cable insulatin, resulting in electrical cnductivity between cpper cnductrs In additin t ther risk reductin methds, batteries and assciated DC cabling shall: Be prtected frm mechanical damage; and, Access t battery systems and pre-assembled BESS shall be restricted t authrised persns. (Refer t Restricted Access and Authrised Persns in 4 DEFINITIONS.) Fire Hazard The manufacturer s SDS shall be assessed t determine if a fire risk is present as per Safety Data Sheet (SDS). Nte that a fire hazard is distinct frm: An energy hazard as defined in Energy Hazard An explsive gas hazard as defined in Explsive Gas Hazard A fire hazard may be present in any chemistry type. A fire hazard may be present where the battery system chemistry is lithium. As per United Natins (UN) 38.3, abuses that may result in fire include: Lw ambient pressure Overheating Vibratin Shck External shrt circuit Impact Overcharge 21

22 Frced discharge Explsive Gas Hazard Under certain cnditins, sme battery systems and pre-assembled BESS emit explsive gas which represents a hazard where an ignitin surce is present. Ignitin surces may include: Battery system islatin and vercurrent devices Switches internal t electrical cmpnents Fans Mtrs General electrical switches (eg. light & pwer) Typically this hazard applies t acid and alkaline based chemistries, particularly lead acid. Risk mitigatin methds include: Ventilatin Clearance frm and/ r eliminatin f ignitin surces Chemical Hazard There are many types f chemical hazards that a battery system may represent. Such hazards may cncern ne r mre f the fllwing: Health (t persns and animals) Physical (such as damage t equipment) Envirnment (including sil and water cntaminatin) Typically, stred chemical energy in the frm f a fluid r gel electrlyte is the surce f a chemical hazard. T determine if a battery system represents such a hazard, the SDS shall be cnsulted. A chemical hazard may ccur: Under nrmal perating cnditins (eg. venting f hydrgen gas when charging) Under fault r abuse cnditins, including: Mechanical (eg. impact, puncture, etc) Thermal (eg. in excess f specified perating cnditins) Electrical (eg. frced discharge) 22

23 Examples f hazard statements frm existing, cmmercially available, energy strage SDS s are as fllws: May be crrsive t metals Harmful if swallwed and/ r inhaled Pssible emissin f txic fumes when invlved in fire May cause severe irritatin, burns and ulceratin t skin and eyes May damage fertility r the unbrn child May cause damage t rgans thrugh prlnged r repeated expsure Very txic t aquatic life with lng lasting effects May cause lng-term adverse effects in the envirnment Risk reductin methds vary accrding t the nature f the chemical hazard. Hwever, general methds include: Prviding restricted access t battery systems Prviding physical barriers, such as bllards, where battery systems may be subject t physical damage such as in a garage Use f bunding t retain harmful substances in the event f spillage and/ r discharge Use f persnal prtective equipment, spill kits and safe wrk prcedures when handling, repairing, maintaining, installing and inspecting battery systems Mechanical Hazard All battery systems represent a mechanical hazard. This hazard relates t the fllwing: Weight Sharp edges/ crners Mving parts (eg. Pumps in flw batteries) Limited balance pints (eg. Tall and thin battery prfiles) Mechanical hazards may be due t: Inapprpriate battery accmmdatin and arrangement An external frce such as a seismic earthquake When installing battery systems, cnsideratin shall be given t: Type Quantity Prfile; and, Size 23

24 The fllwing sectins reduce the risk f mechanical hazards: 7.3 Battery System Accmmdatin 8 HAZARD REDUCTION METHODS Mechanical Hazard 24

25 7 INSTALLATION 7.1 General Manufacturer s Instructins The installatin f all battery systems shall be in accrdance with manufacturer s instructins Safety Data Sheet (SDS) The installatin f all battery systems shall be in accrdance with the safety data sheet applicable t the battery chemistry and battery system/ pre-assembled BESS Restricted Access Restricted access shall be prvided t battery systems t prevent access by unauthrised persns. Restricted access may be achieved by the fllwing: A dedicated battery rm A dedicated enclsure A fenced ff, and secure, sectin f a larger rm A pre-assembled integrated BESS may inherently include a suitable enclsure. Refer t 4 DEFINITIONS a definitin f Restricted Access Envirnmental Effects Pre-assembled BESS shall have an IP rating apprpriate fr the envirnment in which they are installed in accrdance with AS/ NZS All equipment expsed t the utdr envirnment shall be at least IP 54 and UV resistant. Higher ratings shuld be cnsidered fr trpical lcatins. Cnnectin f wiring, cnduit and glands t IP rated equipment and/ r enclsures shall be installed s the minimum IP rating is maintained External Influences BESS and battery systems shall be able t perate safely and functin prperly in the cnditins in which they are likely t be expsed. Particular situatins include: 25

26 Slar radiatin (direct sunlight) Ambient temperature External heat surces Presence f water r high humidity Presence f slid freign bdies Presence f crrsive r plluting substances Impact Vibratin Other mechanical stresses Presence f flra and fauna Vltage Limits Fr dmestic installatins, battery system DC vltages shall nt exceed 600V. Fr nn-dmestic installatins, DC vltages shuld nt exceed 1500V Prduct Standards At all times, batteries and battery mdules shuld meet relevant prduct standards, which may include: Lead Acid AS/ NZS IEC AS 3731 IEC IEC IEC IEC Nickel Cadmium AS 3731 IEC IEC Lithium IEC IEC IEC

