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103207 AS NZS 5139 Public Comment S1.doc - 05/06/2017 11:37:13

COMMITTEE EL-042

DR AS/NZS 5139:2017

(Project ID: 103207)

Draft for Public Comment Australian/New Zealand Standard LIABLE TO ALTERATION—DO NOT USE AS A STANDARD

BEGINNING DATE FOR COMMENT:

13 June 2017

CLOSING DATE FOR COMMENT:

15 August 2017

Important: Please read the instructions on the inside cover of this document for the procedure for submitting public comments.

Electrical installations—Safety of battery systems for use with power conversion equipment (Revision of AS 4086.2—1997)

© Standards Australia Limited

© The Crown in right of New Zealand, administered by the New Zealand Standards Executive

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Draft for Public Comment Australian/New Zealand Standard

The committee responsible for the issue of this draft comprised representatives of organizations interested in the subject matter of the proposed Standard. These organizations are listed on the inside back cover.

Comments are invited on the technical content, wording and general arrangement of the draft.

The method for submission of comment on this document is to register and fill in an online form via Standards Hub Website. Instructions and examples of comment submission are available on the website. . Please use the following link—

https://hub.standards.org.au/hub/public/listOpenCommentingPublication.action

Comment must be via Hub, any emails or forms sent to us by fax or mail will not be considered by the Committee when it reviews the Public Comment received.

Please place relevant clause numbers beside each comment.

Editorial matters (i.e. spelling, punctuation, grammar etc.) will be corrected before final publication.

The coordination of the requirements of this draft with those of any related Standards is of particular importance and you are invited to point out any areas where this may be necessary.

Please provide supporting reasons and suggested wording for each comment. Where you consider that specific content is too simplistic, too complex or too detailed please provide an alternative.

If the draft is acceptable without change, an acknowledgment to this effect would be appreciated.

Once you have registered and submitted your comments via the online form, your comments are automatically submitted to the committee for review.

Normally no acknowledgment of comment is sent. All comments received via the Standards Hub Website by the due date will be reviewed and considered by the relevant drafting committee. We cannot guarantee that comments submitted in other forms will be considered along with those submitted via the Standards Hub online form. Where appropriate, changes will be incorporated before the Standard is formally approved.

If you know of other persons or organizations that may wish to comment on this draft Standard, could you please advise them of its availability. Further copies of the draft are available from the Publisher SAI Global at http://www.saiglobal.com/

For information regarding the development of Standards contact: Standards Australian Limited GPO Box 476 Sydney NSW 2001 Phone: 02 9237 6000 Email: [email protected] Internet: www.standards.org.au

Standards New Zealand15 Stout Street Wellington 6011 (PO Box 1473 Wellington 6140) Freephone: 0800 782 632 Phone: (04) 498 5900 Email: [email protected] Website: www.standards.govt.nz

For the sales and distribution of Standards including Draft Standards for public comment contact: SAI Global Limited Phone: 13 12 42 Email: [email protected] Internet: www.saiglobal.com

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Draft for Public Comment

STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND

Committee EL-042—Renewable Energy Power Supply Systems and Equipment

DRAFT

Australian/New Zealand Standard

Electrical installations—Safety of battery systems for use with power conversion equipment

(Revision of AS 4086.2—1997)

(To be AS/NZS 5139:201X)

Comment on the draft is invited from people and organizations concerned with this subject. It would be appreciated if those submitting comment would follow the guidelines given on the inside front cover.

Important: Please read the instructions on the inside cover of this document for the procedure for submitting public comments

This document is a draft Australian/New Zealand Standard only and is liable to alteration in the light of comment received. It is not to be regarded as an Australian/New Zealand Standard until finally issued as such by Standards Australia/Standards New Zealand.

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DRAFT ONLY 2 DRAFT ONLY

PREFACE

This Standard was prepared by Joint Standards Australia/Standards New Zealand Committee EL-042, Renewable Energy Power Supply Systems and Equipment, to supersede AS 4086.2—1997, Secondary batteries for use with stand-alone systems, Part 2: Installation and maintenance, three months after the date of publication.

The installation of grid-connected energy storage systems, which include batteries, is a relatively new and growing market, and one in which there is a lack of definitive Standards.

Existing Standards for the design and installation of stationary battery systems were prepared for use with traditional lead-acid and nickel cadmium battery technology, and do not address recent production and application innovations and developments. These innovations include the following:

(a) Newer battery technologies, including battery chemistry types other than lead-acid, such as lithium technologies (e.g. lithium ion, lithium iron phosphate), flow technologies (e.g. zinc bromine, vanadium redox flow), and hybrid ion technologies (e.g. aqueous). At this stage, this Standard does not cover high temperature batteries, such as NaNiCl batteries or sodium sulphur batteries.

(b) New developments in interconnection equipment (e.g. multiple-mode inverters), which can result in batteries being continually connected to the grid, and also include photovoltaic (PV) or other energy sources as an integrated system.

(c) Cheaper cost structures resulting in battery systems being utilized more widely and in many more applications, such as becoming more prevalent in domestic dwellings.

This Standard necessarily deals with existing types of energy storage, but is not intended to discourage innovation or to exclude materials, equipment and methods that may be developed in the future.

Due to the innovative nature of many new energy storage technologies and the lack of detailed information on their risks and failures, it is necessary to state that the material contained in this Standard is based on the best information available at the time of its preparation. During the process of the development of this Standard, these technologies are evolving and it is expected that this document will require ongoing updating to truly ensure safe installation and operation of battery energy storage systems. Revisions may be made from time to time in view of such developments, and amendments to this edition will be made when necessary.

This new Standard contains a substantial number of informative components so that the level of knowledge and understanding in this new field of technology and its application is increased and so that this information can act as a guide for interested parties.

The terms ‘normative’ and ‘informative’ have been used in this Standard to define the application of the appendix to which they apply. A ‘normative’ appendix is an integral part of a Standard, whereas an ‘informative’ appendix is only for information and guidance.

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CONTENTS

Page

SECTION 1 SCOPE AND GENERAL 1.1 SCOPE AND APPLICATION ..................................................................................... 5 1.2 OBJECTIVE ................................................................................................................ 6 1.3 NORMATIVE REFERENCES .................................................................................... 6 1.4 DEFINITIONS ............................................................................................................. 8

SECTION 2 BATTERY ENERGY STORAGE SYSTEM CONFIGURATIONS 2.1 GENERAL ................................................................................................................. 17 2.2 BATTERY ENERGY STORAGE SYSTEM ............................................................. 17 2.3 BESS: APPLICATIONS ............................................................................................ 22

SECTION 3 BATTERY ENERGY STORAGE SYSTEM: HAZARDS 3.1 GENERAL ................................................................................................................. 27 3.2 HAZARDS ASSOCIATED WITH BESS .................................................................. 27

SECTION 4 INSTALLATION 4.1 GENERAL ................................................................................................................. 34 4.2 INSTALLATION OF BESS ...................................................................................... 35 4.3 ELECTRICAL HAZARD .......................................................................................... 43 4.4 ENERGY HAZARD .................................................................................................. 62 4.5 FIRE HAZARD ......................................................................................................... 64 4.6 CHEMICAL HAZARD ............................................................................................. 70 4.7 EXPLOSIVE GAS HAZARD .................................................................................... 72 4.8 MECHANICAL HAZARD ........................................................................................ 77

SECTION 5 LABELS AND SAFETY SIGNAGE 5.1 GENERAL ................................................................................................................. 79 5.2 REQUIREMENTS FOR SIGNS AND LABELS ....................................................... 79 5.3 BATTERY TYPE GENERAL LABELLING ............................................................ 79 5.4 SIGNS FOR BATTERY SYSTEM LOCATION ....................................................... 80 5.5 RESTRICTED ACCESS ............................................................................................ 80 5.6 VOLTAGE AND CURRENT .................................................................................... 80 5.7 SDS ............................................................................................................................ 80 5.8 EXPLOSIVE GAS HAZARD .................................................................................... 81 5.9 TOXIC FUME HAZARD .......................................................................................... 81 5.10 CHEMICAL HAZARD ............................................................................................. 81 5.11 ARC FLASH ............................................................................................................. 81 5.12 DISCONNECTION DEVICES .................................................................................. 81 5.13 OVERCURRENT DEVICES ..................................................................................... 82 5.14 BATTERY SYSTEM CABLES ................................................................................. 83 5.15 SEGREGATION ........................................................................................................ 83 5.16 SHUTDOWN PROCEDURE ..................................................................................... 83 5.17 BATTERY LABELLING .......................................................................................... 84 5.18 OTHER EQUIPMENT LABELLING ........................................................................ 84 5.19 SPILL CONTAINMENT ........................................................................................... 84

SECTION 6 COMMISSIONING AND INDUCTION 6.1 GENERAL ................................................................................................................. 85 6.2 VERIFICATION ........................................................................................................ 85

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6.3 TESTING ................................................................................................................... 85 6.4 COMMISSIONING ................................................................................................... 86 6.5 SYSTEM OWNER INDUCTION .............................................................................. 86

SECTION 7 INSPECTION AND MAINTENANCE 7.1 GENERAL ................................................................................................................. 87 7.2 INSPECTIONS .......................................................................................................... 87 7.3 MAINTENANCE ...................................................................................................... 87

SECTION 8 DOCUMENTATION 8.1 GENERAL ................................................................................................................. 90 8.2 SYSTEM MANUAL ................................................................................................. 90 8.3 SYSTEM AND BATTERY SYSTEM RECORD BOOK .......................................... 91

APPENDICES A DECISIVE VOLTAGE CLASSIFICATION (DVC) ................................................. 93 B SAFETY SIGNS ........................................................................................................ 94 C METHOD OF DETERMINING INTERNAL RESISTANCE OF LEAD ACID

BATTERIES ............................................................................................................ 101 D BARRIER REQUIREMENTS FOR BATTERY SYSTEMS WITH VOLTAGE

GREATER THAN DVC-A ...................................................................................... 102 E MINIMUM CLEARANCES WITHIN BATTERY ROOMS

(SHOWING TYPICAL LAYOUT).......................................................................... 103 F SIZING EARTH CABLE EXAMPLE ..................................................................... 105 G BATTERY ENCLOSURES EXAMPLES FOR BATTERY TYPES

CLASSIFIED AS EXPLOSION GAS HAZARDS .................................................. 108 H INSTALLATION REQUIREMENTS ..................................................................... 112 I TYPICAL BATTERY STANDS ............................................................................. 115 J DEGREES OF PROTECTION OF ENCLOSED EQUIPMENT .............................. 117 K FAULT CURRENT (SHORT-CIRCUIT) PERFORMANCE OF CABLES ............. 117 L D.C. CIRCUIT PROTECTION APPLICATION GUIDE ........................................ 127 M ARC FLASH CALCULATION ............................................................................... 130 N RISK ASSESSMENT .............................................................................................. 138

BIBLIOGRAPHY ................................................................................................................... 178

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STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND

Australian/New Zealand Standard

Electrical installations—Safety of battery systems for use with power conversion equipment

S E C T I O N 1 S C O P E A N D G E N E R A L

1.1 SCOPE AND APPLICATION

1.1.1 Scope

This Standard sets out general installation and safety requirements for battery energy storage systems (BESS), where the battery system (BS) is installed on-site in a dedicated enclosure or room, and is connected with power conversion equipment (PCE) to supply electric power to other parts of an electrical installation.

This Standard sets out the requirements from the battery system up to but not including the PCE. This Standard also applies to pre-assembled integrated battery energy storage systems (BESS).

This Standard outlines the hazards that are associated with battery energy storage systems and their associated battery systems and specfies installation methods that eliminate or minimize these risks.

This Standard is applicable for the following battery systems:

(a) With a nominal voltage of 12 V d.c. and above.

(b) Connected to either single or multiple PCEs.

(c) With a rated capacity equal to or greater than 1 kWh, up to and including 200 kWh, at—

(i) C10 rating, for lead acid batteries; or

(ii) 0.1C, for lithium technologies; or

(iii) manufacturer’s specified energy capacity, for other technologies.

Where a system installation includes multiple battery energy storage systems, this Standard applies to each individual battery energy storage system if—

(A) the total energy storage capacity is equal to or greater than 1 kWh; and

(B) each individual BESS is less than or equal to 200 kWh.

This Standard does not apply to the following battery systems:

(1) Battery systems with a storage capacity of less than 1 kWh at C10 rating as applied to lead acid batteries, or 0.1C as applies to lithium technologies.

(2) Battery systems with a storage capacity of greater than 200 kWh at C10 rating as applied to lead acid batteries, or 0.1C as applies to lithium technologies.

(3) Premises with critical power continuity requirements (e.g. acute care hospitals, sub-station support and black start).

(4) Telecommunication applications.

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(5) Electric vehicles.

(6) Portable equipment.

(7) Uninterruptible power systems (UPS) that are in accordance with AS 62040, Parts 1.1 and 1.2.

NOTES:

1 While this Standard applies to systems of up to 200 kWh, the general requirements of this Standard may be applied to larger installations.

2 This Standard may be suitable for application to excluded systems; however, there may be additional hazards that have not been identified.

3 The Australian Design Rules (ADR) also apply for the safety of vehicles containing battery systems subject to this Standard.

1.1.2 Application

This Standard shall apply to battery energy storage systems that are constructed on site and pre-assembled integrated BESS. The construction of pre-assembled integrated BESS does not form part of this Standard where these products have been type tested and shown to conform to applicable product Standards. However, this Standard shall apply to the installation of the complete pre-assembled integrated BESS.

This Standard shall be read in conjunction with AS/NZS 3000.

When the installation of a battery system forms part of a system that is connected to the grid, this Standard shall be read in conjunction with the AS/NZS 4777 series, and the regulated Service and Installation Rules applying to the electricity distributor having responsibility for the network connection within the jurisdiction.

When the installation of a battery system forms part of a stand-alone power system, this Standard shall be read in conjunction with the AS/NZS 4509 series.

Local government and National Construction Code (NCC) requirements for the installation of a BESS may also apply.

1.2 OBJECTIVE

The objective of this Standard is to provide manufacturers, system integrators, designers and installers of battery energy storage systems with the requirements for the safety and installation of battery systems connected to power conversion equipment for the supply of a.c. and/or d.c. power.

1.3 NORMATIVE REFERENCES

The following are the normative documents referenced in this Standard.

NOTE: Documents referenced for informative purposes are listed in the Bibliography.

AS 1530 Methods for fire tests on building materials, components and structures 1530.4 Part 4: Fire-resistance test of elements of construction

3731 Stationary batteries (series)

60529 Degrees of protection provided by enclosures (IP Code)

62040 Uninterruptible power systems (UPS) 62040.1.1 Part 1.1: General and safety requirements for UPS used in operator access

areas 62040.1.2 Part 1.2: General and safety requirements for UPS used in restricted access

locations

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AS/NZS 1170 Structural design actions 1170.1 Part 1: Permanent, imposed and other actions 1170.2 Part 2: Wind actions 1170.4 Part 4: Earthquake actions in Australia

1337 Eye and face protection (series)

1680 Interior and workplace lighting 1680.1 Part 1: General principles and recommendations

3000 Electrical installations (known as the Australian/New Zealand Wiring Rules)

4029 Stationary batteries 4029 Part 2: Lead-acid—Valve regulated type

4509 Stand alone power systems 4509.1 Part 1: Safety and installation

4777 Grid connection of energy systems via inverters 4777.1 Part 1: Installation requirements 4777.2 Part 2: Inverter requirements

5000 Electric cables—Polymeric insulated 5000.1 Part 1: For working voltages up to and including 0.6/1 (1.2) kV 5000.2 Part 2: For working voltages up to and including 450/750 V

5033 Installation and safety requirements for photovoltaic (PV) arrays

60898 Circuit-breakers for overcurrent protection for household and similarinstallations

60898.2 Part 2: Circuit-breakers for a.c. and d.c. operation (IEC 60898-2 Ed. 1.1(2003) MOD)

60950 Information technology equipment 60950.1 Part 1: Safety—General requirements (IEC 60950-1, Ed. 2.2 (2013),

MOD)

AS/NZS IEC 60947 Low-voltage switchgear and control gear 60947.3 Part 3: Switches, disconnectors, switch-disconnectors and fuse-

combination units

NZS 4219 Seismic performance of engineering systems in buildings

IEC 60269 Low-voltage fuses 60269-1 Part 1: General requirements 60269-3 Part 3: Supplementary requirements for uses for use by unskilled persons

(fuses mainly for household or similar applications)—Examples ofstandardized systems of fuses A to F

60896 Stationary lead-acid batteries (series)

60947 Low-voltage switchgear and control gear 60947-2 Part 2: Circuit-breakers

62109 Safety of power converters for use in photovoltaic power systems 62109-1 Part 1: General requirements 62109-2 Part 2: Particular requirements for inverters

62116 Utility-interconnected photovoltaic inverters—Test procedure of islanding prevention measures

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IEC 62619 Secondary cells and batteries containing alkaline or other non-acid

electrolytes—Safety requirements for secondary lithium cells and batteries, for use in industrial applications

UL (Underwriters Laboratories) 1973 Standard for Batteries for Use in Light Electric Rail (LER) Applications and

Stationary Applications

1.4 DEFINITIONS

For the purpose of this Standard, the following definitions and those of AS/NZS 3000 apply. If no definition is given for a term, the definition given in Electropedia (also known as the ‘IEV’ Online) applies. Electropedia is copyright material of the International Electrotechnical Commission and may be accessed through www.electropedia.org.

1.4.1 Accessible, readily

Capable of being reached quickly and without climbing over or removing obstructions, or using a movable ladder, and not more than 2 m above the ground, floor or platform.

1.4.2 Accessories

Those items supplied with a battery, battery module or battery system to facilitate the continued operation of the battery system.

NOTE: Such accessories include distilled water in containers, connectors, connecting bolts and nuts, and hydrometers.

1.4.3 Adjacent

Within 3 m, with each item fully visible from both locations.

1.4.4 Arc flash

An electrical explosion or discharge, which occurs between electrified conductors during a fault or short-circuit condition.

1.4.5 Arc flash incident energy

The measurement applied to determine the available incident arc flash energy at a specified distance originating from an arc flash. This measurement is used to determine the level of personal protection equipment (PPE) and the relevant arc flash protection boundary.

1.4.6 Arc flash protection boundary

The boundary marked by the distance from electrical equipment at which the arc flash incident energy would be 1.2 cal/cm2. Correct personal protective equipment (PPE) is required within this boundary to protect from burns.

1.4.7 Assembled

Having connected together the separate component parts of a battery energy storage system (BESS).