27 Flw [DR] IEC Aqueus In IEC Pre-assembled BESS shall meet relevant prduct standards, which may include: AS AS IEC AS/ NZS ; and, Requirements f AS/ NZS Lcatin General The fllwing lcatin requirements apply t battery systems and pre-assembled BESS. The fllwing shall apply: Be installed in accrdance with the manufacturer s specificatins including ambient minimum and maximum temperatures as per 7 INSTALLATION Manufacturer s Instructins and 7 INSTALLATION External Influences Refer t Figure 5 and Figure 6 fr examples. Figure 5 Example manufacturer s specificatins (temperature, humidity, altitude) 27

28 Figure 6 Example manufacturer s specificatins (clearance) IP & UV rating be suitable fr the envirnment as per 7 INSTALLATION Envirnmental Effects Prtected against physical damage and ther envirnmental and external factrs (eg. Impact frm vehicles, high humidity, etc) as per 7 INSTALLATION External Influences Nt be installed: In ceiling cavities In ceiling spaces; r, On rfs Nt be installed in restricted lcatins fr switchbards, as per AS/ NZS 3000 Nt be installed in damp situatins, as defined by AS/ NZS 3000, including: Baths, shwers and ther fixed water cntainers Swimming pls, paddling pls and spa pls r tubs Funtains and water features Saunas Refrigeratin rms Sanitizatin and general hsing-dwn peratins The fllwing shuld apply: Nt be lcated near heat surces such as sunlight, space heaters, etc, as per 7 28

29 INSTALLATION External Influences Nt be installed near cmbustible materials Nt be lcated where electrlyte spillage cntaminates water supply Nt be installed under flrs f a building envelpe Dmestic Battery systems and pre-assembled BESS shall nt be installed in the fllwing: Habitable rms, as defined by the Natinal Cnstructin Cde (NCC), including: Bedrm Living Rm Lunge Rm Music Rm Televisin Rm Kitchen Dining Rm Sewing Rm Study Playrm Family Rm Hme Theatre Sunrm Spaces ccupied frequently r fr extended perids Subject t all ther requirements in these guidelines, suitable lcatins fr battery systems and preassembled BESS fr dmestic installatins may include: Garages Strage Rms Battery Rms Verandas Nn Dmestic Unless therwise explicitly specified by the Natinal Cnstructin Cde (NCC) r ther relevant Australian Standards, the fllwing applies t battery systems and pre-assembled BESS installed in nn-dmestic buildings: Where a battery system is installed in a (nn-dmestic) building and: 29

30 Exceeds 24 vlts, and; Exceeds 10 ampere hurs Separatin f equipment (battery system/ pre-assembled BESS t building) shall satisfy a Fire Resistance Level (FRL) f nt less than 120/ 120/ 120. This may be achieved thrugh the fllwing: The battery system is installed in a plant rm r separate battery rm; and, the walls f the rm are cnstructed frm: Layers f fire resistant plasterbard Cncrete, masnry r similar 7.3 Battery System Accmmdatin General Battery systems shall be lcated in areas that prevent access by unauthrised persns as per 7 INSTALLATION Restricted Access. Battery systems and pre-assembled BESS shall be installed in ne f the fllwing: A dedicated rm A dedicated enclsure; r A fenced ff, and secure, sectin f a larger rm A pre-assembled BESS may inherently include a suitable enclsure. Refer t 4 DEFINITIONS fr definitins f battery enclsure and restricted access. Battery accmmdatin shall ensure battery systems are readily available. Refer t 4 DEFINITIONS fr a definitin f readily available. Battery system accmmdatin shall cmply with the requirements f: 7 INSTALLATION Lcatin 8 HAZARD REDUCTION METHODS 8.1 Electrical Hazard 8.2 Energy Hazard 8.3 Fire Hazard 8.4 Chemical Hazard 8.5 Explsive Gas Hazard 8.6 Mechanical Hazard 30

31 Battery System Rm Where battery systems are installed in dedicated rms, requirements apply t the rm layut and flr area. The requirements f AS , clause and AS/ NZS , Appendix C shall apply Battery System Enclsure The fllwing requirements shuld apply fr battery system enclsures: Be clean, dry, adequately ventilated and prvide suitable prtectin against envirnmental effects as per 7 INSTALLATION Envirnmental Effects Be insect and vermin prf Allw fr sufficient clearance t prvide access fr installatin, inspectin, maintenance and repairs Nt be near cnductive bjects capable f falling acrss battery terminals and causing a shrt circuit PCE and ther equipment shuld nt be lcated in the same enclsure as the battery system. Where the battery system emits hydrgen, PCE, islatrs and ther surces f ignitin shall nt be lcated in the same enclsure as per Lcatin f Ignitin Surces Fenced f Sectin f Larger Rm Where battery systems are installed in a fenced ff sectin f a larger rm, requirements apply t the cnstructin, height, material and apertures f the fence. The requirements f AS/ NZS , clause shall apply. 31

32 8 HAZARD REDUCTION METHODS 8.1 Electrical Hazard General Where battery systems include accessible live parts and terminals prvisin shall be made t prevent: Direct cntact; and, Indirect cntact Expsed cmpnents shall be insulated and/ r shruded and mechanically prtected, including: Terminals Inter battery system cabling Cnnectins (a small hle fr testing prbes may be prvided abve each terminal) Where a battery system vltage exceeds DVC-A, it shall: Be fitted with islating switches, plugs r links t separate it int sectins nt exceeding DVC-A Be installed t sectinalise the battery int vltage blcks nt exceeding DVC-A. Barriers shall extend a minimum f 50 mm ut frm the expsed side f the battery and a minimum f 400 mm abve the tp f the cntainer. Refer t AS , Appendix A fr further examples Pre-assembled BESS Where a battery system is incrprated int a pre-assembled integrated BESS, manufactured as a cmplete package and cmplies AS the fllwing clauses need nt apply: Islatin Overcurrent Prtectin Battery System Output Wiring Islatin General An islatin device shall be installed between a battery system and PCE; and shall meet the fllwing requirements: Be capable f being secured in the pen psitin 32

33 Be nn-plarised Be DC rated Be rated fr vltage and current under nrmal and fault cnditins Operate simultaneusly n bth ples Cmply with AS/ NZS Cmply with the general requirements fr islatin and switching in AS/ NZS 3000 Remain in place if the PCE is remved, where the PCE is a grid-cnnected inverter with battery strage, as per AS/ NZS , clause 4.5 Nt be a semi-cnductr (slid-state) device A cmbined islatin and vercurrent prtectin device may be used - subject t cmpliance with all islatin and vercurrent requirements Parallel Battery Systems Where multiple battery systems are cnnected in parallel, each battery system shall have an islatr Lcatin The islatin device shall be: Installed as clse as practicable t the battery system Readily available Where the battery system represents an explsive gas hazard, restrictins apply n the lcatin f islatrs, as per Lcatin f Ignitin Surces. An islatin device shuld be adjacent t the PCE t which it is cnnected. Where the PCE is a grid-cnnected inverter, an islatin device shall be adjacent t the inverter prt t which it is cnnected Overcurrent Prtectin General Overcurrent prtectin shall be installed between a battery system and PCE; and meet the fllwing requirements: Be nn-plarised Be DC rated Be rated fr vltage and current under nrmal and fault cnditins 33

34 Be rated t prtect battery system cabling Cmply with the general requirements in AS/ NZS 3000 Meet relevant prduct standards (eg. AS 1775, AS , etc) Must nt be a semi-cnductr (slid-state) device Overcurrent prtectin shuld be selected frm the fllwing: Circuit breakers HRC fuses A battery system which des nt have either utput cnductr cnnected t earth shall have vercurrent prtectin installed in all live cnductrs. All battery systems shuld have vercurrent prtectin installed in all live cnductrs. Battery systems shuld cmprise a single string f cells, where nt managed by a BMS r similar (eg. a string f lead acid cells) Parallel Battery Systems Where multiple battery systems are cnnected in parallel, each battery system shall have separate vercurrent prtectin Lcatin The vercurrent device shall be: Installed as clse as practicable t the battery system (t minimise the length f unprtected cable) Readily available Where the battery system represents an explsive gas hazard, restrictins apply n the lcatin f vercurrent prtectin, as per sectin Lcatin f Ignitin Surces Battery System Output Wiring General Battery system utput cables shall meet the fllwing requirements: Be DC rated Have a vltage rating equal t r exceeding the DVC Have a fault and nrmal perating current greater than the vercurrent prtectin device, including peratin time f the device Be multi-stranded 34

35 Be clearly identified (eg. BATTERY ) at intervals nt exceeding 2 metres Where cabling is in a wiring enclsure (eg. cnduit), the wiring enclsure shall be labelled as abve. Cable identificatin shall be durable, permanent, legible, indelible and visible Selected as t minimise the risk f shrt circuit and earth faults (eg. duble-insulated) Be mechanically prtected by PVC cnduit r equivalent prtectin (where cabling exceeds 2 meters) Cmply with the general requirements f AS/ NZS 3000, particularly Selectin and Installatin f Wiring Systems Battery system utput cables shuld meet the fllwing requirements: Be as shrt as pssible Be duble insulated Be duble insulated where the battery system vltage exceeds DVC-A Where nt installed in cnduit, cables shuld be effectively clamped and sufficient supprt shuld be prvided thrughut the length f cables t minimise sag, and prevent undue strain frm being impsed n the cables r n battery terminals r ther parts f the installatin. Cables shall nt be bent thrugh a radius less than the minimum bending radius specified by the cable manufacturer. Segregatin shall be prvided between the fllwing circuits: AC and DC DVC-A DC and DVC-B DC Parallel Battery Systems Where multiple battery systems are cnnected in parallel, each battery system shuld have cables cnnecting strings f equal resistance (eg. f equal length and crss-sectinal area; and, cnductr material) except where the charge/ discharge regime is cntrlled by a BMS r similar Vltage Drp The maximum vltage drp between the battery system terminals and the PCE: Shall be less than 5% Shuld be less than 2% DC vltage drp can be calculated as per: AS/ NZS , Appendix C2 AS , Appendix A5; r, 35

36 AS 2671, clause 2.6 Typically, the current carrying capacity will determine the crss sectinal area f DC cable, rather than vltage drp especially where vltage levels d nt exceed DVC-A Earthing General There are fur categries f earthing arrangements fr battery systems: Flating/ separated (ie. Nt earthed and nt referenced t earth) Direct earthed Resistive earthed Cnnected t a nn-separated inverter (ie. Reference t the grid and therefre t earth by the inverters internal cnnectins) The PCE and battery system manufacturer s instructins n earthing arrangements shall be fllwed. Examples f earthing arrangements are in Figure 7, Figure 8, Figure 9 and Figure 10. Scpe f this guide Prt 3 Cmms Prt 4 d.c. Battery Prt 5 d.c. Energy Surce INVERTER Electrically SEPARATED between Battery & Grid Prt 1 a.c. Grid cnnect Prt 2 a.c. UPS Lads A N Figure 7 Battery cnnected t an inverter prviding separatin frm the grid 36