1.4.8 Authorized person

The person in charge of the premises, or other person appointed or selected by the person in charge of the premises, who performs certain duties associated with the BESS or battery system installation on the premises. Li

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1.4.9 Auxiliary equipment/battery equipment

Auxiliary equipment required for supporting different battery technologies and associated battery infrastructure. May include pumps, storage tanks, fire suppression, communications equipment, battery monitoring boards and any other equipment required for the battery cell, battery module or battery to operate.

1.4.10 Available, readily

Capable of being reached for inspection, maintenance or repairs without necessitating the dismantling of structural parts, cupboards, benches or the like.

1.4.11 Battery

A unit consisting of one or more energy storage cells connected in series, parallel or series parallel arrangement.

1.4.12 Battery bank

Batteries or battery modules connected in series and/or parallel to provide the required voltage, current and storage capacity within a battery system, and meet the requirements of associated power conversion equipment (PCE).

1.4.13 Battery bank enclosure

An enclosure containing a battery bank that is compatible with the installation location and the associated battery bank components.

1.4.14 Battery enclosure

An enclosure containing one or more batteries or cells that is compatible with the installation location and the associated battery components.

1.4.15 Battery energy storage system (BESS)

Consists of PCE, battery system(s), protection devices and all the necessary additional equipment.

1.4.16 Battery energy storage system enclosure

A dedicated enclosure containing all the components of a battery energy storage system including, but not limited to, PCE, battery system(s) and all the necessary auxiliary equipment that is compatible with the installation location and the associated BESS components. The enclosure may also house ancillary equipment related to the photovoltaic (PV) array connection or diesel generator connection.

1.4.17 Battery energy storage system room

A dedicated room specifically intended to contain all the components of a battery energy storage system including, but not limited to, PCE, battery system(s) and all the necessary auxiliary equipment. The room may also house ancillary equipment related to the PV array connection or diesel generator connection.

1.4.18 Battery management module (BMM)

Distributed battery and battery module devices that feed into the BMS and are generally part of the electronics on an individual cell or module.

1.4.19 Battery management system (BMS)

A device to manage a set of primary safety functions achieving battery protection. The BMS is an electronic system associated with a battery or battery system which monitors and/or manages in a safe manner its electric and thermal state by controlling its environment, and which provides communications between the battery system and the PCE and connected devices (e.g. vents or cooling).

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The BMS monitors cells, battery or battery modules to provide protective actions for the battery system in the case of overcharge, overcurrent, over discharge, overheating, overvoltage and other possible hazards that could occur. Additional BMS functions may include active or passive charge management, battery equalization, thermal management, specific messaging or communications to the PCE regarding charge rates and availability.

1.4.20 Battery module

One or more batteries linked together. May also have incorporated electronics for monitoring, charge management and/or protection.

1.4.21 Battery monitoring system

A device that monitors the battery cells, or battery, or battery modules to provide information/feedback to the PCE or other devices via a communication network, about battery parameters such as voltage, current, state of charge, temperature and other relevant data.

1.4.22 Battery short-circuit current

The potential maximum fault current able to be delivered from a battery under the condition of shorting the terminals.

1.4.23 Battery string

Batteries or battery modules connected in series.

1.4.24 Battery system

A system comprising one or more cells, modules or battery systems. Depending on the type of technology, the battery system may include a battery management system and auxiliary supporting equipment for the system. This does not include the PCE.

1.4.25 Battery system enclosure

A dedicated enclosure containing the battery system and which is compatible with the installation location and appropriate for housing the associated battery system components.

1.4.26 Battery system room

A dedicated room for the battery system and the associated battery system components.

1.4.27 Cable, current-carrying capacity (CCC)

The maximum continuous current at which a conductor will not overheat and cause permanent damage to the conductor insulation. It is affected by conductor cross-sectional area, cable insulation material and the method of cable installation.

NOTE: For further information see AS/NZS 3008.1.1.

1.4.28 Capacity (C)

The quantity of electricity that a fully charged battery is able to deliver under specified conditions.

NOTE: Capacity is measured in ampere-hours (A.h.).

The capacity of a cell or battery is denoted by the symbol C. As the capacity varies with rate of discharge, the symbol C is followed by a numerical suffix giving the rate of discharge. Thus C10 is the capacity in ampere-hours at the 10 h rate of discharge: the amps that the battery can sustain if discharging from 100% to 0% or lowest charge threshold over 10 hours. The specified temperature is usually 25°C. The lowest voltage depends on battery type and conditions of service.

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Capacity may be specified as follows:

(a) Actual capacity The quantity of electricity, in ampere-hours, that can be withdrawn from a cell or battery for a specific set of repetitive operating conditions including discharge rate, temperature, initial state of charge, age, and final voltage.

(b) Rated capacity The minimum quantity of electricity, in ampere-hours, declared by the manufacturer to be the full capacity at the start of the battery’s life, and which the battery can deliver after a full charge under specified conditions based on the battery’s quoted operating life. The rated capacity quoted may reduce over the life of the battery.

NOTE: The specified conditions are rate of discharge, final voltage and temperature.

1.4.29 Cell

Basic functional unit, capable of storing energy or charge. This may consist of assembly including electrodes, electrolyte, container, terminals and separators.

1.4.30 Charging

An operation during which a battery receives electric energy, which is converted to chemical energy, from an external circuit. The quantity of electric energy is known as the charge.

NOTE: Charge is usually measured in ampere-hours.

1.4.31 Combustion by-products

By-products produced by battery systems when combusted. For combustion by-products refer to the safety data sheet (SDS) specific to the battery type.

1.4.32 Competent person

A person who has acquired knowledge and skill, through training, qualifications, experience, or a combination of these, and which enables that person to correctly perform the task required.

1.4.33 Decisive voltage classification (DVC)

A determination of the highest voltage, which occurs continuously between any two arbitrary live parts of the battery system, battery modules or the PCE during worst-case, rated operating conditions when used as intended.

1.4.34 Dedicated room or enclosure

A room or enclosure dedicated to the exclusive use of equipment specified as part of the battery system, BESS or power system (including PV connection and/or generator connections, etc.).

1.4.35 Deflection

The degree to which a structural component is displaced under a load.

1.4.36 Discharging

An operation during which a battery delivers current to an external circuit by the conversion of chemical energy to electric energy.

1.4.37 Domestic dwelling

A building of Class 1, Class 2 or Class 10 as specified in the National Construction Code (NCC) under Australian building classifications.

NOTE: This classification also applies in New Zealand.

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1.4.38 Electrical hazard

Potential source of harm when electric energy is present in an electrical installation (harm relates to injury to persons and/or damage to electrical installations).

1.4.39 Electrolyte

A liquid or solid substance containing mobile ions which will render the substance ionically conductive, for example, sulfuric acid (H2SO4) in lead-acid batteries, sodium hydroxide (NaOH) in nickel-cadmium batteries and zinc bromine (ZnBr2) in zinc bromine batteries.

1.4.40 Explosive gas hazard

A condition where danger exists because hazardous materials that are present may react (e.g. detonate, deflagrate) in a mishap with potential, unacceptable effects (e.g. death, injury, damage) to people, property, operational capability or the environment.

1.4.41 Fire hazard

A condition where danger exists because flammable materials are present in quantities/concentrations that may result in uncontrolled combustion with potential for death, injury, or damage to people, property, operational capability or the environment.

1.4.42 Fire hazard level 1

A fire occurring within a battery system, where the fire is self-sustaining.


A fire occurring within a battery system, where the fire is not self-sustaining.

1.4.44 Fire resistance level (FRL)

The grading period in minutes, determined in accordance with AS 1530.4 for—

(a) structural adequacy;

(b) integrity; and

(c) insulation,

and expressed in that order (e.g. 60/60/60).

1.4.45 Fire separation

A wall or barrier having a specified fire resistance level, constructed and placed for the purpose of preventing the spread of fire.

1.4.46 Habitable rooms

Rooms in domestic dwellings, including bedrooms, living areas, lounge room, music room, television or media room, kitchen, dining room, family room, sewing room, study, playroom, home theatre and sunroom.

1.4.47 Hazard

A situation that has the potential to harm.

1.4.48 Horizontally mounted cell

A cell designed to operate with its terminals and valves mounted on a vertical surface (see Figure 1.1).

1.4.49 Inter cell connections

Those connections made between adjacent cells in a single row.

1.4.50 Inter-row connections

Those connections made between rows of cells.

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1.4.51 Inter-string protection

Devices inserted between adjacent cells within a string for the purposes of isolation and/or overcurrent protection.

1.4.52 Lithium ion technologies

Battery technology, comprising an anode, a cathode and a lithium salt electrolyte. Different types of lithium ion battery technologies comprise varying compositions for each of the anode, cathode and electrolyte.

1.4.53 Live parts

A conductor or conductive part intended to be energized in normal use, including a neutral conductor and conductive parts connected to a neutral conductor.

1.4.54 Mechanical hazard

Factors which may cause injury due to the mechanical properties of products/product parts.

1.4.55 Multiplying factor

A factor applied when determining the arc flash incident energy depending on how the battery system is installed, e.g. multiplying factor of 3 that is applied to battery system installed in an enclosure.

1.4.56 Nominal voltage

A manufacturer’s stated voltage, which is the steady state disconnected charged voltage of a cell. The system’s nominal voltage (Vs nominal) is calculated from the cell nominal voltage (Vn) and the number of cells in series (n)

Vs nominal = Vn n

1.4.57 Partial state of charge

Operation whereby batteries do not typically cycle between full SOC and depletion, and are then fully recharged. PSOC relates to a considerable variation in operation generally between 20% SOC and 90% SOC.

1.4.58 Personal protection equipment (PPE)

Specialized clothing or equipment worn by personnel for protection against safety and health hazards.

1.4.59 Port (of PCE)

Location giving access to a device or network where electromagnetic energy or signals may be supplied or received or where the device or network variables may be observed or measured. [SOURCE: IEC 62109-1:2010, 3.64.]

1.4.60 Power conversion equipment (PCE)

An electrical device converting and/or manipulating one kind of electrical power from a voltage or current source into another kind of electrical power with respect to voltage, current and/or frequency.

Examples include d.c./a.c., inverters, d.c./d.c. converters, charge controllers, etc. NOTE: Battery management systems are not considered to be PCEs for the purpose of this Standard.

1.4.61 Power conversion equipment, non-separated

PCE with no electrical separation between the input and output circuits.

NOTE: An example of a non-separated PCE is a transformerless (non-isolated) inverter.

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1.4.62 Power conversion equipment, separated

PCE with at least simple separation between the input and output circuits.

NOTE: For a PCE that does not have internal separation/isolation between the input and output circuits, but is required to be used with a dedicated isolation transformer, with no other equipment connected to the PCE side of that isolation transformer, the combination may be treated as a separated PCE. Other configurations require analysis at the system level and are beyond the scope of this Standard, however the principles in this Standard may be used.

1.4.63 Pre-assembled battery system

A system comprising one or more cells, modules or battery systems, and/or auxiliary supporting equipment. Depending on the type of technology, the battery system may include a battery management system. Often pre-assembled battery systems also come in a dedicated battery system enclosure.

1.4.64 Pre-assembled integrated BESS

A battery energy storage system manufactured as a complete, pre-assembled integrated package with the PCE, battery system and protection device by the equipment manufacturer.

1.4.65 Prospective fault current

The highest level of fault current that can occur at a point in a circuit. This is the fault current that can flow in the event of a zero impedance short-circuit and if no protective devices operate.

1.4.66 Risk

Combination of the probability of occurrence of harm (likelihood) and the severity of that harm (consequence).

1.4.67 Risk assessment

Overall process comprising a systematic use of available information to identify hazards and to estimate the risk and determine what and how control measures may reduce this risk.

1.4.68 Safety data sheet (SDS)

A document, previously called a ‘Material Safety Data Sheet’ (MSDS), that provides information on the basic physical and chemical properties of the materials used in the manufacture of a product, the safe use and potential hazards associated with that product.

1.4.69 Sealed valve-regulated cell

A cell that is closed under normal conditions, but which has an arrangement that allows the escape of gas if the internal pressure exceeds a predetermined value. Electrolyte is not normally added to a sealed value-regulated cell.

1.4.70 Service life

The total period of useful life of a cell or a battery in operation. For secondary cells and batteries, the service life may be expressed in time, number of charge/discharge cycles, capacity in ampere hours (Ah) or percentage of capacity.

1.4.71 Shall

Indicates that a statement is mandatory.

1.4.72 Short-circuit

When a fault of negligible impedance occurs between live conductors having a difference in potential under normal operating conditions.

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1.4.73 Should

Indicates a recommendation.

1.4.74 Shroud

An insulated cover to protect the terminals and inter-cell connectors from inadvertent contact by personnel and accidental short-circuiting, and which cover may provide protection against corrosion.

1.4.75 Stand-alone power systems (SPS)

Systems that are not connected to the power distribution systems of an electricity entity/distributor. Stand-alone systems are supplied with power from one or more of a number of sources, including, but not limited to, a photovoltaic array, a wind turbine generator, a micro-hydro generator and a motor-generator set.

1.4.76 State of charge (SOC)

The amount of capacity that remains in a battery or battery system expressed as a percentage of the rated capacity of the battery or battery system.

1.4.77 Terminal/terminal post

A part provided for the connection of a cell or a battery to external conductors.

1.4.78 Tiered stand

A stand, on which rows of containers are placed above containers of the same or another battery.

1.4.79 Toxic fumes

Gases classified as poisonous or dangerous to people.

1.4.80 Ventilation, aperture or opening

Any aperture or system or means intended to provide the intake or exhaust of air to a room, building, etc.

1.4.81 Vertically mounted cell

A cell designed to operate with its terminals and valves mounted on its upper horizontal surface (see Figure 1.1).

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(a) Hor izontal ly mounted cel l (b) Ver t ical ly mounted cel l

FIGURE 1.1 CELL TERMINOLOGY

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S E C T I O N 2 B A T T E R Y E N E R G Y S T O R A G E S Y S T E M C O N F I G U R A T I O N S

2.1 GENERAL

Battery energy storage systems (BESS) are used to supply power to an application circuit.

Figure 2.1 illustrates the general functional configuration of a battery energy storage system.

Bat tery Energy Storage System

Appl icat ion c ircui tBESS

FIGURE 2.1 GENERAL FUNCTIONAL CONFIGURATION OF A BATTERY ENERGY STORAGE SYSTEM

2.2 BATTERY ENERGY STORAGE SYSTEM

2.2.1 Overview

There are many different battery energy storage systems possible. The following list comprises examples of factors that affect the BESS design and installation requirements:

(a) Battery system voltage.

(b) Inverter port classification and configuration.

(c) Battery system earthing arrangements.

(d) Battery short circuit current/prospective fault current.

(e) Battery system capacity.

(f) Battery system chemistry.

(g) Available access to the battery system e.g. location restrictions for battery access, enclosure aspects.

(h) BESS application requirements.

(i) Acceptable risk factors.

2.2.2 Battery system chemistries

The following types of battery system chemistries are considered in the provisions of this Standard:

(a) Lead acid.

(b) Nickel cadmium.

(c) Flow.

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(d) Hybrid ion.

(e) Lithium ion.

NOTE: The general provisions of this Standard may be applied to other battery system chemistries provided all the hazards listed in Section 3 as well as any specific hazards related to that chemistry type are accounted for (e.g. sodium sulphur batteries have high temperature hazards).

Any individual battery system shall be made up of only one type of technology or chemistry. While it may be possible to combine different types of battery systems within one BESS, this should only be considered when separate ports or separate PCEs are used to manage the charging and discharging of these battery systems.

2.2.3 Battery systems

Battery systems may incorporate numerous devices in addition to the actual battery cell/s, including battery protection devices (these may be fuses or thermal devices that protect against short-circuit at the terminals), battery management modules, battery management systems, pumps, thermal management devices, fire suppression devices, etc.

For the purpose of protection and disconnection device requirements, the electrical output of a battery system is defined at a point where the voltage is that of the d.c. operating voltage of the system. For some battery types, the battery system comprises one single string of the battery type e.g. lead acid batteries, flow batteries. For some technologies, a battery system may comprise battery modules in series and parallel which are connected to a battery management system. The electrical output is on the output terminals of the battery management system.

Selection of a battery system or its subsets should consider (but not be limited to) the following:

(a) Compatible PCE.

(b) Expected operational characteristics (maximum charge and discharge currents; rated capacity and timeframe for typical charge and discharge events; potential for partial state of charge operation).

(c) Expected service life.

(d) Available installation location including environmental factors.

(e) Maximum acceptable nominal system voltage.

(f) Additional hazard considerations (see Clause 3.2).

(g) Service provisions and ability to replace components.

2.2.4 BESS: Key components

BESS generally comprise the following components:

(a) Power conversion equipment (PCE).

(b) Battery connection and interface (protection, accessories, etc.).

(c) Battery system.

Figure 2.2 illustrates the main components of a BESS.

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PCE

BatterySystem

Inter faceProtect ionDevice

Bat tery Energy Storage System (BESS)

Appl icat ion Circuit

Inter face(See Note 2)

Inter face(See Note 3)

Over Current Protect ionand Isolat ion device

(See Note 1)

NOTES:

1 Over-current protection device (see Clause 4.3.2) and isolation device (see Clause 4.3.3).

2 Power conversion equipment may consist of one or multiple PCEs.

3 The interface may be a communications link, and/or monitoring.

FIGURE 2.2 MAIN COMPONENTS OF A BATTERY ENERGY STORAGE SYSTEM

2.2.5 Battery system components

Figure 2.3 illustrates some possible components of a battery system.

Auxi l iar y Bat tery

Equipment

Bat tery Bat tery Bat tery Bat tery

Bat tery Module

Bat tery

Bat tery Module

Bat tery

Bat tery Bank

BMS

BMM BMM

Bat tery System

FIGURE 2.3 TYPICAL COMPONENTS OF BATTERY SYSTEM

2.2.6 BESS: Typical configurations

This Clause applies to all BESS. Figures 2.4 to 2.7 illustrate a number of battery system types available that may form part of a BESS.

Figure 2.4 is an example of a BESS with battery system comprising individual battery cells (e.g. lead acid or nickel cadmium) connected in series without the need for any battery management system. A single string of these types of batteries are defined as a battery system.

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PCE

Battery Bat tery Bat tery Bat tery Bat tery

Bat tery System

Bat tery


Protect ion and Isolat ion Device

FIGURE 2.4 TYPICAL BESS WITH BATTERY SYSTEM COMPRISING INDIVIDUAL BATTERY CELLS AND NO BATTERY MANAGEMENT SYSTEM

(e.g. TYPICAL LEAD ACID SYSTEM)

Figure 2.5 is an example of a BESS with battery system comprising a number of lithium ion battery modules in parallel and/or series with the required battery management system.

PCE

Battery Module

Bat tery System

Bat tery Bank


Protect ion and Isolat ion Device Inter face

Bat tery Management System

Bat tery Module

Bat tery Module Bat tery ModuleAuxi l iar y Bat tery

Equipment

FIGURE 2.5 TYPICAL BESS WITH BATTERY SYSTEM COMPRISING LITHIUM ION BATTERY MODULES

Figure 2.6 is an example of a BESS with battery system comprising individual lithium ion batteries, each having their own separate circuit board for all monitoring and/or balancing and interconnected with the battery management system.

Auxiliary equipment as shown in this figure may include devices such as battery system alarms or fire suppression systems, or items such as inbuilt cooling systems and specific battery system communication devices.

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Bat tery

Bat tery System

Bat tery Bank


Bat tery Bat tery Bat tery Bat tery Bat tery

Circui tboard

Circui tboard

Circui tboard

Circui tboard

Circui tboard

Circui tboard

Bat tery Management System

PCEInter faceProtect ion and Isolat ion Devices

Circui t boards mounted on each bat tery provid ing l inks back to the BMS

FIGURE 2.6 TYPICAL BESS WITH BATTERY SYSTEM COMPRISING INDIVIDUAL LITHIUM ION BATTERIES, EACH HAVING THEIR OWN CIRCUIT BOARD

INTERCONNECTED TO A BATTERY MANAGEMENT SYSTEM

Figure 2.7 shows a BESS with a battery system comprising a flow battery module, auxiliary equipment and battery management system. Typical auxiliary equipment in this case may include pumps, leak detection alarms, pump controls and protection for auxiliaries.

Bat tery energy storage system (BESS)

Bat tery management system

PCEInter faceProtect ion and isolat ion devices

Bat tery module

Bat tery system

Bat tery bank

Auxi l iar ybat tery

equipment

FIGURE 2.7 TYPICAL BESS WITH BATTERY SYSTEM COMPRISING FLOW BATTERY MODULE, AUXILIARY EQUIPMENT AND BATTERY MANAGEMENT SYSTEM

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2.3 BESS: APPLICATIONS

2.3.1 Applications

The following types of BESS are covered by this Standard:

(a) BESS comprising PCE connected to d.c. application circuit.

(b) BESS comprising a separated/isolated PCE connected to a.c. system. (d.c. connections may also be present).

(c) BESS comprising a non-separated/non-isolated PCE connected to a.c. system (d.c. connections may also be present).

The PCE functions include the following:

(i) d.c. to d.c. converter or a.c to d.c battery charger.

(ii) stand-alone inverter or multiple mode inverter or other grid connect inverter which allows interconnection with battery systems.

NOTE: Some battery systems have a d.c. to d.c. converter PCE incorporated into the battery system. They require an additional PCE for use in connection with an application circuit. These inbuilt PCEs (d.c. to d.c. converters) are considered part of the auxiliary equipment and form part of the battery system.

2.3.2 System architectures

A system installation may comprise any one of the following:

(a) A BESS having one battery system connected to one or more PCE(s).

(b) A BESS having parallel battery systems connected to one or more PCE(s).

(c) Multiple BESSs, each individual BESS comprising one or more battery systems connected to one or more PCE(s).

When an installation comprises multiple BESSs (see Figures 2.11 and 2.12), for which the combined energy storage rating of the installation is >200 kWh, this Standard applies to each individual BESS forming part of that installation and for which the energy storage rating is ≤200 kWh.

2.3.3 Electrical diagrams

Figures 2.8 to 2.12 illustrate some typical electrical configurations of BESS installations: ranging from a BESS comprising a single battery string and single PCE through to multiple BESSs connected in parallel to the battery port of the PCEs.

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PCEB

att

ery

sy

ste

m

PCE disconnect ion and protect iondevice i f appl icable see Note 1

Bat tery System disconnect ion and protect ion device

NOTES:

1 PCE disconnection device required if battery system is not adjacent to the PCE (see Clause 4.3.7.2) and protection device installed if required (see Clause 4.3.6.8).

2 Switched fuses are shown as the protection and disconnection devices, these could be suitably rated d.c. circuit breakers.

FIGURE 2.8 TYPICAL BESS INSTALLATION DIAGRAM: BESS WITH SINGLE BATTERY SYSTEM CONNECTED TO SINGLE PCE.

PCE

PCE disconnect ion and protect ion devicei f appl icable see Note 1

Bat tery System disconnect ionand protect ion device

Bat tery system

NOTES:


2 Switched fuses are shown as the protection and disconnection devices, these could be suitably rated d.c circuit breakers.

FIGURE 2.9 TYPICAL BESS INSTALLATION DIAGRAM: BESS WITH PARALLEL BATTERY SYSTEMS CONNECTED TO SINGLE PCE

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Ba

tte

ry s

ys

tem

PCE

PCE

PCE(a)

(b)

PCE disconnect ion andprotect ion device i fappl icable See Note 1


See Note 2 NOTES:

1 PCE disconnection device required if battery system is not adjacent to the PCE (see Clause 4.3.7.2) or if the PCE’s are performing different functions) (see Clause 4.3.7.3, and protection device installed if required (see Clause 4.3.6.8).

2 Insert either common ganged disconnection device in location (a) or insert main battery disconnection device in location (b).

3 Switched fuses are shown as the protection and disconnection devices; these could be suitably rated d.c circuit breakers.

FIGURE 2.10 TYPICAL BESS INSTALLATION DIAGRAM: BESS WITH SINGLE BATTERY SYSTEM CONNECTED TO MULTIPLE PCEs

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PCE

Ba

tte

ry

sy

ste

mB

att

ery

s

ys

tem

PCE

BESS

BESS

NL

+

–

+

–

PCE disconnect ion and protect iondevice i f appl icable, see Note 1


NOTES:


2 Switched fuses are shown as the d.c. protection and disconnection devices, these could be suitably rated d.c circuit breakers.

FIGURE 2.11 TYPICAL BESS INSTALLATION DIAGRAM: MULTIPLE BESS EACH WITH SINGLE BATTERY SYSTEM CONNECTED TO SINGLE PCEs

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N NN

PC

E

PC

E

PC

E

Battery system

BE

SS

BE

SS

(a)

(b)

L1L

2L

3

L1L

2L

3

PC

E

PC

E

PC

E

Battery system

(a)

(b)

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e N

ote

3S

ee

No

te 2

PC

E d

isc

on

ne

cti

on

an

d p

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cti

on

de

vic

e i

f a

pp

lic

ab

le,

Se

e N

ote

1B

att

ery

Sy

ste

m d

isc

on

ne

cti

on

a

nd

pro

tec

tio

n d

ev

ice

Se

e N

ote

5

Se

e N

ote

4

NOTES:

1 PCE disconnection device required if battery system is not adjacent to the PCE (see Clause 4.3.7.2) or if the PCEs are performing different functions (see Clause 4.3.7.3) and protection device installed if required (see Clause 4.3.6.8).

2 Typical variation shown: two groups of three single phase PCE. Other variations are possible.

3 PCE isolation shall meet requirements of AS/NZS 4777 series or AS/NZS 4509 or AS/NZS 3000 as suitable.

4 Insert either common ganged disconnection device (a) or insert main battery disconnection device (b).

5 Switched fuses are shown as the d.c. protection and disconnection devices, these could be suitably rated d.c circuit breakers.

FIGURE 2.12 TYPICAL BESS INSTALLATION DIAGRAM—MULTIPLE BESS EACH WITH SINGLE BATTERY SYSTEM CONNECTED TO MULTIPLE PCEs

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S E C T I O N 3 B A T T E R Y E N E R G Y S T O R A G E S Y S T E M : H A Z A R D S

3.1 GENERAL

BESS and battery systems use chemicals to store significant energy within a relatively compact space. The consideration and management of hazards associated with battery systems and BESS shall be considered in the design and installation of these systems. Any battery energy storage system can present or create many or all of the hazards noted within this Section. This Section details the types of hazards a battery system can present. Later Sections deal with design and installation practices to eliminate, minimize and manage in consideration of these hazards.

The safety data sheet (SDS) and the manufacturer’s installation instructions shall be provided for all battery energy storage systems or their equipment subsets to set out specific information in relation to the hazards covered in this Section 3.

3.2 HAZARDS ASSOCIATED WITH BESS

3.2.1 General

This Clause 3.2 outlines the following six main hazard types associated with battery energy storage systems and any part thereof:

(a) Electrical hazard.

(b) Energy hazard.

(c) Fire hazard.

(d) Explosive gas hazard.

(e) Chemical hazard.

(f) Mechanical hazard.

Appropriate installation requirements to prevent or minimize the risks from these hazards are included in Section 4.

3.2.2 Hazard classification by battery type

3.2.2.1 General

A battery energy storage system may comprise one or more battery types. Each of these battery types presents type-specific operating characteristics and hazards. The safe handling, installation, operation and servicing of different battery types rely on identifying which hazards are peculiar to each of the battery types and taking this into account in their installation.

Table 3.1 sets out the relationship of the specified battery types to a range of hazards. Clauses 4.3 to 4.8 provide installation requirements for the management of each of the hazard types shown. If the battery type intended for installation or servicing is not included as part of this Table 3.1, a risk assessment shall be undertaken to classify the battery type with respect to the hazard classifications stated in Table 3.1 or any other hazard relevant to that battery type. A copy of the risk assessment shall be included with the documentation provided with the system documentation to the client as required in Section 8.

NOTE: Example risk assessments are shown in Appendix N.

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TABLE 3.1

HAZARD CLASSIFICATIONS BY BATTERY TYPE

Battery chemistry

Electrical hazard

Energy hazard

Fire hazard:

level 1 or 2 See Notes

Chemical hazard

Toxic gas hazard

Explosive gas hazard

Mechanical hazard

Lead acid 2 N/A

Nickel alkaline based 2 N/A

Lithium based 1 N/A

Note 1

Flow N/A

Note 2

Hybrid ion N/A N/A N/A

NOTES:

1 Fire hazard level 1: fires which are self-sustaining.

2 Fire hazard level 2: fires which are not self-sustaining.

NOTE: Lithium chemistries that release hydrogen under fault conditions should be considered an explosive gas hazard, e.g. lithium manganese.

Flow batteries having an acidic water-based solution may produce explosive and toxic gases.

3.2.3 Electrical hazard

3.2.3.1 General

The electrical risks associated with a battery system are strongly dependent on the voltage of the battery bank, the characteristics of any other equipment that is connected to the battery system (e.g. inverter and/or energy source), the earthing, the protection systems and siting of protection devices.

3.2.3.2 Decisive voltage classification (DVC) NOTE: See Appendix A for additional information.

The decisive voltage classification (DVC), as defined in IEC 62109-1, shall be applied in this Standard. Table 3.2 provides a summary of DVC levels.

The DVC system refers to the voltage level and also the degree of separation of the relevant battery port from the grid or from any other energy source (e.g. in the case of a charge controller, as installed with a PV array). This type of classification simplifies the decisions associated with protection and enclosure requirements for a battery system.

The classification of circuits of power conversion equipment (PCE) (including inverters and charge controllers) shall be made according to their decisive voltage classification (DVC).

All inverter and PCE ports shall be classified and marked according to their DVC classification. Refer to AS/NZS 4777.2:2015 Clause 9.3.3(h) and IEC 62109-1.

NOTE: See also Appendix A.

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TABLE 3.2

SUMMARY OF DECISIVE VOLTAGE CLASSIFICATION VOLTAGE RANGES

Decisive voltage classification

(DVC)

Limits of working voltage V

a.c. voltager.m.s. UACL

a.c. voltagepeak

UACL

d.c. voltage mean UDCL

A1 ≤ 25 ≤35.4 ≤60

B2 ≤50 ≤71 ≤120

C2 >50 >71 >120

NOTES:

1 Under fault conditions, DVC-A circuits are permitted to have voltages up to the DVC-B limits for a maximum of 0.2 s.

2 If a battery system is either DVC-B or DVC-C it will be treated as an LV installation as defined in AS/NZS 3000.

3.2.3.3 Battery system prospective fault current/ short-circuit current

The prospective fault current (or prospective short circuit current) at the battery terminals of the battery system shall be based on the fault current able to be supplied by the battery cell prior to the interaction of any battery management system.

The battery system manufacturer should be consulted with regard to the sizing of battery fault current protection. If information regarding the fault current protection of a battery system is not available from the manufacturer, the battery system should not be installed.

NOTE: The internal resistance of a cell (lead acid type or similar) may be determined by the method shown in Appendix C.

The cell short-circuit current may be calculated according to the following equation:

ocsc

i

VI

R . . . 3.2.3

where

Isc = cell short-circuit current, in amperes

Voc = cell open-circuit voltage

Ri = cell internal resistance at full charge, in ohms

3.2.4 Energy hazard

3.2.4.1 General

Arc flash occurs when electrical current passes through the air between electrified conductors when there is insufficient isolation or insulation to withstand the applied voltage.

Arc flash incident energy is dependent on the voltage, current and the length of time that the arc occurs. The energy dissipates out from the arc flash incident so it is at its greatest at the incident and diminishes further away from the incident.

All BESS and battery systems shall be protected from electrical faults and inappropriate or uninformed use, e.g. electrical shorting across the battery ports. Clause 4.3 details protection requirements for battery systems and battery energy storage systems.

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Batteries of all types and their associated d.c. cabling shall be protected from mechanical damage in order to minimize the risk of dangerous energy discharge. See Clause 4.3.5.3 for the mechanical protection requirements.

To minimize the energy hazard, all battery systems shall be located in an area that shall be designed to prevent access by unauthorized persons. See Clause 4.2 for the installation requirements of battery systems.

3.2.4.2 Determining arc flash incident energy

3.2.4.2.1 General

The arc flash incident energy for battery systems having system voltages equal or less than 1000 V d.c. is calculated using the following equation:

2m sys arc arc0.01IE V I T D MF . . . 3.2.4(1)

where

IEm = estimated d.c. arc flash incident energy at the maximum powerpoint, in cal/cm2

Vsys = system voltage, in volts

Iarc = arcing current, in amps

Tarc = arcing time, in seconds

D = working distance, in centimetres

MF = multiplying factor

While

arc bf0.5I I . . . 3.2.4(1)

where

Ibf = battery prospective fault current, in amps (see Clause 3.2.3.3) NOTE: See Appendix M for worked examples.

3.2.4.2.2 Working distance

When calculating the arc flash energy, a maximum working distance of 45 cm shall be applied (see also Clause 4.4.1.5).

3.2.4.2.3 Arcing time

The arcing time will relate to which part of the system is having work undertaken.

For work being undertaken on the PCE side of the battery system’s protection device, the operating time for the protection based on the prospective fault current shall be used as the arcing time.

If the operational time of the protective device is unknown, an arcing time of two seconds shall be applied.

For work being undertaken on the battery system side of the battery system’s protective device, an arcing time of two seconds shall be applied.

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3.2.4.3 Multiplying Factor

The arc flash energy calculated according to Equation 3.2.4(1) is dissipated radially. A battery system (or systems) is located in an enclosure or in a room, where the area over which the energy to be dissipated is restricted by walls, enclosure roof or even the battery system. This physical limitation means that the amount of energy dissipated in the direction of a person working on the battery could be increased. The factor by which it is increased is known as the multiplying factor.

For battery system enclosures and BESS enclosures, a minimum multiplying factor of 3 shall be applied; while for battery system rooms or BESS rooms, a minimum multiplying factor of 1.5 shall be applied, unless specific other information is provided by the manufacturer.

NOTE: See Appendix M for example arc flash calculations.

3.2.4.4 Selecting PPE

The required PPE shall be determined having calculated the arc flash energy and by applying Table 3.3.

TABLE 3.3

PERSONAL PROTECTIVE EQUIPMENT FOR ARC FLASH PROTECTION*

PPE level cal/cm2 PPE description

0 Less than 1.2 No specific PPE protection required

1 >1.2 and 4 Flame retardant long sleeve shirt and pants, safety glasses with side shields (AS/NZS 1337)

2 >4 and 7.8 Flame retardant long sleeve shirt and pants, arc flash rated gloves, footwear, ear plugs, face shield

3 >7.8 and 25 Flame retardant long sleeve shirt and pants, arc flash rated gloves, footwear, ear plugs, face shield

4 >25 and 40 Multiple layered fire retardant clothing, arc flash rated gloves, footwear, ear plugs, face shield

5 >40 Multiple layered fire retardant clothing, arc flash rated gloves, footwear, ear plugs, face shield

* PPE protection may also be required for mechanical and chemical hazards.

NOTE: PPE Clothing is rated in ‘cal’. The unit ‘joule’ is not used in this application. The conversion of ‘cal’ to ‘joule’ is temperature dependent, e.g. at 15°C, the conversion factor is 1 cal = 4.18 joules.

3.2.5 Fire hazard

3.2.5.1 General

Based on the type of battery system used, the risk of fire may result from the following:

(a) Excessively high and low temperatures.

(b) Over and under voltage.

(c) Over charged or over discharged.

(d) Puncturing or failure of the battery case either under normal operating conditions or due to overload, component failure, insulation breakdown loose connections or misuse.

Battery systems and BESS shall be installed in such a manner that, in the event of fire originating within the battery system or battery energy storage system, the spread of fire will be kept to a minimum.

Clauses 3.2.5.2 and 3.2.5.3 detail the fire risk directly related to the specific types of battery system. Section 4 details how to minimize the fire risks.

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3.2.5.2 Batteries that emit explosive gases

The risk of a fire from a lead acid or nickel cadmium battery systems or battery systems with similar chemistries may result from the combination of an ignition source and the local concentration of hydrogen gases that are emitted when the battery system is being overcharged.

Clause 3.2.6 refers to the explosive gas hazard of these types of batteries.

A fire may accelerate if there is combustible material in the vicinity of the explosion. Refer to Clause 4.7.2 regarding the ventilation requirements to reduce the concentration of the hydrogen to a safe level and Clause 4.7.5 regarding removing the risk of spark hazards where the explosive gases are present.

3.2.5.3 Lithium ion batteries

Fire in a lithium ion battery is caused by the following:

(a) The thermal runaway of the batteries.

(b) A short-circuit event of the internal electrodes, which leads to thermal runaway.

(c) Overvoltage/overcharge, which builds internal pressure, eventually venting explosive gasses for some chemistries and housing types.