37 Figure 8 Battery cnnected t an inverter prviding separatin frm the grid with a direct earth cnnectin Scpe f this guide Prt 3 Cmms Prt 4 d.c. Battery INVERTER Electrically SEPARATED between Battery & Grid Prt 1 a.c. Grid cnnect A N Prt 5 d.c. Energy Surce Prt 2 a.c. UPS Lads Figure 9 Battery cnnected t an inverter prviding separatin frm the grid with resistive earth cnnectin Scpe f this guide Prt 3 Cmms Prt 4 d.c. Battery Prt 5 d.c. Energy Surce INVERTER Electrically NOT SEPARATED between Battery & Grid Prt 1 a.c. Grid cnnect Prt 2 a.c. UPS Lads A N Figure 10 Battery cnnected t a nn-separated inverter i.e. n separatin between the battery and the grid (eg. transfrmerless) 37

38 Earth Fault Alarm Where unearthed battery systems, including pre-assembled BESS, exceed DVC-A an earth fault alarm shuld be installed which, n an earth fault, causes an actin t be initiated t crrect the earth fault. The fllwing cnditins shuld als apply: Repeat peratin at least at hurly intervals until the earth fault is crrected Be placed in an area that shall be nticed Be reliable (eg. audible signal and/ r light pwered frm a cnstant surce) It may take the frm f: Visual alarm (eg. light) Audible signal Fax SMS A set f peratinal instructins shall be prvided t the custmer that includes the actins t take when the alarm perates Equiptential Bnding If the battery system enclsure and/ r battery system stand is metallic and the battery system is perating at vltages exceeding DVC-A, the enclsure and/ r stand shuld be earthed in accrdance with AS/ NZS Energy Hazard Battery systems represent an inherent arc flash hazard which cannt be eliminated. The fllwing measures reduce the risk f an arc flash hazard: Battery utput cabling shall be selected as t minimise the risk f shrt circuit faults (eg. duble-insulated), as per Battery System Output Wiring General DC cable shall be prtected frm mechanical damage as per Battery System Output Wiring General Terminals, inter-cell cnnectrs and utging busbars shall be insulated r shruded as per 8 HAZARD REDUCTION METHODS Electrical Hazard General Access t battery systems shall be restricted t authrised persns as per Restricted Access Overcurrent prtectin shall be placed as clse as practicable t the battery system as per 8.1 Electrical Hazard Overcurrent Prtectin Lcatin 38

39 Islatrs shall be installed as per 8.1 Electrical Hazard Islatin Where a battery system vltage exceeds DVC-A, it shall be fitted with islating switches, plugs r links t separate it int sectins nt greater than DVC-A as per 8.1 Electrical Hazard General Standard perating prcedures shuld be develped t facilitate safe wrk prcedures Persnal Prtectin Equipment (PPE) shuld be used when wrking n battery systems 8.3 Fire Hazard The fllwing measures reduce the risk f a fire hazard. The fllwing risk reductins measures shall apply: DC cable shall be prtected frm mechanical damage as per Battery System Output Wiring General Battery Systems shall be mechanically prtected as per 7 INSTALLATION Envirnmental Effects Prtectin shall be prvided against fire initiated r prpagated by cmpnents f the electrical installatin as per AS/ NZS 3000 Shall be installed such that the minimum and maximum temperatures are nt exceeded fr safe peratin as per manufacturer s specificatin as per 7 INSTALLATION Manufacturer s Instructins Shall meet natinal and lcal requirements with respect t FRL & separatin between battery system and any buildings Where the battery system requires a BMS fr safe peratin, ne shall be installed that is cmpatible with the chemistry and verall system; and prvides prtectin against abuse cnditins, including: Excess temperature Minimum temperature Overcurrent Over vltage Over discharge Prtectin against mechanical damage shall be prvided t withstand abuse cnditins, including: Crushing Impact Vibratin Shck Puncturing The fllwing risk reductin measures shuld apply: Be installed n a nn-cmbustible surface (eg. brick, cncrete, etc) 39

40 Installatin f a hard-wired smke alarm, with battery back up Nt be installed under flrs f a building envelpe Nt be installed within 1 metre f a neighburing prperty, building r dividing fence Nt be installed within 1 metre f any access/ egress area Nt installed near cmbustible material 8.4 Chemical Hazard General The fllwing general requirements apply t reducing the risk f chemical hazards: The battery manufacturer SDS shall be cnsulted and installatin instructins shall be fllwed Battery systems shall be lcated in areas designed t prevent access by unauthrised persns, as per clause Restricted Access Where subject t physical damage, mechanical prtectin shall be prvided t the battery system t minimise the risk f such, resulting in electrlyte leakage, including: Crushing Impact Puncturing Mechanical prtectin may be achieved via the use f a suitable battery system enclsure and/ r bllards. Use f mechanical prtectin shall ensure battery systems and pre-assembled BESS are readily available. An example f prtectin thrugh a bllard barrier can be fund in Figure

41 Figure 11 Battery system mechanically prtected by a bllard in a garage Where electrlyte may leak r spill, the fllwing shuld be installed t restrict the spread: Electrlyte-resistant material r catings; r, Suitable drip trays, bunds r sumps Where electrlyte is crrsive and vents: Exhaust air shuld nt pass ver battery system terminals r ther electrical devices Fumes shuld be vented utside Safe Wrk Prcedures Safe wrk prcedures shuld be develped t address ptential chemical hazards which may include: Cracked r damaged battery casings Spillage f electrlyte Inhalatin f, and physical expsure t, electrlyte What t d in the event f a fire Persnal Prtective Equipment The fllwing equipment may be required fr safe handling f battery systems and prtectin f authrised persns: 41

42 Cmbinatin veralls r dust cat (acid resistant) Bib Aprn Glves Face shield r gggles Running water r water cntainers fr rinsing eyes and skin in case f electrlyte spillage Bicarbnate f sda fr acid spills, r bric acid fr alkaline electrlyte spills, r ther suitable neutralising agent recmmended by the manufacturer 8.5 Explsive Gas Hazard General Battery systems and pre-assembled BESS that represent an explsive gas hazard shall be installed in accrdance with risk reductin methds as per 8.5 Explsive Gas Hazard. Typically, battery systems that represent an explsive gas hazard prduce hydrgen during charging, especially during bst and vercharging, cnditins. This includes chemistries such as lead acid and nickel cadmium. Hwever, the battery system and pre-assembled BESS manufacturer SDS shall be cnsulted t determine if an explsive gas hazard is present as per Safety Data Sheet (SDS) Ventilatin General The average hydrgen cncentratin by vlume in a battery rm r enclsure shall be less than 2% Flded (vented) and Sealed Valve-Regulated Lead Acid Cells Ventilatin shall be prvided fr all lead acid battery system chemistries Rate f Ventilatin (Lead Acid) The minimum exhausted ventilatin rate required t maintain hydrgen cncentratin belw 2% is calculated by the fllwing equatin: where qv = 0.006nl qv = the minimum exhaust ventilatin rate, in litres per secnd 42

43 n = the number f battery cells l = the charging rate, in amperes (refer t Charging Rate) Where multiple parallel battery systems are present, the ttal ventilatin rate is the sum f all battery systems Charging Rate General Battery charging shall ccur t minimise cnditins, as listed in the battery manufacturer s specificatins, that result in excessive explsive gas emissin, such as vercurrent and vervltage cnditins Flded Lead Acid Battery Systems The charging rate fr vented cells is: The maximum utput rating f the charging surce (eg. slar array); r, The rated utput f the vercurrent prtectin device f the charging surce Sealed Valve Regulated Lead Acid Battery Systems The charging rate fr valve-regulated battery systems differs accrding t the fllwing cnditins: a. Cnditin 1 If the charger des nt have an autmatic vervltage cut-ff, the charging current shall be based n the rate fr flded lead acid battery systems (refer t Flded Lead Acid Battery Systems) b. Cnditin 2 If the charger des have an autmatic vervltage cut-ff (set at the battery manufacturer s recmmended level) the charging rate is: 0.5A per 100Ah at the 3hr rate f discharge f battery capacity Methd f Ventilatin General Natural ventilatin shuld be used, in preference t mechanical ventilatin, due t the ptential failure f fans r ther such equipment. Ventilatin paths shall be designed t minimise the risk f vented gas entering equipment. 43

44 Natural Ventilatin Where natural ventilatin is used, the minimum size f inlet and utlet apertures is determined frm the fllwing equatin: where A = 100qv A = the minimum area f the apertures, in square centimetres qv = the minimum exhaust ventilatin rate, in litres per secnd With natural ventilatin, an air velcity f at least 0.1 m/s is assumed t flw thrugh the apertures. Where apertures are circular and the diameter is knwn, the area f a circle can be determined as per the fllwing frmula: where A = ¼ π d 2 A = Area d = Diameter Mechanical Ventilatin Where mechanical ventilatin is used, the minimum flw rate is determined by Rate f Ventilatin (Lead Acid). If mechanical ventilatin is used, an airflw sensr shall be installed t initiate an alarm t indicate fan failure. Mechanical ventilatin shuld be f a type that is nt a surce f ignitin Arrangement f Ventilatin The fllwing applies t the arrangement and layut f the ventilatin systems fr battery rms and enclsures: Battery enclsures shuld be designed t prevent the frmatin f pckets f gas Ventilatin shall be prvided by means f hles, grilles r vents s that air sweeps acrss the battery Exhaust air shuld nt pass ver ther electrical equipment as per 8.4 Chemical Hazard General Inlet and utlet vents shuld: Cnsist f: A number f hles spaced evenly alng the side f the enclsure; r, 44

45 A slt running alng the side f the rm r enclsure; and, Be n laterally ppsite sides f enclsures; and, Where required, prevent entry f vermin thrugh the installatin f a carse screen Ventilatin inlets shuld: Be at a lw level Be n higher than the tps f the individual battery cells Ventilatin utlets shuld: Be at the highest level in the battery enclsure Nickel Cadmium Fr nickel cadmium battery systems, all the requirements f Ventilatin apply. Hwever, recmmended charging rate (I) used in the ventilatin rate in Rate f Ventilatin (Lead Acid) is 1.5A per 100 A.h. at the 3hr rate f discharge f battery capacity Other Battery System Chemistries Fr battery system chemistries ther than lead acid and nickel cadmium, the manufacturer s instructin f ventilatin rates shall be fllwed Lcatin f Ignitin Surces General Arc-prducing devices shall nt be lcated in areas where hydrgen cncentratins can becme significant, such as directly abve battery cells Exclusin Znes A minimum hrizntal separatin f 500mm shall be prvided between the battery and all ther equipment frm 100mm belw battery terminals except where there is a slid separatin barrier. 45