NOTES:

1 Thermal runaway occurs when the lithium breaks down at the cathode and reacts with the electrolyte and causes an exothermic reaction, which results in oxygen being released and a fire. The temperature at which thermal runway occurs varies according to the lithium ion chemistry. The breakdown in lithium at the cathode can result from overcharging leading to overvoltage or operating cell temperatures in excess of the maximum temperature allowed for the battery or from charging currents exceeding the maximum charge current.

2 Short-circuiting of lithium ion batteries occurs either through dendrite growth on the anode or copper from the anode dissolving in the electrolyte which can be caused by over-discharge of the battery.

3 Lithium ion chemistries will present different risk profiles according to the chemistry type, physical construction and combustion by-products.

4 Many lithium batteries have the potential, when on fire, to sustain the fire. They are categorized as fire hazard level 1—self-sustaining, as they are likely to continue to burn for a significant period. As this battery burns it generates more fuel to burn. This can occur regardless of whether it is the source of the fire, or is independent of the fire source.

3.2.6 Explosive gas hazard

This Clause refers to those batteries that generate hydrogen when being charged, and hence are deemed an explosive gas hazard. Battery systems that exhibit this characteristic consist of acid and alkaline-based batteries. The most common acid battery is the lead acid battery, while nickel cadmium and nickel metal hydride batteries are included in the alkaline category. Lead acid and alkaline batteries are available as vented or sealed valve-regulated batteries.

Generally batteries will be irreversibly damaged when subjected to sustained electrical abuse, therefore, the manufacturer’s recommended charging regimes shall be observed. Sealed valve-regulated lead acid batteries generally have much tighter charging tolerances than vented cells.

NOTE: The battery will release hydrogen and oxygen gases when the charge received is incorrectly adjusted, for example due to incorrect charge settings or a faulty charger or failure of some protection devices (e.g. where there are multiple strings). If the hydrogen and air mix in a proportion of between 4% and 76% by volume of air, the hydrogen by volume is combustible and burning is enhanced by oxygen enrichment. In this environment, any electrical sparks can cause explosions including internally to the devices installed and enclosures installed e.g. fans, motors, switches and lights.

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3.2.7 Chemical hazard

Safety data sheets are required for all chemicals that are part of the battery system. The information contained within the safety data sheet needs to be understood by those persons working with the battery systems. Information in the safety data sheets includes important handling information, what to do in the event of an emergency or spill, first aid information and the hazards of the chemical including health, physical and environmental hazards. The different chemicals used can result in burns to skin, environmental hazards if leaked into soils or waterways, accelerated failure of supporting infrastructure, e.g. accelerated corrosion.

All battery systems store chemical energy, and most contain fluid or gel electrolyte materials. In the event of an accident that damages the battery casing, chemical leakage can create a hazard.

3.2.8 Mechanical hazard

Mechanical hazards related to battery systems include the following:

(a) Weight.

(b) Sharp edges and corners.

(c) Moving parts (e.g. pumps in flow batteries).

(d) Falling over/tipping (e.g. BESS products and certain battery formats which are tall and narrow).

(e) Lack of lifting or securing accessories on batteries or systems.

When installing a battery system, consideration shall be given to the mechanical hazards applicable to the type, quantity, profile and size of the battery system to be installed.

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S E C T I O N 4 I N S T A L L A T I O N

4.1 GENERAL REQUIREMENTS

4.1.1 General

This Standard uses the decisive voltage classification (DVC) (see Clause 3.2.3.2). The maximum safe level for touch voltage shall be 60 V d.c.

NOTE: See Appendix A for guidance on DVC.

For domestic installations, the maximum potential difference between any two points in the battery system shall not exceed 600 V d.c.

All system equipment and components shall comply with AS/NZS 3000:2007 Section 4 External influences.

Equipment that is mechanically damaged shall not be installed.

Each battery energy storage system and all associated components thereof shall include the relevant safety data sheet (SDS) and the manufacturer’s installation instructions. This published information shall identify the hazards associated with the relevant battery type and associated components.

A risk assessment shall be undertaken prior to planning an installation of a BESS and shall form part of the system documentation to be provided to the system owner and/or operator. The risk assessment is required for the execution of the BESS installation, fault-finding or maintenance work.

NOTE: See Appendix N for additional information on risk assessment.

Lead acid batteries shall comply with AS/NZS 4029.2, or IEC 60896, or equivalent battery standard.

Lead acid and nickel cadmium batteries shall comply with AS 3731 series.

Secondary lithium cells and batteries shall comply with IEC 62619.

Where other battery system technologies are installed, they shall follow appropriate standards for the technology as they become available.

4.1.2 Preassembled integrated BESS

In addition to the requirements of Clause 4.1.1, a preassembled integrated BESS shall be constructed and conform to the requirements of AS 62040.1.1, AS 62040.1.2:

(as applicable) or IEC 62109 series. If the pre-assembled integrated BESS is intended to operate in parallel with the grid and/or the injection of electric power through an electrical installation into the grid, the BESS shall meet all the requirements of AS/NZS 4777.2. If the pre-assembled integrated BESS is intended to operate as a stand-alone power system, the BESS shall meet all the requirements of AS/NZS 4509.1.

The construction methodology and materials of a pre-assembled integrated BESS is generally outside the scope of this Standard. However, the pre-assembled integrated BESS shall house the battery system in accordance with the specific hazard reduction requirements specified in this standard for the battery type included in the pre-assembled integrated BESS. The installation of the pre-assembled integrated BESS shall meet—

(a) all requirements specified in Clauses 4.2, 4.4, 4.5, 4.6, 4.7 and 4.8 except where specific exemptions are stated; and

(b) the relevant requirements as specified for pre-assembled integrated BESS within Clause 4.3 (on electrical hazards).

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The a.c. electrical interconnection of the pre-assembled integrated BESS to the switchboard or distribution board shall comply with AS/NZS 3000 and, if the BESS is able to operate in parallel to the grid or inject electric power into an electrical installation connected to the grid at low voltage, the system shall comply with AS/NZS 4777.1.

4.2 INSTALLATION OF BESS

4.2.1 General

The installation of all BESS, shall meet the requirements of Clauses 4.2.2 to 4.2.6.

Installation of battery systems and BESS shall be limited to competent persons. Maintenance of battery systems and BESS shall be performed by competent persons, or where appropriate authorized persons.

NOTES:

1 Table 3.1 shows those battery types classified as energy hazards.

2 Exemptions for pre-assembled integrated BESS are stated where appropriate.

4.2.2 Location

4.2.2.1 General

Battery systems should be located in an area designed to prevent access by unauthorized persons.

Battery systems and BESS shall be installed such that they are adequately protected against physical damage that might be reasonably expected from environmental and other external influences, e.g. if a system is being installed in a car port or garage. These conditions would be those expected during normal operation for the service life of the system. Battery systems shall be installed in accordance with the manufacturer’s instructions and shall be installed in one of the following:

(a) A dedicated enclosure: An enclosed area that is not sufficiently large to allow a person to stand and move around inside. The dedicated enclosure shall contain only the battery system and battery system’s associated equipment or the BESS and any of its associated equipment. (See Clause 4.2.5.)

(b) A dedicated room: An enclosed area that is accessible only via a door (or doors) of sufficient size to allow a person to enter and walk within this area. The dedicated room shall contain only the battery system and battery system’s associated equipment or the BESS and any of its associated equipment. (See Clause 4.2.6.)

NOTE: If using battery system enclosure then the rest of the BESS equipment does not need to be enclosed.

4.2.2.2 Battery systems classified as a fire hazard level 1

Battery systems that are classified as a fire hazard level 1 shall be restricted regarding where they are able to be located (see Clause 4.5.3). All other battery types do not have the same restrictions and their location shall meet the location requirements specified in Clause 4.2.2.3.

4.2.2.3 Domestic buildings

In domestic buildings, battery systems and BESS shall not be located in habitable rooms (see Clause 1.4.46) or in areas of access/egress.

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Suitable areas for battery systems and BESS in these buildings may include garages, storage rooms, dedicated BESS or battery system room and verandas, provided that they comply with the locational restrictions for battery systems: located as to the same requirements as for switchboards from a designated damp area (refer AS/NZS 3000:2007 Section 6) and safety requirements specified for each of the identified hazards: electrical (see Clause 4.3); energy (see Clause 4.4); fire (see Clause 4.5); chemicals spills and fumes (see Clause 4.6); explosive gases (see Clause 4.7); and mechanical (see Clause 4.8).

Battery systems and BESS shall not be installed—

(a) in ceiling spaces and cavities; or

(b) on roofs.

4.2.3 Environmental considerations

The floor, base or wall upon which the battery system or BESS is installed shall provide adequate structural support (see Clause 4.8).

The following environmental considerations shall apply to the battery system and BESS location:

(a) Battery systems and BESS shall not be installed in locations where the battery system or BESS will be exposed to temperatures lower than the minimum or greater than the maximum temperatures, as specified by the battery system manufacturer.

(b) The battery system equipment shall be selected and installed to provide adequate protection against damage that might reasonably be expected from the presence of water, high humidity or solar radiation (direct sunlight).

The following environmental considerations should apply to the battery system and BESS location:

(i) The design of the battery system and BESS installation should be such that localized or general heat sources such as sunlight, generators, steam pipes, against walls uninsulated from direct sunlight and space heaters are avoided.

(ii) A battery system should not be located near combustible materials.

4.2.4 IP Rating

Battery energy storage systems and their installation shall have adequate protection against external influences and shall have an ingress protection (IP) rating appropriate for the environment in which they are installed in accordance with AS/NZS 3000.

If the battery system installation in an internal area is potentially subject to water spray, then the battery system shall be installed to the requirements for an outdoor installation. For example, due to the environment not being fully sealed from the effects of weather, or having water or other liquid storage system in the same location, or being in the vicinity of or areas where use of a hose or washing activity of any kind may occur, or having water taps or the like.

For BESS or battery systems installed indoors, the battery terminals and other connected conductive parts of the BESS or battery system shall provide protection to prevent inadvertent access to such parts. The battery enclosure shall have minimum protection of IP2X from battery terminals and other connected conductive parts.

For BESS or battery systems installed outdoors, the enclosure of the battery system shall provide minimum protection of IP23 for the battery system terminals and other connected conductive parts. Higher IP rating protection may be required depending on the installation location and the battery system type.

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NOTES:

1 The installation of battery system and BESS enclosures indoors may have other restrictions based on their identified hazards.

2 The battery system enclosure or room (see Clauses 4.2.5 and 4.2.6) may provide the minimum IPX4 protection, subject to assessment that it meets that requirement, but this IP rating is not considered to be the means to meet the minimum IP2X requirement to prevent access to battery terminals or other connected conductive parts.

3 Appendix J gives details of the protection levels of the different IP classifications.

4.2.5 Battery system and BESS enclosure requirements

4.2.5.1 General

The design of enclosures shall include means to prevent access by unauthorized persons.

It should be clean, dry, ventilated, and provide and maintain protection against detrimental environmental conditions and other external factors.

The enclosure shall meet the installation requirements of—

(a) Clauses 4.3 and 4.4;

(b) Clause 4.5, if the battery system type is classified as a fire hazard;

(c) Clause 4.6, if the battery system type is classified as a chemical hazard;

(d) Clause 4.7, if the battery system is classified as an explosive gas hazard; and

(e) Clause 4.8, for mechanical hazards.

4.2.5.2 Battery system enclosure

4.2.5.2.1 General

A battery system enclosure shall take the form of—

(a) a cabinet with lockable doors or doors locked by a padlock; or

(b) a cabinet with doors that require the use of a tool for access; or

(c) a covering box with a lid that requires the use of a tool for access; or

(d) other suitable housing that requires the use of a tool for access.

The battery system enclosure shall provide protection against electrical contact or damage to the battery.

4.2.5.2.2 Design, layout and construction

The design, layout and construction of the battery system enclosure shall meet the following (excluding pre-assembled integrated BESS):

(a) Be suitable for the battery type and battery system being installed.

(b) Either—

(i) all batteries or battery modules shall have all live surfaces insulated or shrouded; or

(ii) all potential differences between exposed live parts exceeding DVC-A shall be separated by 2.5 m (measured in a string line).

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(c) The area inside the enclosure for the battery system shall allow for the following clearances:

(i) Space between batteries The space between cell/battery containers shall be at least 3 mm unless otherwise specified by the manufacturer.

(ii) Space between battery and top or roof of enclosure (unless top opening) For vertically mounted flooded cells/batteries there shall be a minimum clearance of 300 mm between the highest point of a battery and the lowest point of the underside of the upper bearers of the roof above for battery enclosures with front opening access. For other battery types, this minimum distance shall be half the distance to the rearmost terminal of the battery or 75 mm, whichever is the greater, however the vertical clearance need not exceed 200 mm.

(iii) Single-row batteries There shall be a minimum of 25 mm clearance between a battery or battery module and any wall of the enclosure. This does not preclude battery stands touching adjacent walls or structures, provided that the battery shelves have a free air space for no less than 90% of their length.

(iv) Double row battery A double row battery may be installed in accordance with Item (iii) for single row batteries provided all live surfaces are insulated or shrouded.

(v) Tiered batteries A tiered, cell/battery shall meet the requirements of Items (i), (ii), (iii) and (iv). In addition, for vertically mounted flooded cells/batteries there shall be a minimum clearance of 300 mm between the highest point of a battery and the lowest point of the underside of the upper bearers of the tier above. For other battery types, this minimum distance shall be half the distance to the rearmost terminal of the battery or 75 mm, whichever is the greater, however the vertical clearance need not exceed 200 mm.

(vi) Maximum height for batteries Batteries shall be mounted with the highest point no greater than 2 m above the floor level.

(d) Each battery or battery module terminal shall be readily available.

(e) The installation of the battery or battery modules and the associated wiring within the enclosure shall meet all the requirements of Clause 4.3.

(f) The enclosure shall meet the ventilation requirements for cooling of the battery type as specified by the manufacturer.

(g) No metallic equipment shall be mounted in the enclosure above the battery or battery modules, which could fall on the battery terminals causing a short.

The enclosure’s entry doors and panels shall allow unobstructed access to the battery system for installation and/or maintenance purposes.

The size of the enclosure should allow for sufficient clearance around the battery system to provide safe handling and access for installation and maintenance. The design, layout and construction of the battery system enclosure should meet the following:

(A) The enclosure should include means to prevent access by unauthorized persons.

(B) The battery enclosure should be insect and vermin proof.

4.2.5.3 BESS enclosure

Enclosures that house a complete BESS shall comply with Clause 4.2.5.2 and all the requirements specified for battery system enclosures in Clause 4.2.5.4.

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4.2.5.4 Installer assembled BESS enclosure

The following provisions shall apply:

(a) The BESS enclosure shall have at least two separate compartments: one that houses the battery system and one that houses the PCE and associated equipment including protection and isolation devices (preassembled integrated BESS are exempt).

(b) The battery system and equipment enclosures shall be accessed separately (e.g. via separate doors); (preassembled integrated BESS are exempt).

The following provisions should be met:

(i) A purpose-built equipment enclosure may be installed above or alongside a purpose-built battery system enclosure.

(ii) The battery system and PCE equipment compartments should be ventilated using natural ventilation (i.e. without the use of an electrically powered fan).

NOTE: When required, natural ventilation is preferred, however forced ventilation may be required.

4.2.5.5 Installation of battery system enclosure or BESS enclosure

For all battery system or BESS enclosure installations, the following requirements apply:

(a) If the enclosure is top opening, no equipment shall be placed above the battery system enclosure except for non-metallic battery maintenance equipment.

(b) If the enclosure is top opening, luminaires shall not be installed directly over the battery system enclosure.

(c) Unimpended space of at least 1000 mm around battery system (batteries and battery modules) with doors in any position.

For battery system and BESS enclosures installed externally to the building, the following statements apply:

(i) The enclosure shall have a minimum IP rating of IP23 for the battery system (as stated in Clause 4.2.4 and IP24 for the section housing the PCE.

(ii) The enclosure shall be located in accordance to the requirements of Claus 4.2.3.

(iii) The enclosure shall be located a minimum of 600 mm from any hot water unit, air conditioning unit or any other appliance.

(iv) The enclosure shall be located a minimum of 600 mm from any window or ventilation opening.

(v) The enclosure shall be located at a distance from any low pressure gas cylinder according to the exclusion zones shown in Figure 4.1 in respect of hazardous areas presented by a gas cylinder.

NOTE: Consideration should be given so that the flow of heated air from any appliance is directed away from and is not impacting on the battery system enclosure.

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* This d istance is measured from the top of any cyl inder valve.

Ground level

B

A

500*

DIMENSIONS IN MILLIMETRES

NOTE: This includes LP Gas and propane gas cylinders.

FIGURE 4.1 EXCLUSION ZONE DEFINED BY HAZARDOUS AREA PRESENTED BY A GAS CYLINDER OUTDOORS FOR HEAVIER THAN AIR GASES

4.2.6 Battery system and BESS room requirements

4.2.6.1 General

The battery system or BESS room shall be mechanically sound and shall be located so that access to a battery system is not obstructed by the structure of the building or by the fixtures and fittings within the building.

It should be clean, dry, adequately ventilated and provide, and maintain protection against, detrimental environmental conditions and other external factors.

The room shall meet the installation requirements of—

(a) Clauses 4.3 and 4.4;

(b) Clause 4.5, if the battery system type is classified as a fire hazard;

(c) Clause 4.6, if the battery system type is classified as a chemical hazard;

(d) Clause 4.7, if the battery system is classified as an explosive gas hazard; and

(e) Clause 4.8, for mechanical hazards.

The size of the room should allow for sufficient clearance around the battery system to provide safe handling and access for installation and maintenance as well as the requirements of Clause 4.2.6.2. The design, layout and construction of the battery system enclosure should meet the following:

(i) The room should include appropriate means to prevent access by unauthorized persons unfamiliar with the hazards of battery system.

(ii) The battery room should be insect and vermin proof.

The room’s entry doors and panels shall allow unobstructed access to the battery system for installation and maintenance purposes.

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The PCE and auxiliary equipment, rotating machinery other than exhaust fans, and other equipment not directly part of the BESS shall—

(A) be located outside the battery system room; or

(B) have no exposed live parts within a BESS room.

4.2.6.2 Battery system and BESS room layout and floor area

The layout and floor area of the room containing the battery system or BESS shall meet the following requirements (see Appendix E, Figure E1):

(a) Either—

(i) all batteries or battery modules shall have all live surfaces insulated or shrouded; or

(ii) all potential differences between exposed live parts exceeding DVC-A shall be separated by 2.5 m (measured in a string line).