46 Restricted Zne 500mm hrizntal separatin abve the battery 100mm belw the battery terminals Scket Outlets Scket utlets shall nt be installed in battery enclsures. Where a battery system is installed in a dedicated rm, r fenced ff area f a larger rm, all scket utlets shall cmply with the fllwing: Be lcated at least 1800m frm the battery system r battery enclsure Fr scket utlets installed within 5m f the battery enclsure, the utlet shall be a minimum f 100mm belw the tp f the battery r battery vent Luminaires Luminaires shall nt be installed: Directly ver a cell Within 200mm f a battery system Other Equipment Cntrl equipment, such as thse used fr exhaust fans, shall be lcated mre than 1800mm frm the battery system and a minimum f 100mm belw ventilatin apertures. 8.6 Mechanical Hazard General Battery system accmmdatin shall cmply with the requirements f 7.3 Battery System Accmmdatin. Fr grund munted battery systems/ pre-assembled BESS, such as thse in a dedicated rm, the grund structure and type shall be designed t withstand the prevailing weight. 46

47 Fr wall-munted battery systems/ pre-assembled BESS, the structural integrity f the wall shall be able t withstand the prevailing weight. The supprting surface f any enclsure shall have adequate structural strength t supprt the battery system/ pre-assembled BESS weight and its supprt structure Battery stands, supprts and enclsures shuld prtect battery systems/ pre-assembled BESS frm damage due t seismic (earthquake) activity and shuld cmply with AS (Australia) and NZS 4219 (New Zealand). Battery systems/ pre-assembled BESS shuld nt be installed at a height exceeding 2 m abve a flr r platfrm Mving Parts Where a battery system/ pre-assembled BESS cnsist f mving parts, such as pumps, such equipment shall be prvided with prtectin t prevent inadvertent cntact. Preventing inadvertent cntact may be achieved thrugh the use f shields r barriers. 47

48 9 LABELS AND SAFETY SIGNAGE The fllwing prvides guidance n the safety signs assciated with battery systems.. Labelling may als be required in accrdance with: AS/ NZS Installatin and safety requirements fr phtvltaic (PV) arrays AS/ NZS Grid cnnectin f energy systems via inverters Installatin requirements Wrked labelling examples can be fund n the Slar Accreditatin website in the Technical Infrmatin sectin within the Installer Area (lg in required) n the Slar Accreditatin ( website. 9.1 Energy Strage and Battery Type UN Number Sites with battery systems shall include a circular green reflectr sign at least 70mm in diameter with the letters ES adjacent t the meter bx and main switchbard as t be readily visible t appraching emergency wrkers. Additinally, the UN number f the battery chemistry shall be listed as per the fllwing: UN Number UN 3480 UN 3090 UN 2794 UN 2800 UN 3496 UN 2794 UN Battery Chemical Type Lithium in (including in plymer) Lithium metal batteries Flded lead acid battery Valve regulated lead acid battery Nickel-metal hydride battery Nickel cadmium battery Sdium in batteries Refer t Figure 12 and Figure 13 fr examples. 9.2 Battery System Lcatin Where a battery system may be difficult t lcate, such as in large buildings, a plan r site map shall be placed at the main metering panel and fire panel indicating where it can be fund. Refer t Figure 14 fr an example. Where battery systems are accessible within: 48

49 A dedicated battery rm A dedicated enclsure A fenced ff, and secure, sectin f a larger rm A sign shall be adjacent t the enclsure r n all drs t the rm/ sectin f a larger rm indicating that restricted access is nly permitted fr authrised persns. Refer t Figure 15 fr an example. 9.3 Vltage and Current A sign stating the fllwing shall be munted adjacent t battery enclsures r all drs t the rm/ fenced ff sectin f a larger rm: Battery System Lcatin Ptential shrt-circuit current rating Maximum DC vltage The abve sign shall be adjacent t the battery system islatr. Where the sign is nt adjacent an additinal ne shall be installed. Refer t Figure 16 fr an example. Where battery system vltages exceed 600V, the abve signage shall include the wrds Hazardus DC Vltage. Nte that further details can be fund in AS/ NZS , clause 6.5(a). Refer t Figure 14 fr an example. 9.4 Explsive Gas Hazard A battery system that represents an explsive gas hazard shall have a sign installed which includes the wrds Danger, Risk f Battery Explsin. The sign shall be adjacent t the enclsure r n all drs t the rm/ sectin f a larger rm. Refer t Figure 18 fr an example. 9.5 Chemical Hazard A battery system that represents a chemical hazard shall include an apprpriate sign applicable t the specific risk. Fr example, such a sign may refer t: 49

50 Electrlyte burns Txic fume emissins The sign shall be adjacent t the enclsure r n all drs t the rm/ sectin f a larger rm. Refer t Figure 19 and Figure 20 fr examples. 9.6 Energy Hazard All battery systems cntain an inherent energy hazard that cannt be eliminated. Battery systems shuld include a general sign t indicate an energy hazard. The sign shall be adjacent t the enclsure r n all drs t the rm/ sectin f a larger rm. Refer t Figure 21 fr an example. 9.7 Islatin Devices Battery system islatrs shall be labelled with the fllwing wrds: Battery System Islatr Refer t Figure 22 fr an example. 9.8 Overcurrent Devices Battery system vercurrent prtectin devices shall be labelled with the fllwing wrds: Battery System Circuit Breaker Battery System Circuit Breaker and islating switch; r Battery System Fuse; r Battery System Switch Fuse and Islatr Refer t Figure 23 fr an example. 9.9 Battery System Cables Battery system cabling (r cnduit where cabling is enclsed), shall be labelled BATTERY at intervals nt exceeding 2 metres. Refer t Battery System Output Wiring fr further details. 50

51 9.10 Shutdwn Prcedure All BESS shall include a shutdwn prcedure detailing the shutdwn prcedure t safely shut dwn the system. This prcedure shall be specific t the BESS that is installed as generic labelling may nt be accurate r apprpriate. The shutdwn prcedure shall be lcated: At the main switchbard; and, At the distributin bard (where a BESS terminates int such); and, Adjacent t equipment t be perated (eg. battery vercurrent prtectin) Refer t Figure 24 fr an example Persnal Prtective Equipment Where persnal prtective equipment is required t access battery systems, a sign shuld be installed t indicate: The requirement fr persnal prtective equipment; and, The specific type f equipment The sign shall be adjacent t the enclsure r n all drs t the rm/ sectin f a larger rm. Refer t Figure 25 fr an example. 51

52 10 COMMISSIONING AND TESTING After installatin, a battery system and pre-assembled BESS shall be cmmissined in accrdance with manufacturer s instructins and the requirements f this sectin. The fllwing shall ccur: Cnfirmatin f the installatin: Labelling; and, Signage Submissin f dcumentatin as per 11 DOCUMENTATION Visual inspectin including: Basic prtectin (eg. cable insulatin and cnduit integrity, etc) Fault prtectin (eg. installatin f switchgear, apprpriately insulated cable, etc) Prtectin against hazardus parts (eg. shruded terminals, battery accmmdatin restricting access t authrised persns, etc) Prtectin against spread f fire, as per 8.3 Fire Hazard General cnditin and integrity f cnnected electrical equipment Check tightness f battery system terminals, links, intercell cnnectins as per manufacturer s specified trque settings Ensure peratinal parameters are crrectly set (eg. charge and discharge settings, cmmunicatin, etc) Testing, including: Plarity Resistance between active cnductrs and earth, where relevant Battery system vltage Individual battery vltages, where relevant Other relevant battery parameters, such as specific gravity, state f charge, etc Islatin in accrdance with specified shut dwn prcedure Cnfirmatin f functining charge and discharge cycle Nte, AS 4086 prvides guidance regarding initial charge fr traditinal chemistries Testing and Cnfirmatin f anti-islanding and emergency pwer supply mde Cnfirmatin f functining mnitring system(s), where relevant Cmmissining may be cnducted in accrdance with: AS/ NZS , clause 10 AS & 2, clause 5.5 AS , Appendices C, D, E & F 52

53 An example cmmissining checklist, as adapted frm CSIRO s Energy Strage Safety reprt, can be fund in APPENDIX A EXAMPLE COMMISSIONING SHEET. 53

54 11 DOCUMENTATION 11.1 General At the cmpletin f the installatin f a battery system r pre-assembled BESS, dcumentatin shall be prvided in accrdance with the requirements f this sectin. This dcumentatin shall ensure that key system infrmatin is readily available t custmers, inspectrs, maintenance service prviders and emergency service persnnel. Additinal dcumentatin may als be required in accrdance with: AS/ NZS Installatin and safety requirements fr phtvltaic (PV) arrays AS/ NZS Grid cnnectin f energy systems via inverters Installatin requirements 11.2 System Manual A manual, cmplete with the fllwing items, shall be prvided: Installer address and cntact details Battery system infrmatin, including: kwh capacity Vltage UN cde and chemistry Operating instructins (eg. a shrt descriptin f the functin and peratin f all installed battery system equipment) Safety Certificate, where applicable Safety Data Sheet (SDS) A cmplete list f installed equipment, including mdel and serial numbers A list f actins t be taken in the event f an earth fault alarm, where applicable The shutdwn and islatin prcedure fr emergency, maintenance, repairs and inspectin A basic cnnectin diagram that includes electrical ratings f the battery system and the ratings f all switchgear System perfrmance estimate Recmmended maintenance f the system Maintenance prcedure and timetable Warranty infrmatin Manufacturer s dcumentatin, datasheets, handbks, etc Recmmendatins n battery end-f-life recycling and dispsal 54

55 12 MAINTENANCE Battery system and pre-assembled BESS maintenance will prmte and prlng: Safety Reliability Perfrmance Only authrised persns shall perfrm battery system and pre-assembled BESS maintenance. Maintenance shall be cnducted in accrdance with: Manufacturer s: Instructins Safety Data Sheet System Manual, as per 11.2 SYSTEM MANUAL Recmmended maintenance f the system Maintenance prcedure and timetable Wrk Health and Safety Standard perating prcedures Safe wrk methds statement Maintenance may be cnducted in accrdance with: AS/ NZS , Appendix A AS & 2, clause 6.4 AS , clause 3.2 Examples f battery system/ BESS maintenance include: Cleaning battery system terminals f dirt and electrlyte Ensuring electrical terminals are set t crrect trque settings Ensuring battery accmmdatin integrity is maintained (eg. nt damaged, free frm debris/ rubbish; and, access is nt bstructed) Ensure prper functining f vercurrent and islatin devices Check charge and discharge parameters are crrectly set Ensure crrect ventilatin has been prvided and is maintained Check cable mechanical supprt, prtectin and penetratin is maintained 55