(b) The floor area shall allow for the following clearances:

(i) Aisle width The minimum aisle width shall be 1000 mm. A greater aisle width may be necessary in installations requiring the use of mechanical handling equipment for battery maintenance.

(ii) Space between batteries The space between cell/battery containers shall be at least 3 mm unless otherwise specified by the manufacturer.

(iii) Single-row batteries In addition to the minimum aisle width, there shall be a minimum of 25 mm clearance between a battery or battery module and any wall or structure on a side not requiring access for maintenance. This does not preclude battery stands touching adjacent walls or structures, provided that the battery shelves have a free air space for no less than 90% of their length.

(iv) Double-row battery A double row battery may be installed accordance with Item (iii) for single row batteries provided all live surfaces are insulated or shrouded.

(v) Tiered batteries A tiered, cell/battery shall meet the requirements of Items (i), (ii), (iii) and (iv). In addition, for vertically mounted flooded cells/batteries there shall be a minimum clearance of 300 mm between the highest point of a battery and the lowest point of the underside of the upper bearers of the tier above. For other battery types, this minimum distance shall be half the distance to the rearmost terminal of the battery or 75 mm, whichever is the greater, however the vertical clearance need not exceed 200 mm (see Appendix E, Figures E2 and E3).

(vi) Maximum height for batteries Batteries shall be mounted with the highest point no greater than 2 m above the floor level.

(vii) PCE The minimum aisle width requirements shall be as shown in Figure 4.2.

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PCE withhinged

door

+ + + + +

PCE with removable

doors

+ + + + + + + + + +

Minimum ais le c learance

(a) (b) (c)

Open door

Ex tremity of h inged door in open posi t ion

Bat tery System or otherequipment



600 mm

1000 mm 1000 mm

FIGURE 4.2 MINIMUM AISLE WIDTH REQUIREMENTS

If a PCE or other auxiliary electrical equipment is located in a BESS room, the aisle width between any battery system or systems and any part of the enclosure, PCE equipment or auxiliary equipment shall be—

(A) as shown in Figure 4.2(a): a minimum of 600 mm between opposing sets of hinged doors in the open position; and at least a total distance of 1000 mm from live terminals of batteries and the live terminals of the PCE; or

(B) as shown in Figure 4.2(b): a minimum of 1000 mm from any PCE enclosure with removable door in the open position; and at least a total distance of 1000 mm from live terminals of the batteries and the live terminals of the PCE; or

(C) as shown in Figure 4.2(c): a minimum of 1000 mm from any fixed part of the enclosure or removable access panel (see Appendix E, Figure E1).

NOTE: Typical battery layouts are shown in Appendix G.

4.2.6.3 Location of luminaires

The lighting provision for battery system and BESS room shall be installed in accordance with AS/NZS 1680.1. Luminaires shall not be installed directly over a BESS, a battery system or an exposed live part.

4.2.7 Battery or battery module stands

The requirements of AS/NZS 1170.1, AS/NZS 1170.2 and AS 1170.4 shall apply.

The following provisions should apply for battery stands either within a battery system room, BESS room or part of an enclosure (pre-assembled or installer assembled):

(a) When battery or battery modules are mounted vertically, stands should be designed so that the installation per stand is limited to a depth of two rows of batteries.

(b) The overall height of the battery system installation should not exceed 2 m.

(c) If the height of the battery or battery module is its greatest dimension, horizontal restraining bars should be installed at the front and back of the battery stands.

NOTE: See Appendix I for typical battery stands.

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4.2.8 Seismic (earthquake) forces

The battery system enclosure and/or battery system stand(s) shall be designed to withstand seismic (earthquake) forces, given the combined weight of the battery, inverter or other equipment associated with the BESS.

When the battery system comprises large individual battery or battery modules, the provision of a suitable level of seismic (earthquake) restraint is essential to prevent battery or battery module case damage to the maximum extent possible, and in particular in the case of flooded batteries or flow batteries, to prevent damage to battery or battery module cases and leakage of the chemicals.

For Australia, for battery enclosures and associated equipment, the battery seismic (earthquake) restraint shall comply with AS 1170.4.

For New Zealand, where a higher level of seismic restraint is required, the battery seismic (earthquake) restraint shall comply with NZS 4219.

The requirements for seismic restraint also mean that tall BESS or battery systems comprising tall individual batteries should be installed as close as possible to the floor. Use of multi-tier battery system stands or enclosures increases the seismic restraint requirements for the upper tier(s) of batteries or battery modules, and in turn, increases the size of the vertical components and diagonal parts of the battery stand. In general, multi-tier battery system stands will require the use of metal framing systems to achieve the level of seismic restraint required in most installations.

When a high level of seismic (earthquake) restraint is required, the battery stand(s) can be very substantial and mechanically robust structures, which reduces the ease of access for installation and servicing of batteries.

For battery installations in the above locations, the designer should seek advice from a structural engineer or similar, who is able to provide assurance that the building structure and standards are suitable.

4.3 ELECTRICAL HAZARDS

4.3.1 General

A BESS shall not be installed if the battery system—

(a) has a voltage of DVC-A; and

(b) is connected to an inverter that does not have at least simple, electrical separation between the d.c. port and the a.c. or grid port.

The cabling and installation requirements of the BESS shall be treated as DVC-C if a non-separated PCE other than an inverter is installed and the non-battery side of the PCE is greater than DVC-A.

4.3.2 Over-current protection from battery system

4.3.2.1 General

Overcurrent protection shall be installed in all live conductors (excluding control and monitoring circuits) in all battery systems. The overcurrent protection shall be located so as to minimize the length of the unprotected cable from the battery system.

The overcurrent device shall—

(a) be of the non-polarized type;

(b) be d.c. rated;

(c) have a voltage rating greater than the battery system’s maximum voltage under all operating conditions;

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(d) be rated to withstand the maximum prospective fault current;

(e) specify a minimum rating in relation to the rated current for the BESS plus a safe operating margin to avoid false operation;

(f) meet the requirements of AS/NZS 3000;

(g) be rated to protect the cabling in the battery system; and

(h) not rely on a semi-conductor switching device for protection of the battery system.

NOTE: When connected to a system comprising multiple PCEs, the rated current of the BESS is the total sum of the currents that can be supplied from the PCEs to the battery system or the maximum rated current of the PCE’s required to operate from the battery system.

Protective devices should be selected from the following:

(i) HRC fuses.

(ii) Combination fuse-switch units incorporating HRC fuses.

(iii) Miniature circuit breakers (MCBs) or moulded case circuit-breakers (MCCBs). NOTE: MCBs and some MCCBs have limited d.c. short-circuit current ratings and may require back up by HRC fuses.

Where parallel battery systems are installed, each battery system shall include a separate overcurrent protective device. This is to prevent discharge from one battery system into a parallel battery system if a fault occurs in one battery system.

4.3.2.2 Requirements for circuit breakers

In addition to the requirements specified in Clause 4.3.1, circuit breakers used for overcurrent protection shall—

(a) comply with either AS/NZS 60898.2 or IEC 60947-2; and

(b) operate simultaneously in all live conductors.

Circuit breakers for indoor use shall be mounted in enclosures that obtain a minimum rating of IP23.

Circuit breakers for outdoor use shall be mounted in enclosures that obtain a minimum rating of IP56.

Information supplied with circuit breakers shall include a diagram and method of series connecting poles for each operational rating, and, if for outdoor use, suitable derating factors for higher ambient temperatures.

NOTE: Method of connection of circuit breakers shall take into account voltage when system is earthed and unearthed—this may be necessary to consider where the earth is not connected to the positive or the negative leg of the battery system, but rather a centre tap or similar.

4.3.2.3 Requirements for HRC fuses

In addition to the requirements specified in Clause 4.3.1, HRC fuses used for overcurrent protection for battery systems shall—

(a) comply with IEC 60269 Parts 1 and 3;

(b) be mounted in a purpose built fuse holder;

(c) not be a type able to be rewired;

(d) require a tool to access live parts or terminals; and

(e) meet the ingress protection requirements of AS 60529.

NOTE: See Appendix J for additional information on degrees of protection of enclosed equipment.

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4.3.2.4 Battery systems not requiring a battery management system

The output conductors of a battery system shall be protected against overcurrent according to Clause 4.3.1.

Where there are parallel battery systems and each of the battery systems’ output conductors connect individually to a PCE (see Figure 2.8), all output conductors connected to each of the battery systems shall be protected against overcurrent.

Where there are parallel battery systems and the output conductors of each battery system are connected at a common point as shown in Figures 4.3 and 4.4, overcurrent protection devices shall be installed in—

(a) each battery system cable as required by Clause 4.3.1; and

(b) each cable going to the PCE if the current-carrying capacity of each of the cables going to the PCE is less than the sum of the overcurrent protection devices protecting the individual battery systems.

To PCE

To PCE

Bat terySystem

Bat tery system disconnect ionand protect ion device

Note 1

NOTES:

1 If a battery system cable connected to a PCE requires its own overcurrent protection device, it shall have a minimum rating equal to the maximum rated current of the PCE.

2 Overcurrent protection required for live conductors when conductor current-carrying capacity is less than the sum of all individual battery system overcurrent protection devices.

3 Switch fuses are shown as overcurrent protection devices.

FIGURE 4.3 TYPICAL OVERCURRENT PROTECTION REQUIREMENTS FOR A BATTERY MODULE HAVING PARALLEL BATTERY SYSTEMS CONNECTED

AT A COMMON POINT

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To PCE

To PCE

Bat terySystem


Note 1

NOTES:

1 Overcurrent protection required for live conductors when conductor current-carrying capacity is less than the sum of all individual battery system overcurrent protection.

2 Circuit breakers are shown as overcurrent protection devices.

FIGURE 4.4 OVERCURRENT PROTECTION REQUIREMENTS FOR A BATTERY MODULE HAVING PARALLEL BATTERY SYSTEMS CONNECTED SHOWN

4.3.2.5 Battery systems that include a battery management system

The BMS protection devices shall meet the requirements for protection of the output cables from the battery system where—

(a) a battery system requires a battery management system (BMS) to operate safely; and

(b) the BMS includes overcurrent protection which is a readily available circuit-breaker or HRC fuse; and

(c) the battery system manufacturer's instructions permits the overcurrent protection of the BMS to meet the protection of the battery outgoing cables.

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4.3.2.6 Protection as part of a battery system

Battery protection devices should be mounted as close as practicable to the battery terminals (keeping battery leads as short as possible). For many battery technologies, there is no protection provided if a short/fault occurs before the protection devices installed in this manner, that is, no protection for the internal cables that interconnect the battery or battery modules in series within a battery system. These cables could be protected if there is a protection device located in one of the battery or battery module interconnecting cables as shown in Figure 4.5. This shows a protection device in series in the middle of the string. Installing a protection device within the battery system as shown in Figure 4.5 would reduce the calculated arc flash incident energy for work being undertaken on the battery system side of the battery system’s protective device. (See Clause 3.2.4.2.3.)

Protect ivedevice

Bat teryor

bat tery module

Bat teryor

bat tery module

Bat teryor

bat tery module

Bat teryor

bat tery module

Bat teryor

bat tery module

Bat teryor

bat tery module

FIGURE 4.5 PROTECTION DEVICE IN SERIES IN MIDDLE OF BATTERY OR BATTERY MODULE STRING

4.3.3 Isolation of the battery system

4.3.3.1 General

All battery systems shall be capable of being electrically isolated from all other equipment within the BESS. Where a battery system includes an internal non-serviceable battery management system, the point of isolation shall be after the output terminals of the battery system. All required isolation devices shall be capable of being secured in the open position.

4.3.3.2 Battery system switch-disconnector

The location of the switch-disconnector shall minimize the length of the unprotected cable from the battery to the switch-disconnector. The switch-disconnector shall operate simultaneously in all live conductors.

If a d.c. circuit breaker is used as the over-current protection device, it can also perform the function of the switch-disconnector provided it is rated for isolation. A combination switch fuse can meet both the over-current protection and isolation requirements.

If the battery system includes a BMS that meets the over-current protection requirements, a switch-disconnector or MCB able to be secured in the ‘open’ position shall be installed that isolates the output of the battery system.

4.3.3.3 Preassembled battery systems

For a preassembled battery system, where the battery system connection point is after the battery management system and the preassembled battery system comprises two or more strings of batteries or battery modules, a single switch-disconnector operating in all live conductors shall isolate the battery system.

The preassembled battery system shall include an isolating switch operating in all live conductors in accordance with the requirements of Clause 4.3.2.1 and the location requirements of Clause 4.3.3. If installed according to these requirements, no additional external switch-disconnector is required. If not installed according to these requirements, an additional separate isolator meeting Clauses 4.3.2.1 and 4.3.3 shall be installed.

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For a preassembled battery system that is capable of expansion of the battery system, the manufacturer’s instructions shall be followed. If the addition to the battery system is installed on the battery side of the battery management system, no further protection or isolation requirements should be required.

4.3.3.4 Parallel battery systems

For battery energy storage systems where there are two or more battery systems connected in parallel, each battery system shall have an isolating switch in all live conductors. This isolation device is to facilitate the isolation of one battery system for maintenance and allow the continuous operation of the remaining system.

4.3.3.5 Requirements for battery system: switch-disconnector

Switch disconnectors used as a load breaking disconnection device shall—

(a) conform to AS/NZS 60947.3;

(b) be of the non-polarized type;

(c) be d.c. rated;

(d) have a voltage rating greater than the battery system’s maximum voltage under all operating conditions;

(e) be rated to withstand the maximum prospective fault current;

(f) specify a minimum rating in relation to the rated d.c. current for the BESS;

(g) meet the requirements of AS/NZS 3000;

(h) be rated for independent manual operation;

(i) have a minimum pollution degree 3 classification;

(j) be able to be locked in the open position, and only lockable when the main contacts are in the open position; and

(k) conform to requirements for isolation, including marking requirements for an isolation device.

In addition, switch-disconnectors shall operate simultaneously in all live conductors.

Switch-disconnectors for indoor use shall be mounted in enclosures that obtain a minimum rating of IP23.

Switch-disconnectors for outdoor use shall be mounted in enclosures that obtain a minimum rating of IP56NW when tested under conditions of Clause D.8.3.13.4, D.8.13.3.5, D.8.3.13.6, D.8.13.3.7 and D.8.13.3.8 of AS/NZS 60947.3:2017*.

Information supplied with switch-disconnectors shall include a diagram and a method of series connecting poles for each operational rating, and if for outdoor use, suitable derating factors for higher ambient temperatures.

4.3.3.6 Battery system: internal isolating requirements

If the battery system includes individual battery or battery modules that are serviceable and which are installed in a battery system enclosure or battery system room or battery energy storage system room that is accessible and has either—

(a) a voltage exceeding DVC-A, or

(b) is installed in a domestic building and has an arc flash incident energy level above 4 cal/cm2;

* To be published.

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for the purposes of maintenance, the battery system installation shall be fitted with isolating switches, plugs or links to separate the battery system into sections where each section has a voltage below DVC-A and/or sections that will reduce the arc flash incident energy levels to tolerable levels for the installation location and tasks required. Isolation may be required to meet the requirements of Clause 4.3.4.3.

4.3.4 Location of over-current protection devices and isolators

4.3.4.1 General

Battery systems that are classified as explosive gas hazards have restrictions regarding where protection devices and isolating switches are able to be located. All other battery types do not have the same restrictions.

4.3.4.2 Battery system not classified as explosive gas hazards

When a battery system protection device or devices are not included within the BMS in accordance with Clause 4.3.1.4, the protection devices shall be—

(a) installed as close as practical to the output terminals of the battery system; and

(b) readily available.

The battery system disconnection switch shall be—

(i) installed as close as practical to the output terminals of the battery system; and

(ii) readily available.

4.3.4.3 Battery systems classified as explosive gas hazards

The protection devices and disconnection switches shall be located in accordance with the requirements of Clauses 4.7.3, 4.7.4 and 4.7.5.

4.3.5 Screening from touch of live parts

4.3.5.1 General

Consideration shall be given as to how the complete battery system is screened to prevent accidental short-circuiting of the battery terminals and connections.

All battery systems, including those within preassembled integrated BESS, having the terminals on the batteries and interconnecting cable connections accessible for the purpose of maintenance and/or fault-finding shall have appropriate screening from touch.

The battery system equipment may include probe or testing apertures for the execution of maintenance and/or fault-finding purposes. Any probe or testing apertures should meet the appropriate IP ratings to ensure the safe access and operation of this equipment.

NOTE: Refer to Appendix J for information on degrees of protection of enclosed equipment.

The insulation system provided by all parts and components of the battery system shall meet the provisions of AS/NZS 3000 for protection against, amongst others—

(a) direct contact; and

(b) indirect contact.

4.3.5.2 Battery systems operating at DVC-A level and above

Exposed live battery system terminals (including battery and battery modules), inter battery system cable connections (between batteries and/or battery modules) and battery system cabling connections shall be insulated and mechanically protected. Any cover shall be able to be removed for inspection and maintenance of the terminals and interconnections.

NOTE: Covers may be made from PVC conduit or ducting or may be covers supplied by the battery system manufacturer.

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Exception: If the battery system manufacturer’s documentation states that individual, live battery terminals may not be covered because it reduces the safe operation of the battery (such as reducing cooling of a particular lithium ion batteries), the terminals shall not be covered. Screening from touch shall be installed to prevent accidental short-circuiting of the battery terminals and connections.

4.3.5.3 Battery systems operating at DVC-B level and DVC-C level

All battery systems shall have all live terminals and connectors insulated and/or shrouded. Where battery systems have the ability to expose live parts and terminals, shrouding or insulation shall be structured such that removal of this protection is able to expose sections with voltage difference of no greater than DVC-A. In the case of the exception noted in Clause 4.3.4.2 above for DVC-B and DVC-C battery systems, the battery system layout shall prevent simultaneous touching of battery and/or battery modules where the voltage difference is greater than DVC-A. This may be achieved byany one or a combination of the following:

(a) Position those battery and/or battery modules having greater than DVC-A between them more than 2.5 m apart in a string line.

(b) Install barriers having an IP rating of IP2X, so a person’s arm span cannot directly touch the batteries or battery modules.

(c) Install interlocks, as specified in Clause 4.3.4.5.

(d) Segment screening devices such that only groupings of batteries or battery modules having less than DVC-A allow exposed parts through the removal of any single screening device.

The installation shall be fitted with isolating switches, plugs or links to separate the battery system/s into sections not greater than DVC-A for maintenance. Suitably identified inter-cell connectors (e.g. with insulation of a different colour to other inter-cell connectors) may be used for this purpose.