56 APPENDIX A EXAMPLE COMMISSIONING SHEET Battery enclsure, rm r fenced ff sectin f a larger rm is: mechanically sund suitable fr the lcal envirnmental cnditins designed t prevent the frmatin f gas pckets (where an explsive gas hazard is present) nt in a habitable rm (as defined by the Natinal Cnstructin Cde 2015) nt in direct cntact with the flr f the enclsure r rm. The system is installed in accrdance with the envirnmental cnditins it will be subjected t All battery terminatins and intercnnect cable cnnectins have been checked fr tightness, where applicable All electrical cables, islatrs and fuses are crrectly rated and sized fr perating and fault cnditins There are n readily accessible live parts n any installed equipment. All battery cell intercnnects and terminals are cvered and prtected against accidental shrt circuit, where applicable All live cables have been tested fr electrical leakage t earth, where applicable Electrical wiring is ruted s as t be prtected frm any physical damage r mechanical stress and expsure that culd cause crrsin Installatin activities have nt caused any damage t any cable insulatin All electrical wiring has been installed in accrdance with AS/NZ 3000, and equipment is certified fr use in Australia Unearthed cnductrs in battery banks (including multiple strings) are prtected by vercurrent prtectin devices Battery banks have a means f islatin. Such islatin has been checked and tested All ther apprpriate signage is displayed; fr example, shut dwn prcedure, Warning Spark hazard, electrlyte Burns, battery vltage and shrt circuit fault current warning Vltage, current and pwer thrughput have been verified and are within the design specificatin fr intended use and lad prfile Metering is installed t mnitr the battery vltage Visual and audi alarms and warning ntificatins have been tested crrectly A tailred fire respnse, including, if necessary, a fire extinguisher has been installed adjacent t the batteries alng with a sign detailing the actins t be taken in the event f a fire All cmmissining tests and results have been dcumented 56

57 Lead-acid specific All crimp lugs have been fitted using an apprpriate tl Batteries are installed n a timber r ther suitable platfrm (t reduce shrt circuit risk and hazardus gas prductin if a battery were t leak acid) The clearance and ventilatin f equipment and arc-prducing devices is in accrdance with manufacturer s installatin guidelines r relevant standards, including AS and AS The enclsure is cnstructed f crrsive-resistant materials Persnal prtective equipment and electrlyte cntainment is prvided, including spill kit, eye prtectin, glves and eye wash water Lithium specific Platfrm and enclsure is cnstructed f aluminum, steel r equivalent (t minimize risk f fire) Batteries are in a sealed enclsure with pressure activated venting, ducted t the pen atmsphere away frm living spaces r areas ccupied by peple and animals Enclsure base is sealed frm the atmsphere Battery management system has been verified as perating crrectly, including lgging data 57

58 APPENDIX B SIGNS Figure 12 Example sign fr energy strage required adjacent t the meter bx and main switchbard Refer t 9.1 Energy Strage and Battery Type UN Number Figure 13 Example sign fr energy strage required adjacent t the meter bx and main switchbard Refer t 9.1 Energy Strage and Battery Type UN Number 58

59 Figure 14 Example sign indicating lcatin f battery system (where difficult t lcate such as large buildings) required at the main metering panel and fire panel Refer t 9.2 Battery System Lcatin Figure 15 Example sign where battery systems are accessible. Required n the battery enclsure; r, all drs t the rm/ fenced ff sectin f a larger rm where the battery system is accmmdated Refer t 9.2 Battery System Lcatin 59

60 BATTERY SUPPLY LOCATION: SHORT CIRCUIT CURRENT: MAX DC VOLTS: A V Figure 16 Example sign fr battery systems (nt exceeding 600VDC). Required n enclsures, drs t battery rms/ fenced ff sectin f a larger rm. The sign shall be adjacent t the battery system islatr r an additinal sign shall be installed. Refer t 9.3 Vltage and Current BATTERY SUPPLY LOCATION: SHORT CIRCUIT CURRENT: MAX DC VOLTS: A V WARNING: HAZARDOUS DC VOLTAGE Figure 17 Example sign fr battery systems (exceeding 600VDC). Required n enclsures, drs t battery rms/ fenced ff sectin f a larger rm. The sign must be adjacent t the battery system islatr r an additinal sign shall be installed. Refer t 9.3 Vltage and Current 60

61 Figure 18 Example sign where explsive gas hazards apply. Required n enclsures, drs t battery rms/ fenced ff sectin f a larger rm. Refer t 9.4 Explsive Gas Hazard Figure 19 Example sign where a txic fumes hazard applies. Required n enclsures, drs t battery rms/ fenced ff sectin f a larger rm Refer t 9.5 Chemical Hazard 61

62 Figure 20 Example sign where an electrlyte burns hazard applies. Required n enclsures, drs t battery rms/ fenced ff sectin f a larger rm Refer t 9.5 Chemical Hazard Figure 21 Example sign shuld be installed n battery systems. Required n enclsures, drs t battery rms/ fenced ff sectin f a larger rm. Refer t 9.6 Energy Hazard Figure 22 Example sign fr battery system islatr. Required in a prminent lcatin t identify the switchgear t which it applies. 62

63 Refer t 9.7 Islatin Devices Figure 23 Example sign fr battery system vercurrent prtectin (eg. Circuit Breaker). Required in a prminent lcatin t identify the switchgear t which it applies. Refer t 9.8 Overcurrent Devices Figure 24 Example Shutdwn Prcedure sign. Required at the main switchbard, at the distributin bard (where a BESS terminates int such); and, adjacent t equipment t be perated (eg. battery vercurrent prtectin) Refer t 9.10 Shutdwn Prcedure 63

64 Figure 25 Example sign fr battery systems where access requires persnal prtective equipment. The sign shuld be adjacent t the enclsure r n all drs t the rm/ sectin f a larger rm. Refer t 9.11 Persnal Prtective Equipment 64