The use of links in each battery system to disconnect it into DVC-A maximum blocks of battery or battery modules shall be provided, as required by Clause 4.3.2.6. The disconnection links should only be removed when the battery system’s overcurrent protective device has been removed and before any major battery system maintenance is carried out.

The battery disconnection links shall safely carry the rated current of the BESS or the overcurrent protective rating, whichever current rating is the lesser of the two.

4.3.5.4 Battery systems located in a dedicated battery room or accessible battery systems in enclosures.

4.3.5.4.1 Take-off battery terminals and outgoing busbars and cables

If outgoing busbars are connected to the battery system or battery modules, the outgoing busbars shall—

(a) be insulated from the battery system or battery module terminals to a height of 2.5 m or the battery system room ceiling height, whichever is the lower; and

(b) be clearly identified and segregated from other supply circuits.

If outgoing cables are connected to the battery system or battery modules, the outgoing cables shall meet all the requirements of Clause 4.3.5.

Take-off battery terminals and busbar connections shall—

(i) be shrouded or be protected by insulating barriers, having an IP rating of IP2X, to prevent accidental contact; and

(ii) have their polarity clearly identified.

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4.3.5.4.2 Inter tier and inter row connections

The battery and battery module terminals and busbar and cable interconnections between inter-row and inter-tier terminals shall be either—

(a) shrouded; or

(b) protected by insulating barriers, having an IP rating of IP2X, to prevent accidental contact.

4.3.5.4.3 Inter battery connections

To avoid accidental contact with inter-cell and inter-battery and inter battery module connectors, a battery system shall have all live surfaces insulated or shrouded, having an IP rating of IP2X, or the following insulating barriers shall be fitted:

(a) Double-row batteries or battery modules: Insulating barriers between double-row batteries (or battery modules) shall be installed for the entire length of the battery extending 100 mm past the end terminal, unless those terminals are shrouded (see Appendix D Figure D2 and Appendix E Figure E1).

(b) Battery system voltage exceeding DVC-A: Where the nominal voltage of the battery system exceeds DVC-A, interblock barriers shall be installed to sectionalize the battery into voltage blocks not exceeding DVC-A (see Appendix D Figure D2 and Appendix E Figure E1).

NOTE: These interlock barriers are to prevent a person touching voltage in excess of DCV-A. However, the requirement for 1000 mm in front of the battery system for servicing, in accordance with Figure 4.2, applies to the installation of interlock barriers.

4.3.5.5 Safety interlocks

Safety interlocks and disconnection systems in accordance with AS/NZS 60950.1:2012, Clause 2.8 shall be installed on the access door or cover to any enclosure or room housing a battery system, battery systems or preassembled integrated BESS where—

(a) an authorized or competent person has access to the room or enclosure; and

(b) that room and enclosure contains live parts at voltages greater than DVC-A and which are accessible by a test finger.

In accordance with AS/NZS 60950.1, other provisions include:

(i) Safety interlocks should be designed so that inadvertent reactivation of the hazard cannot occur when doors or covers are not in a closed position.

(ii) A competent person may override the interlock to service the battery system, where the override facility—

(A) requires a tool to operate; and

(B) resets automatically to normal operation when the battery system servicing is complete, or the override will prevent normal operation unless the technician has reset the override facility.

(iii) Fail-safe operation of the interlock over long-term operation (AS/NZS 60950.1:2012 Clause 2.8.4).

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4.3.6 Battery system output wiring

4.3.6.1 General

Consideration should be given to the minimization of inductive loops in battery wiring.

4.3.6.2 Type of cable

Battery system output wiring shall be installed in accordance with AS/NZS 3000.

The battery system output cable shall be protected from overcurrent from the battery system in accordance Clause 4.3.2.

Any battery system cable forming the connection between a battery system terminal and the PCE, shall be rated to withstand the prospective fault current for a time at least equal to the operating time of the associated overcurrent protective device (see AS/NZS 3000:2007 Clause 5.3.3.1).

The major considerations in wiring selection are as follows:

(a) Rated operational voltage.

(b) Rated continuous current of switchgear.

(c) Fault current levels.

(d) Rated making and breaking current of switchgear.

4.3.6.3 Mechanical protection

Unprotected battery system output cables shall—

(a) not exceed 2 m in length;

(b) be only used for the connection of a battery system terminal and the battery system overcurrent device;

(c) be contained in a battery system enclosure or a battery system room; and

(d) be double insulated if the voltage exceeds DVC-A.

Battery system cables exceeding 2 m in length from the battery system terminal to point of connection at the battery system overcurrent protection device shall be protected by PVC conduit or equivalent protection.

All cables as described in Item (b) above which exit the areas described in Item (c) above shall be mechanically protected by PVC conduit or equivalent.

Battery system output cables not installed within conduit shall be adequately clamped and sufficient support shall be provided throughout the length of cables to minimize sag and to prevent undue strain being imposed on the cables, on the battery terminals or on other parts of the installation. Where these cables pass through apertures, they shall be glanded and protected from any sharp surfaces

NOTE: Battery cables may move when loads increase significantly.

Cables shall not be bent through a radius less than the minimum bending radius specified by the cable manufacturer.

For battery systems operating at DVC-B or DVC-C, the cable between the overcurrent protection device and the PCE shall have adequate mechanical protection for the installed position external to the battery enclosure or battery stand.

NOTES:

1 Refer to AS/NZS 3000:2007 Appendix H.

2 It is recommended that, for battery systems operating at DVC-A or less, the cable between the overcurrent protection device and the PCE is double insulated.

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4.3.6.4 Type of cable

Battery system cables shall comply with—

(a) AS/NZS 5000.2:2006 (450/750 V insulation) for battery systems with a maximum operating voltage less than 400 V d.c.; and

(b) AS/NZS 5000.1:2005 (0.6/1 kV insulation) for battery systems with a maximum operating voltage less than 600 V d.c.

4.3.6.5 Voltage drop

The maximum voltage drop between the battery system and the PCE shall be 2% based on the rated current of the PCE. Where multiple PCEs and/or parallel battery systems are used, contingency operation should be considered in voltage drop calculations.

4.3.6.6 Current-carrying capacity

The current-carrying capacity of the battery system’s output cable shall be based on the d.c. current rating of the associated overcurrent protection (see Clause 4.3.2).

4.3.6.7 Parallel battery systems

For battery energy storage systems consisting of two or more battery systems connected in parallel, the output cable from each battery system to a point where the parallel battery systems connect (e.g. PCE or junction box), shall have equal cable resistance, except in the instance where a BMS or similar device provides managed voltage and current charge/discharge control to each separate system. This can be achieved by the cables, which connect the battery systems to a common connection point, being of equal length, equal cross-sectional area and conductor materials.

4.3.6.8 Protection from overcurrent from PCE

Overcurrent protection shall be installed on the battery system’s d.c. port of the PCE if—

(a) the PCE's charging current or load current under fault conditions is greater than the current-carrying capacity of the conductor between the PCE and battery system; and

(b) the distance between the PCE and the battery system protection device is greater than 3 m.

4.3.7 Isolation of PCE from battery system

4.3.7.1 General

PCEs shall be capable of being isolated from the battery system for the purpose of maintenance, repair and fault-finding.

Isolation shall be provided by switch-disconnectors. Any switch-disconnector used for this purpose shall be able to clear the rated current of the PCE and maximum prospective fault current from the battery system.

4.3.7.2 BESS with single PCE

If the PCE is not adjacent to the battery system(s), a separate disconnecting device is required to isolate the PCE.

4.3.7.3 BESS with multiple PCEs performing different functions

When a BESS includes multiple PCEs performing different functions (e.g. one is an MPPT, the other an inverter), each PCE shall be capable of individual isolation. Li

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4.3.7.4 Disconnecting method

When a PCE has its own switch-disconnector, one of the two following disconnecting methods shall be used:

(a) An adjacent and physically separate switch-disconnector.

(b) A switch-disconnector that is mechanically interlocked with a replaceable module of the PCE, and allows the module to be removed from the section containing the switch-disconnector without risk of electrical hazards.

4.3.7.5 Type of switch-disconnector

When a separate switch disconnector is required, it shall be either—

(a) a suitably rated switch-disconnector, as specified in Clause 4.3.3.5; or

(b) a d.c. circuit breaker suitably rated as an isolator, as specified in Clause 4.3.2.2

4.3.8 Segregation of circuits

4.3.8.1 General

The segregation of circuits shall—

(a) meet the segregation requirements detailed in AS/NZS 3000;

(b) be provided between d.c. and a.c. circuits within enclosures and be physically segregated from each other by segregation insulation barrier/s between connections and pathways;

(c) be equivalent to double insulation for the highest voltage level present;

(d) be appropriate for the installation environment as required for barriers between the d.c. and a.c. circuits;

(e) be indicated by clear identification of the different types of circuits; NOTES:

1 Identification by labels and by use of different coloured cable sheath or conductor are acceptable methods.

2 These labels should be located typically every two metres, depending on the route of the cable and its accessibility.

(f) Provide a separation of 50 mm or a segregation insulation barrier between a.c. and d.c. circuits for areas external to enclosures; and

(g) Be at the appropriate level for the installation environment, and not less than the degree of protection IP4X.

4.3.8.2 DIN-rail

Where devices such as switches for circuits requiring segregation are mounted on a common mounting rail in a non-conductive enclosure, this rail shall be insulated and shall not be metallic or conductive.

4.3.9 Earthing of the battery systems

4.3.9.1 General

The four categories of earthing arrangements for battery systems connected to inverters are listed as follows:

(a) Floating/separated, i.e. not earthed and not referenced to earth.

(b) Direct earthed.

(c) Resistive earthed.

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(d) Connected to a non-separated inverter (i.e. referenced to the a.c. grid and therefore to earth by the inverter’s internal connections).

The inverter and battery manufacturer's instructions should be followed to determine the best earthing arrangement.

Battery systems connected to inverters that do not have separation between the d.c. port and the a.c. port or grid port, shall not be functionally earthed.

Examples of system configurations with respect to earthing are shown in the following figures:

Inver ter e lectr ical ly

SEPARATED orNON-SEPARATED

betweenbat tery system

and gr idPor t 5

D.C. energysource

Por t 2 A.C. backuploads

Por t 1 A.C. gr idconnect

Por t 3commsPor t 4

D.C.bat tery

A

N

Ba

tte

ry s

ys

tem

Inver ter d isconnect ion and protect ion deviceIf appl icable See Note 1

See Note 2

Bat tery systemdisconnect ion and protect iondevice

NOTES:

1 PCE disconnection device required if the battery system disconnection device is not adjacent (see Clause 4.3.6.2).

2 Port 1 is the a.c. port shown for a grid-connected system. This port could also be the input from a generator.

FIGURE 4.6 BESS INSTALLATION DIAGRAM: FLOATING BATTERY SYSTEM CONNECTED TO AN INVERTER (SEPARATED OR NON-SEPARATED)

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SEPARATED between

bat tery system and gr idPor t 5

D.C. energysource



Por t 3commsPor t 4

D.C.bat tery

A

N

Ba

tte

ry s

ys

tem

Inver ter d isconnect ion and protect ion devicei f appl icable See Note 1

See Note 3


See Note 2

NOTES:

1 PCE disconnection device required if the battery system is not adjacent (see Clause 4.3.6.2).

2 Earth fault protection (See Clause 4.3.9) required for battery systems greater than DVC-A. For BESS at DVC-A, AS/NZS 5033:2014 methodology has been applied.


FIGURE 4.7 BESS INSTALLATION DIAGRAM: BATTERY CONNECTED TO AN INVERTER PROVIDING SEPARATION FROM THE GRID

WITH A DIRECT EARTH CONNECTION.


SEPARATED between

bat tery system and gr idPor t 5

D.C. energysource



Por t 3commsPor t 4

D.C.bat tery

A

N

Ba

tte

ry s

ys

tem

Inver ter d isconnect ion and protect ion devicei f appl icable See Note 1

See Note 2


NOTES:

1 PCE disconnection device required if the battery system is not adjacent (see Clause 4.3.6.2).


FIGURE 4.8 BESS INSTALLATION DIAGRAM: BATTERY CONNECTED TO AN INVERTER PROVIDING SEPARATION FROM THE GRID WITH RESISTIVE EARTH

CONNECTION.

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4.3.9.2 BESS d.c. supply is earthed, either directly or via a resistor

If the BESS comprises parallel battery systems, the maximum earth fault current available shall be the sum of the prospective fault current of each of the installed battery systems.

The battery system protection device (or multiple protection devices if more than one battery system), in unearthed battery systems shall break the earth fault current in the event of an earth fault. The low internal impedance of the battery system/s will be the main earth fault current source.

The battery port of the PCE, if it is providing battery system charging current may add to the earth fault current available until the overcurrent protection arrangement in those inverters or generators operates or trips.

NOTE: Compared with the battery system fault current, this will usually add only a small additional current to the earth fault current.

The earthing connection shall be on the load side of the battery isolator (see Figure 4.9). Therefore, operation of the battery isolator will remove the earth reference of the battery bank. By removing the earth reference, the isolated battery bank becomes a floating system. See Figure 4.6.

For example, if the system comprises a centre tapped earth then a 3 pole switch-disconnector is required for breaking simultaneously the two battery system output cables and the centre tapped earth.

Ba

tte

ry s

ys

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FIGURE 4.9 LOCATION OF EARTH CONNECTION ON SINGLE BATTERY SYSTEM

When the BESS is earthed on the d.c. supply side and comprises multiple parallel battery systems, there shall be an earth connection at each of the parallel battery systems on the load side of the battery isolator as shown in Figure 4.10.

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Bat tery system

FIGURE 4.10 LOCATION OF EARTH CONNECTION ON PARALLEL BATTERY SYSTEMS

Where the battery system is required to be earthed, one conductor of the battery system shall be connected to the main earthing conductor (see Figure 4.11). The main earthing conductor shall be rated to withstand the prospective fault current of the battery system for a time at least equal to the operating time of the associated overcurrent protective device (see AS/NZS 3000:2007 Clause 5.3.3.1).

PCE

Ba

tte

ry s

ys

tem

To instal lat ion ear th electrode

PCE disconnect ionand protect ion devicei f appl icable


FIGURE 4.11 BATTERY SYSTEM EARTH CONDUCTOR CONNECTED TO MAIN EARTH

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If there are multiple parallel battery systems that are earthed, each system shall have a conductor that is—

(a) connected to the main earthing electrode via one earth conductor (see Figure 4.12); and

(b) rated to withstand the total prospective fault current of the battery system for a time at least equal to the operating time of the associated overcurrent protective device (see AS/NZS 3000:2007 Clause 5.3.3.1).

PCE

To instal lat ion ear th electrode

Bat tery system

PCE disconnect ionand protect iondevice i f appl icable

Bat tery Systemdisconnect ion and protect iondevice

FIGURE 4.12 MULTIPLE BATTERY SYSTEM EARTH CONDUCTORS CONNECTED TO MAIN EARTH

If there are multiple parallel BESSs and each BESS is earthed on the d.c. supply side, each BESS shall—

(i) have a conductor connected to the main earthing electrode (see Figure 4.13); and

(ii) be rated to withstand the total prospective fault current of the battery for a time at least equal to the operating time of the associated overcurrent protective device (see AS/NZS 3000:2007 Clause 5.3.3.1).

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PCE

Ba

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sy

ste

mB

att

ery

s

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PCE

BESS

BESS

PCE disconnect ion and protect iondevice i f appl icable


To main ear th electrode

To main ear th electrode

FIGURE 4.13 MULTIPLE BESS EARTHING CONDUCTORS CONNECTED TO MAIN EARTH

4.3.9.3 Size of earth cable

When the BESS is functionally earthed at the battery system or PCE, the earth cable shall be sized to carry the maximum earth fault current for a time at least equal to the operating time of the associated overcurrent protective device (see AS/NZS 3000:2007 Section 5 and AS/NZS 5033:2014 Section 3).

NOTE: In the event of unintentional contact of an earth conductor to unearthed (live) parts, the fault current can be significant.

AS/NZS 3000:2007 Table 5.1 shall be used to determine the minimum earthing conductor size for the earthing connection of the battery system for each BESS.

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If the BESS comprises multiple parallel battery systems, the ‘nominal size of active conductor’ shall be either—

(a) if there is only one battery cable connected to the PCE (see Figure 4.12), the earth cable shall be sized to carry the maximum earth fault current for a time at least equal to the operating time of the associated overcurrent protective device for that cable (see Note 1) (see AS/NZS 3000 Section 5); or

(b) the earth cable shall be sized to carry the sum of the maximum earth fault currents for a time at least equal to the operating time of the associated overcurrent protective device for the individual battery cable (see Note) (refer to AS/NZS 3000:2007 Section 5 and AS/NZS 5033:2014 Section 3) or the sum of the individual battery system battery cables (see Figure 4.10).

NOTE: If there is no single fuse protecting the single cable than Item (b) applies.

If the battery system is functionally earthed, the functional earth shall be disconnected before servicing the battery system.

NOTE: See Appendix F for sample calculations for sizing earth cables.

4.3.9.4 Protective Earthing

4.3.9.4.1 General

If the battery system enclosure and/or battery system stand is metallic and the battery system is operating at voltages greater than DVC-A, the enclosure and/or stand shall be earthed.

4.3.9.4.2 Battery system is functionally earthed

AS/NZS 3000:2007 Table 5.1 shall be used to determine the minimum protective earthing conductor size for the earthed connection of the battery system for each BESS. When using this Table, the ‘nominal size of active conductor’ shall be taken to be the size of the main battery conductor for the unearthed side of the battery system.

If the BESS comprises multiple parallel battery systems, the ‘nominal size of active conductor’ shall be either—

(a) the size of the main battery if the parallel cables connect at one point, and there is only one cable connected to the PCE (see Figure 4.12); or

(b) the sum of the individual battery system battery cables (see Figure 4.10).

4.3.9.4.3 Bonding of battery system not functionally earthed

If the battery system is not functionally earthed, there will be no earth fault current with respect to the battery systems and PCE in the first earth fault event.

For an installation comprising a single BESS with voltages greater than DVC-A, all metallic equipment enclosures that are located within 2.5 m of each other and the BESS installation, shall be equipotentially bonded together to prevent a shock hazard occurring. The equipotential bonding cable shall be sized for the maximum possible d.c. equipotential current that could flow under multiple equipment fault conditions for a time at least equal to the operating time of the associated overcurrent protective device (see AS/NZS 3000:2007 Section 5).

The minimum size of the equipotential bonding conductor shall be 6 mm2.

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4.3.10 Earth fault protection—Monitoring alarm

In a BESS, including pre-assembled integrated BESS, where the battery system is operating at DVC-B or DVC-C, an earth fault alarm system shall be installed that, once an earth fault is detected, causes an action to be initiated to correct the earth fault. The monitoring alarm system should cycle its monitoring operation at least at hourly intervals until the earth fault is corrected.

The alarm system should be activated to inform the system operator by email, SMS or similar.

The alarm system shall include an audible signal activated in a location where operational staff or system owners are informed of the signal.

4.4 ENERGY HAZARD

4.4.1 Arc flash

4.4.1.1 General

There is no possibility to completely avoid arc flash hazards when working near live parts. When working with battery systems and BESS, some parts of the battery system and BESS will remain energized, however, the work procedures should facilitate that work be done with de-energized systems or systems being able to have exposure levels significantly reduced through isolation procedures. Work procedures shall consider various installation and maintenance tasks required for the battery system.

Personal protection equipment (PPE) against arc flash is rated in accordance with the available energy from the flash, in cal/cm2. When working on battery systems, the correct level of PPE based on the potential arc flash energy for the battery system shall be selected and worn within the arc flash boundary.

NOTE: See Table 3.3 for further information on PPE ratings.

4.4.1.2 Risk Assessment

Table 4.1 provides the estimate consequences based on the calculated arc flash energy. Prior to installing a battery system, the arc flash energy shall be calculated based on a short-circuit occurring at the output terminals of the battery system.

TABLE 4.1

CONSEQUENCE LEVELS BASED ON ARC FLASH ENERGY

Consequence level Arc flash incident energy level, cal/cm2

Insignificant 0.0, <1.2

Minor 1.2, <4.0

Moderate 4.0, <8.0

Major 8.0, <40

Catastrophic 40

4.4.1.3 BESS installed as part of a domestic building

The calculated arc flash energy at the output terminals shall not be greater than 4.0 cal/cm2 for a BESS installed in any of the following locations:

(a) Within the domestic dwelling.

(b) Externally where the enclosure is against an external wall of the dwelling.

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If the BESS to be installed has a calculated arc flash value greater than 4.0 cal/cm2, one of the following shall apply:

(i) Inter string protection devices shall be installed to reduce the arc flash energy below 4.0 cal/cm2.

(ii) The BESS is relocated to a dedicated battery room not attached to the dwelling.

(iii) The BESS is installed at least to the requirements of fire hazard level 1.

(iv) The BESS is not installed.

A BESS installed externally and not connected to domestic dwellings should have arc flash energy less than 8 cal/cm2. If arc flash of less than 8 cal/cm2 cannot be achieved, the arc flash value shall not exceed 40 cal/cm2 and the battery system configuration shall ensure that the battery system can be isolated into blocks no greater than 4 cal/cm2.

Exception: Preassembled systems are acceptable at up to 8 cal/cm2 where housed in such a way as to be unable to access individual battery cells and where there may be some internal protective devices or clear instructions to manage the battery system and avoid arc flash.

4.4.1.4 BESS installed in non-domestic buildings

BESS with a calculated arc flash energy greater than 4.0 cal/cm2 shall be installed in a dedicated battery room within non-domestic buildings or within a dedicated enclosure located outside.

BESS installed for non-domestic buildings shall have arc have flash energy less than 40 cal/cm2.

4.4.1.5 Arc flash boundary

The arc flash boundary shall be the distance at which incident energy equals 5 J/cm2 (1.2 cal/cm2).

The arc flash boundary can be determined using the following equations:

AFB = SQRT (0.0083 × Vsys × Iarc × Tarc × MF) . . . 4.4(1)

or

AFB = SQRT ((0.01 × Vsys × Iarc × Tarc × MF)/1.2) . . . 4.4(2)

where

AFB = arc flash boundary, in cm

Vsys = system voltage, in volts

Iarc = arcing current, in amps

Tarc = arcing time, in seconds


while

Iarc = 0.5 × Ibf

where

Ibf = battery system prospective fault current in amps

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An arc flash boundary nominal distance of 45 cm has been used for the calculation of incident energy. This is based on a ‘nominal’ working distance and risk of injury to the body and face of persons working on equipment. It is necessary to ensure that appropriate measures are taken, for example, when working on battery cells, where a person’s hands and arms may be within the arc flash boundary, where likely incident energy levels are far higher. As a result it is required that all tools used be appropriately insulated, and appropriate hand protection should also be used. The PPE equipment as required from Table 3.3 shall be worn whenever a person intends to work in an area located within the determined arc flash boundary.

4.5 FIRE HAZARD

4.5.1 General

In addition to the enclosure and room requirements specified in Clauses 4.2.4 and 4.2.5, all battery types that are classified as fire hazards as identified in Table 3.1 shall be installed in accordance with relevant requirements specified.

A smoke alarm or detector linked to a fire indication panel shall be installed according to applicable fire regulations within any room housing a battery system or BESS.

The BESS’ location, enclosure and any fire barrier shall meet the relevant local, state or territory or national requirements, according to the building classification code, to ensure adequate fire separation is maintained between the battery system and the building to which it is attached and any adjacent building or allotment boundary.

4.5.2 Installation requirements determined by fire rating level

For the battery system enclosures and rooms and BESS enclosures and rooms, the fire hazard category is specified in Table 3.1. Clauses 4.5.3 or 4.5.4 and shall be achieved by either—

(a) the enclosure which houses the battery system; or

(b) the room which houses the battery system or BESS. NOTE: Fire resistance level (FRL) is defined in the National Construction Code as the grading period in minutes for three criteria: structural adequacy, integrity and insulation.

The 60/60/60 FRL level refers to the following criteria for containing the fire:

(i) The enclosure and/or battery stands shall support the weight of the battery system and maintain structural integrity for 60 minutes (structure).

(ii) The enclosure or battery room shall contain the flames and hot gases for 60 minutes (integrity) (See Note 1).

(iii) The enclosure shall be insulated to a level such that the outside walls do not achieve temperatures on average in excess of 180C for 60 minutes (insulation).

Since many battery systems require ventilation of the normal gases types, to meet this 60-minute requirement, the ventilation from the battery enclosure or battery system room shall exhaust to outside of the building only (see Figure 4.14).

NOTE: Refer to AS 1530.4 for further information.


The installation requirements for battery types shown as fire hazard level 1 in Table 3.1, are as follows:

(a) Shall not be installed inside a domestic dwelling.

(b) Shall not be installed within 1 m of any access/egress area.

(c) Shall not be installed under any part of a domestic dwelling.

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(d) If installed at a commercial premise, the battery system shall be housed in a room rated at the FRL of a minimum of 60/60/60.

(e) If installed on a domestic property they shall be in a detached building or structure where the battery system shall be housed in a purpose-built room or enclosure rated at the FRL of a minimum of 60/60/60, or if installed externally and adjoining or within 1 m of a domestic dwelling or other building within the same property allotment, a barrier of fire-rated material of a minimum of 60 minutes (with respect to containing flames) shall be installed according to the following:

(i) Between the battery system and the immediately adjacent building’s wall/s. This barrier shall extend to a minimum of 600mm on either side of the battery system. This barrier shall extend to the floor and to a minimum of 2 m above the battery system or BESS. If clearance above the battery system or BESS is less than 2 m, an overhead barrier shall be required [see Item (f)].

(ii) Between the battery system and the floor beneath the battery system. This barrier shall extend at least 600 mm in the horizontal direction from all extremities of the battery system or BESS unless obstructed to the sides and rear by the building’s wall/s (in which case wall barriers are required).

(f) If required (see Item (e)(i) above), a barrier shall be installed at the junction of the wall above the battery system to protect the building’s eaves, roof or ceiling, e.g. veranda, ceiling. This overhead barrier shall be installed to extend a minimum of 600 mm from the extremities of the battery system or to the building’s extremity, whichever is the lesser.

(g) Any penetration of the fire barrier that has an internal free space greater than 5 mm diameter shall be sealed to stop any draft effect that could allow the spread of fire (Refer AS/NZS 3000 Section 2); and

(h) Shall not be installed within 1 m of a neighbouring property, building or dividing fence.

Figures 4.14, 4.15 and 4.16 illustrate the installation requirements as prescribed in 4.5.3 using the example of an enclosure mounted on the wall. Appendix H illustrates the installation requirements as prescribed in Clause 4.5.3 for the enclosure installed in additional locations.

All joints between horizontal and vertical fire barriers shall be sealed with an appropriate proprietary, flexible fire rated sealant to achieve minimum 60 minute fire rating in accordance with sealant manufacturer instructions.


The installation requirements for battery types shown as fire hazard level 2 in Table 3.1, are as follows:

(a) Shall not be installed within 1 m of any access/egress area.

(b) Shall not be installed under any part of a domestic dwelling.

(c) If installed in a domestic dwelling or other building, the battery system shall be housed in either—

(i) an enclosure internally lined with or constructed of material fire-rated for a minimum of 60 minutes with respect to resisting the incipient spread of flames; or

(ii) a room internally lined or constructed of fire-rated material as described in Item (i) above and fitted with a door having a minimum fire rating of 60 minutes.

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(d) If installed externally and not contained in an enclosure described in Item (c)(i) above, and is adjoining or within 1 m of a domestic dwelling or other building within the same property allotment, a barrier of fire-rated material for a minimum of 60 minutes, with respect to resisting the spread of flames, shall be installed according to the following:

(i) Between the battery system and the immediately adjacent building’s wall/s. This barrier shall extend to a minimum of 600 mm on either side of the battery system unless a building wall exists in the 600 mm lateral space. This barrier shall extend to the floor and to a minimum of 2 m above the battery system or BESS. If clearance above the battery system or BESS is less than 2 m, an overhead barrier shall be required [see Item (e)].

(ii) Between the battery system and the floor beneath the battery system. This barrier shall extend at least 600 mm in the horizontal direction from all extremities of the battery system or BESS unless obstructed to the sides and rear by the building’s wall/s.

(e) If required [see Item (d)(i)] above, a barrier shall be installed at the junction of the wall above the battery system to protect the building’s eaves, roof or ceiling, e.g. veranda, ceiling. This overhead barrier shall be installed to extend a minimum of 600 mm from the extremities of the battery system or to the building’s extremity, whichever is the lesser.

(f) Any penetration of the fire barrier that has an internal free space greater than 5 mm diameter shall be sealed to stop any draft effect that could allow the spread fire (Refer AS/NZS 3000 Section 2).

(g) Shall not be installed within 1 m of a neighbouring property, building or dividing fence unless installed in enclosure described in Item (c)(i).

Figures 4.14, 4.15 and 4.16 illustrate the installation requirements as prescribed in Clause 4.5.4 using the example of an enclosure mounted on the wall. Appendix H illustrates the installation requirements as prescribed in Clause 4.5.3 for the enclosure installed in additional locations.

All joints between horizontal and vertical fire barriers shall be sealed with an appropriate proprietary, flexible fire rated sealant to achieve minimum 60 minute fire rating in accordance with sealant manufacturer instructions.

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Bat terysystem

or BESS

Floor of bui ld ing

Floor barr ier shal l ex tend a minimum of600 mm of 60 minute f i re rated mater ia lfrom the lower ex tremity of the Bat terysystem or BESS

Barr ier of 60 minute f i re Rated Mater ia lprotect ing wal l: shal l ex tend for ver t ical height of 2 m minimum, i f ver t icalc learance to eave less than 2 m, f i rebarr ier should ex tend to eave andcont inue outwards for minimum distanceof 600 mm or to ex tremity of bui ld ing (whichever is less)

Top Fire Barr ier required i f ver t icald istance of 60 minute f i re rated mater ia lis less than 2 m from top of Bat terySystem or BESS

Top f i re barr ier at least 600 mm or width of eave (whichever is less)

600 mm600 mm

FIGURE 4.14 WALL-MOUNTED: FRONT VIEW OF WALL-MOUNTED BATTERY SYSTEM OR BESS INSTALLED EXTERNALLY TO ANY BUILDING.

Bat terysystem or BESS

Floor of bui ld ing

Wal l of bui ld ing

Floor barr ier shal l ex tend a minimum of 600 mm of 60 minute f i re rated mater ia l from the lower ex tremityof the Bat tery system or BESS

600 mm

600 mm

Barr ier of 60 minute f i re Rated Mater ia l protect ing wal l: shal l ex tend for ver t ical height of 2 m minimum,i f ver t ical c learance to eave less than 2 m, f i re barr iershould ex tend to eave and cont inue outwards forminimum distance of 600 mmor to ex tremity of bui ld ing (whichever is less)

Top Fire Barr ier required i fver t ical d istance of 60 minutef ire rated mater ia l is less than2 m from top of Bat tery Systemor BESS

Top f i re barr ier at least 600 mmfrom the ex tremity of the bat terysystem or width of eave(whichever is less)

FIGURE 4.15 WALL-MOUNTED: SIDE VIEW OF BATTERY SYSTEM OR BESS INSTALLED EXTERNALLY TO ANY BUILDING.

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Wall of bui ld ing

Bat tery systemor BESS

600 mm

600 mm 600 mm

Barr ier of 60 minute f i re Rated Mater ia l above bat tery system protect ing wal l; shal l ex tend for ver t ical height of 2 m minimum

Barr ier of 60 minute f i re RatedMater ia l above bat tery system,required i f ver t ical d istance of 60 minute f i re rated mater ia l from ground is less than 2 m and shal lex tend ei ther 600 mm from wal l orto the ex tent of bui ld ing or frontof the Bat tery System or BESS(whichever is less)

FIGURE 4.16 WALL-MOUNTED: PLAN VIEW OF BATTERY SYSTEM OR BESS INSTALLED EXTERNALLY TO ANY BUILDING.

4.5.5 Battery management system

Battery systems that are classified as fire hazards due to fault conditions identified in Clauses 4.5.7 to 4.5.11 shall be installed with a battery management system that is compatible with that particular battery system. The battery management system shall monitor all the potential and controllable fault conditions that may result in a fire if they occur. The battery management system shall either take direct action as specified in Clauses 4.5.7 to 4.5.11 and/or provide an actionable alarm.

Lithium based battery systems shall include a battery management system (BMS) suitable for the particular battery system or, in the event that more than one battery chemistry is provided to constitute a BESS, for each of the battery chemistries or technologies used. The BMS should—

(a) monitor the battery system’s temperature and voltage; and

(b) maintain the charging and discharging of the battery system between the manufacturer’s specified voltage and temperature windows.

4.5.6 Battery alarm system

The alarm system may be an audible signal placed in an area where operational staff or system owners will be aware of the signal or another form of fault communication, for example email, SMS or similar, shall be applied to inform to the system operator.

A set of operational instructions shall be provided to the system owner that includes the actions to be taken when the alarm is activated.

4.5.7 Excess temperature

The battery system shall never be exposed to temperatures greater than the maximum temperature specified by the product’s manufacturer. For those battery types shown as fire hazard level 1 in Table 3.1, where high temperature can result in a fire, the battery management system shall—

(a) monitor the temperature of at least every thermally coupled block of cells; and

(b) act to shutdown the battery or battery module if the temperature exceeds the maximum value as specified by the manufacturer. Li

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4.5.8 Minimum temperature

The battery system shall never be exposed to temperatures lower than the minimum temperature specified by the product’s manufacturer. For those battery types shown as fire hazard level 1 for which low battery temperature can result in a fire, the battery management system shall monitor the temperature of the battery or battery module and shall act to shutdown the battery or battery module if the temperature falls below the minimum value as specified by the manufacturer.

4.5.9 Overcurrent

The maximum available charge current being applied to the battery system shall not be greater than the maximum allowable charge current as specified by the manufacturer.

The battery system shall have a battery management system that monitors the charge current and either—

(a) disconnects the charging source when the battery exceeds the maximum current as specified by the manufacturer; or

(b) limits the charging current to no greater than the maximum value allowed.

4.5.10 Over voltage

The maximum allowable voltage of the battery system shall not be exceeded.

The battery system classified as fire hazard level 2 shall have a battery management system that monitors the battery system voltage and either—

(a) disconnects the charging source when the battery system exceeds the maximum voltage as specified by the manufacturer is reached; or

(b) reduces the charging current so that the voltage does not rise above the maximum allowable voltage.

For those battery types classified as fire hazard level 1, the battery management system shall act to shutdown the battery if the voltage of any particular cell, battery or module exceeds the maximum value as specified by the manufacturer.

When maximum voltage is exceeded an over voltage alarm shall provide be activated.

4.5.11 Over discharged

For those battery types classified as fire hazard level 1, where a deep discharge past a specified point can result in a fire:

(a) The battery management system shall electrically disconnect the battery or battery module from the system if the battery system’s voltage or battery system’s state of charge drops below the minimum voltage or state of charge specified by the battery manufacturer.

(b) If the point of discharge outlined in Item (i) above is reached, the battery system shall shutdown and shall not be able to recharge.

For those battery types classified as fire hazard level 2, the battery system shall include a PCE which cannot draw power from the battery system when the battery system’s voltage or state of charge is less than the minimum voltage or state of charge specified by the battery manufacturer.

For those battery types where the over-discharged batteries are not shut down, there shall be an alarm activated.

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4.5.12 Protection against mechanical damage from external forces

For battery types classified as fire hazard level 1 which are susceptible to fire due to puncturing of an individual battery cell, battery or battery module, they shall be installed with mechanical protection to withstand crushing, impacts, vibration and shock abuse.

4.6 CHEMICAL HAZARD

4.6.1 General

Battery systems that are classified as chemical hazards shall be installed in accordance with risk reduction requirements of Clauses 4.6.2 to 4.6.5.

NOTE: Table 3.1 shows those battery types classified as chemical hazards.

4.6.2 Puncturing

Battery and battery modules within a battery system shall be mechanically protected to minimize the risk of the case of the battery or battery module being damaged. This can be achieved via the use of a suitable battery system enclosure.

When a battery system is installed in a dedicated battery system or BESS room, considerations shall be given to minimize the potential damage to the battery or battery module case occasioned by other equipment being located within the room.

4.6.3 Toxic fumes

If the battery system type is classified to emit toxic fumes under certain fault or failure conditions, the installation shall be undertaken in accordance with the instructions of the manufacturer.

Any instructions provided by the manufacturer shall be included in the documentation provided to the system owner and the system owner shall be made aware of these instructions.

Signs (see Section 5) warning of the dangers of toxic fumes shall be located on the door leading to the room where the system is installed or if installed outside on the battery system enclosure.

4.6.4 Containment

Battery systems that contain liquid chemicals shall include a containment system (bunding or spill trays) within the battery system enclosure and/or battery system room in the case of battery system case damage or other chemical spills that may occur when servicing the battery system. The following requirements apply to bunding or spill trays:

(a) Shall be made of materials suitable for the containment of the battery system’s liquid chemicals.

(b) Shall be sized to contain a minimum amount of spilt or discharged chemical equal to either—

(i) one battery or battery cell, if lead acid batteries are installed; or

(ii) one battery or battery module, if other battery types are installed.

(c) Shall retain battery chemicals within the battery enclosure/room for the ease of collection and for the prevention of the spreading of the battery electrolyte to adjacent areas.

Safety signs (see Section 5) shall be installed informing the actions that shall be undertaken in the event of a chemical spillage or leak.

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4.6.5 Additional requirements for enclosures and rooms

In addition to the requirements specified for the enclosure and room in Clauses 4.2.5 and 4.2.6, battery system enclosures and rooms and BESS enclosures and rooms shall meet the following requirements for BESS that include battery systems classified as chemical hazards:

(a) The enclosure shall be resistant to the effects of any chemical spillage from the particular battery type installed. This shall be achieved by either the selection of materials used or by appropriate coatings.

(b) Any building material within 1 m of a battery system in a room should be resistant to the effects of the battery system’s chemical either by a selection of the materials used or by appropriate coatings.

(c) If the fumes from the chemicals are corrosive—

(i) no electrical equipment shall be located above the enclosure or battery system; and

(ii) the fumes shall be vented outside.

Figures 4.17 and 4.18 show examples of a battery enclosure installed in a room where the battery enclosure is vented to the outside of the building.

*

Equipment room

Elevat ion

* Space overhead should be unenclosed or al low no hydrogen pockets to accumulate above

Enclosure for bat terywith ex ternal vent i lat ion

600 mm

No equipment in th is space

600 mm

No equipmentin th is space

Vent

FIGURE 4.17 BATTERY ENCLOSURE WITHIN A ROOM WHERE THE BATTERY ENCLOSURE IS VENTED TO OUTSIDE THE BUILDING

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Bat tery enclosure

Plan

VentVent

600 mmtypical a l laround

FIGURE 4.18 BATTERY ENCLOSURE WITHIN A ROOM WHERE THE BATTERY ENCLOSURE IS VENTED TO OUTSIDE THE BUILDING

4.7 EXPLOSIVE GAS HAZARD

4.7.1 General

Battery systems that are classified as explosive gas hazards shall be installed in accordance with risk reduction requirements specified in Clauses 4.7.2 to 4.7.6. Ventilation of the battery systems shall be in accordance with the applicable requirements of Clause 4.7.2 and the rate of ventilation shall be determined based on the battery system type.

The enclosure or room where battery systems classified as explosive gas hazards are installed shall have ventilation installed to ensure that all gases are exhausted to the outside.

4.7.2 Ventilation

4.7.2.1 General

All battery system installations shall be supplied with either natural or forced ventilation depending on the amount of hydrogen gas generated. This Clause 4.7.2 provides requirements for natural and forced ventilation for battery system installations.

4.7.2.2 Flooded (vented) and sealed valve-regulated lead acid cells.

All battery system enclosures and battery system rooms containing lead acid cells shall be ventilated, whether the battery system is of the sealed valve-regulated (sealed) type or flooded (vented) type.

All secondary cells generate hydrogen and oxygen gases during charging. The major release of hydrogen gas occurs after a cell has achieved 95% of charge, or during any boost charging or overcharging of the battery.

Under conditions of overcharge or electrical abuse, significant amounts of hydrogen gas can be generated and emitted from sealed valve-regulated cells. Further, the thermal and charge management of sealed valve-regulated cells is more critical than for vented cells, and generally the sealed valve-regulated cell will be irreversibly damaged when subjected to sustained electrical abuse, therefore, the manufacturer’s specified charging regime for sealed valve-regulated batteries shall be observed.

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NOTES:

1 Significant gas production should not occur when a battery is on float charge.

2 The chemistry of a sealed valve-regulated battery operates on an internal oxygen-recombination cycle which is arranged to suppress hydrogen gas evolution. Under normal operating conditions, hydrogen gas evolution and venting in sealed valve-regulated cells is much lower than the hydrogen gas released by conventional vented (flooded) cells. The hydrogen suppression efficiency in valve-regulated batteries varies with cell technology, but typically exceeds 80% for gel cells and 90% for absorbent glass mat cells.

4.7.2.3 Rate of ventilation (lead acid)

The average hydrogen concentration by volume in a battery system enclosure or battery system room shall be maintained below 2%.

The minimum exhaust ventilation rate required to maintain hydrogen concentration below 2% shall be calculated by the following equation:

qv = 0.006nI . . . 4.7(1)

where

qv = minimum exhaust ventilation rate, in litres per second

n = number of battery cells

I = charging rate, in amperes

If there are multiple parallel battery systems in the battery system enclosure or battery system room the total exhaust ventilation rate is the sum of the rates of ventilation of all the battery strings or battery systems.

4.7.2.4 Charging rate

4.7.2.4.1 Flooded lead acid battery systems

The charging rate in the ventilation equation shall be the maximum output rating of the charger or the rating of its output fuse or circuit-breaker.

4.7.2.4.2 Sealed valve-regulated lead acid battery systems

The charging rate for valve-regulated cells in the ventilation equation is determined for two conditions, as follows:

(a) Condition I If the PCE(s) acting as a charger does not have an automatic overvoltage cutoff, the charging current is the maximum output rating of the charger or the rating of the output fuse or circuit-breaker of the charger.

(b) Condition II If the PCE(s) acting as a charger has an automatic overvoltage cutoff set at the battery manufacturer’s specified level, the charging rate is 0.5 A per 100 A.h. at the 3 h rate of discharge of battery capacity.

NOTE: These charging rates are based on a float voltage of 2.27 V per cell and have been selected to provide a safe level of ventilation for all types of battery construction.

4.7.2.5 Method of ventilation

4.7.2.5.1 General

Where possible, natural ventilation should be used for battery rooms and enclosures because of the fault potential of mechanical ventilation.

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4.7.2.5.2 Natural ventilation

If natural ventilation is used, the minimum size of inlet and outlet apertures is determined from the following equation:

A = 100qv . . . 4.7(2)

where

A = the minimum area of the apertures, in square centimetres

qv = the minimum exhaust ventilation rate, in litres per second

With natural ventilation, an air velocity of at least 0.1 m/s is assumed to flow through the apertures.

4.7.2.5.3 Mechanical ventilation

If mechanical ventilation is used, the minimum flow rate is determined by the ventilation formula specified in Clause 4.7.2.2.

Where mechanical ventilation is used, it shall be on only the air inlet to prevent fan damage from the battery acid fumes and remove electrical equipment from what is potentially an explosive gas zone.

An air flow sensor shall also be installed to activate an alarm and discontinue charging in the event of a fan failure.

4.7.2.5.4 Arrangement of ventilation

The following requirements apply to the arrangement and layout of the ventilation system:

(a) Battery rooms and enclosures shall be provided with ventilation by means of holes, grilles or vents so that air sweeps across the battery.

(b) Except when the inlet and outlet vents meet the requirements as shown in Figure 4.19 the inlet and outlet vents shall be on laterally opposite sides of the enclosure.

Bat tery enclosure withintake and out let ventson the same wal l

Depth of enc losure not greater than 2 rows of cel ls or b locks

Sloping internal cei l ing ofenclosure designed to ensure al l hydrogen escapingfrom the bat tery is d irected to the ex ternal vent

Lengths of vents at least75% of the enclosure faceand central ly located

FIGURE 4.19 BATTERY ENCLOSURE WITH THE INTAKE AND OUTLET VENTS ON THE SAME WALL

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The following recommendations apply to the arrangement and layout of the ventilation system:

(i) Ventilation outlets should be at the highest level in the battery system enclosure and/or battery system room.

(ii) Ventilation inlets should be at a low level in the battery system enclosures. Inlets should be no higher than the tops of the individual batteries or battery modules, and, where required, fitted with a screen to prevent the entry of vermin.

(iii) To avoid stratification of the airflow, ventilation inlets and outlets should consist of—

(A) a number of holes spaced evenly along the side of the room or enclosure; or

(B) a slot running along the side of the room or enclosure. NOTE: Appendix G provides examples of battery enclosures.

4.7.2.5.5 Nickel cadmium batteries

For nickel cadmium battery systems, all the requirements of Clause 4.7.2.1 (lead acid batteries) to Clause 4.7.2.5.4 apply, with the exception that the charging rate (I) used in the ventilation Equation 4.7(1) is 1.5 A per 100 A.h. at the 3 h rate of discharge of battery capacity.

NOTE: These charging rates are based on a float voltage of 1.45 V per cell and has been selected to provide a safe level of ventilation for all types of battery construction.

4.7.2.5.6 Other battery system chemistries

For battery system chemistry types other than lead acid or nickel cadmium, the manufacturer’s instructions on ventilation requirements shall be followed.

NOTE: It is important that the installer follows the manufacturer’s instructions as there are lithium ion systems that have specific ventilation requirements.

4.7.3 Additional requirements for battery system enclosures.

In addition to the enclosure requirements specified in Clause 4.2.5, battery system enclosures shall meet the following requirements for battery systems classified as explosive gas hazards:

(a) The design of the enclosure shall prevent the formation of gas pockets.

(b) The enclosure shall meet ventilation requirements for the particular battery types specified by Clauses 4.7.2.

(c) No equipment, which could cause a spark or arc, shall be installed above the battery or battery modules inside the enclosure.

(d) The enclosure shall provide a gas tight seal to all doors, access panels, cable entry glands between the batteries and any other part of the BESS. This ensures that air flows from inlet to outlet vents across the battery and not by other unsealed apertures.

(e) Battery system protection devices and battery system isolating switches shall be mounted outside the battery system enclosure, but as close as practicable to the battery system enclosure (to minimize cable length).

(f) General purpose outlets shall not be installed within the enclosure.

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4.7.4 Additional requirements for BESS enclosures

This Clause 4.7.4 shall apply for installer-built enclosures and preassembled integrated BESS.

In addition to the enclosure requirements specified in Clause 4.2.5 and 4.7.3, BESS enclosures shall meet the following requirements for battery system types installed that are categorized as explosive gas hazards:

(a) Where battery system protection devices and isolating switches are mounted in the BESS enclosure, the device shall be mounted a minimum of 100 mm below the battery terminals or a minimum of 600 mm horizontally from the batteries.

(b) A purpose-built equipment enclosure installed above a purpose-built battery system enclosure shall meet all of the following:

(i) Only those batteries that minimize the formation of explosive gases shall be installed. For example, where the battery type is lead acid or similar chemistry, only sealed valve-regulated batteries shall be installed in the battery enclosure.

(ii) Where the equipment enclosure is above the battery enclosure, a gas proof horizontal barrier shall be in place between the battery system enclosure and the equipment enclosure.

(iii) The battery and equipment enclosures shall be accessible separately (e.g. via separate doors).

(iv) The ventilation paths for the battery enclosure and the equipment enclosure shall be specifically designed to minimize the possibility of air having been exhausted from the battery enclosure entering the air inlets on the equipment enclosure.

NOTE: See Figure G3 in Appendix G.

The battery system and PCE equipment compartments should be ventilated using natural ventilation (i.e. without the use of an electrically powered fan).

NOTE: Typical combined battery and inverter or electronic enclosures are shown in Appendix G.

4.7.5 Additional requirements for installation of battery system or BESS enclosures

In addition to the enclosure requirements specified in Clause 4.2.5 for battery system types installed that are categorized as explosive gas hazards the installation of the battery system or BESS enclosure shall comply with the following:

(a) For enclosures installed within a room, the battery system enclosure outlets vents shall be vented outside, unless the enclosure is mounted in a dedicated BESS room, and the size of the inlet and outlet ventilations shall be determined in accordance with the formulas in Clause 4.7.2.

(b) Arc-producing devices shall not be located in areas where the concentration of explosive gases (e.g. hydrogen) can exceed 2% by volume, e.g. directly above battery vent or top opening enclosures.

(c) No equipment shall be placed above the battery system enclosure except where the access doors and vents are not top opening, there is a gas proof horizontal barrier in place between the battery system enclosure and the equipment and the outlet vents are vented to the outside.

(d) Luminaires shall not be installed within 200 mm of any battery system enclosure.

(e) All general purpose socket-outlets shall be located at least 1800 mm from the battery system enclosure and a minimum of 100 mm below the top of the battery or any battery vent, if within 5 m of the battery system enclosure.

NOTE: See Appendix G Figure G1.

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(f) Battery system or BESS enclosure externally to a building shall comply with the following:

(i) AS/NZS 3000:2007 Section 4.

(ii) The enclosure shall be located a minimum of 600 mm in the horizontal direction from any window.

(iii) The enclosure shall not be located below any window or ventilation opening.

4.7.6 Additional requirements for battery system and BESS rooms

In addition to the room requirements specified in Clause 4.2.6, battery system rooms and BESS rooms installed in a dedicated area shall meet the following requirements for BESS that include battery systems classified as explosive gas hazards:

(a) The design of the room shall prevent the formation of gas pockets.

(b) The size of the inlet and outlet ventilations shall be determined in accordance with the formulas in Clause 4.7.2.

(c) The room outlet vents shall be ventilated to outside.

(d) Where battery system protection devices and isolating switches are mounted in the BESS room, the device shall be mounted a minimum of 100 mm below the battery terminals or a minimum of 600 mm horizontally from the batteries.

(e) Luminaires shall not be installed within 200 mm of any battery system or battery system enclosure.

(f) All general purpose socket-outlets shall be located at least 1800 mm from the battery system within a BESS room and a minimum of 100 mm below the top of the battery system, if within 5 m of the battery system. NOTE: See Appendix G.

(g) A minimum horizontal separation of 600 mm shall be provided between the battery system and all other equipment within a BESS room from 100 mm below battery terminals, except where there is a solid separation barrier. NOTE: See Appendix G, Figure G1.

Battery system protection devices and battery system isolating switches should be mounted outside the battery system room and the cable length between the protection and isolating devices should be minimized.

4.8 MECHANICAL HAZARD

4.8.1 General

All battery system types shall be classified as mechanical hazards due to the weight of the battery system.

When installing a battery system, consideration shall be given to the mechanical hazards applicable to the type, quantity and size of the battery system to be installed.

NOTE: Table 3.1 shows those battery types classified as mechanical hazards.

4.8.2 Weight of battery

For ground mounted battery systems, the ground structure and type shall be designed to withstand any damage due to the weight of the battery system.

For wall-mounted battery systems, the structural integrity of the wall shall be able to withstand the weight of the battery system.

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4.8.3 Additional requirements for battery system and BESS enclosures

In addition to the enclosure requirements specified in Clause 4.2.5, the installation of the battery system or BESS enclosure shall comply with the following:

(a) The supporting surface of the enclosure shall have adequate structural strength to support the battery system weight and any support structure;

(b) The deflection of the shelves in the enclosure, after installation and after normal settlement has taken place under load, shall not be more than 3 mm; and

(c) Any battery stand shall meet the requirements specified in Clauses 4.8.2 and 4.2.7.

4.8.4 Additional requirements for battery system and BESS rooms

In addition to the room requirements specified in Clause 4.2.6, and in particular the battery stand requirements in Clause 4.2.7, the following recommendations apply to the installation of the battery stand in a room:

(a) The deflection of the shelves in the battery stand, after installation and after normal settlement has taken place under load, should not be more than 3 mm.

(b) The projected area of the base of the battery or battery module should be contained within the stand.

(c) Horizontal restraining bars should be installed at the front and back of the battery stands, if the height of the battery or battery module is its greatest dimension.

(d) The consequences of seismic activity should be considered. NOTE: See Appendix I for typical battery stands.

4.8.5 Moving parts

Any equipment having moving parts shall be protected to prevent inadvertent personal contact with these parts. Where such protection has not been provided by the manufacturer, guards shall be fitted and appropriate instructions included in the equipment’s safety and handling documentation.

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S E C T I O N 5 L A B E L S A N D S A F E T Y S I G N A G E

5.1 GENERAL

The purpose of the provisions of this Section is to clearly indicate that the electrical installation has a battery system installed and to provide required safety signs and labels.

Signs relating to the battery system shall be placed on the battery system enclosure or room or the battery energy storage system enclosure or room as detailed in this Section.

All safety signs shall be permanently displayed in accordance with this Section.

To provide assistance for emergency services, additional signs should be provided at fire indicator panels and the main metering panel.

5.2 REQUIREMENTS FOR SIGNS AND LABELS

All labels and signs required shall be designed to have a lifetime greater than or equal to the service life of the battery system. Factors that shall be incorporated to ensure fitness for purpose include the following:

(a) Construction of durable materials suitable for the location, including UV stabilized materials where the installed labels and signs are exposed to direct sunlight.

(b) The method of fixation shall remain secure.

(c) Locate where clearly visible to intended user. NOTE: Considerations affecting suitable locations include:

(i) Some signs may be enclosed in a switchboard cabinet, if they are visible when an operator opens the switchboard to perform maintenance or emergency services.

(ii) Some battery signs may need to be within the battery enclosure and, hence, may only become visible after opening the battery enclosure.

(iii) Signs should not be obscured by the door of the enclosure when in an open position.

(d) The language shall be English

(e) Letter size and style shall be legible to user.

NOTE: As a guide, the size of sign lettering should be based on uppercase lettering of 5 mm high and lowercase of 4 mm high per metre of viewing distance

(f) Any print shall be indelible. NOTES:

1 Examples of signs are given in Appendix B.

2 As a guide, the background colour and lettering colour should follow the principles listed below:

(a) Signs for general information should be white with black lettering.

(b) Signs for the essential safety of service personnel should be yellow with black lettering.

(c) Signs for attention of emergency personnel should be red with white lettering.

5.3 BATTERY TYPE GENERAL LABELLING

Locations where battery energy storage systems are installed shall require a circular green reflector sign at least 70 mm in diameter with the letters ‘ES’ on or immediately adjacent to the main metering panel and main switchboard, so as to be readily visible to approaching emergency workers. Below the ‘ES’ lettering shall be included the United Nations number for the primary chemistry installed at the installation, e.g. UN No: 2794.

NOTE: See Appendix B, Figure B1 for an example.

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5.4 SIGNS FOR BATTERY SYSTEM LOCATION

Battery system locations that are difficult to find, not evident from the main metering panel or in large buildings should be shown on a plan (map or drawing) located at the main metering panel and/or fire panel.


5.5 RESTRICTED ACCESS

Battery systems, which are accessible within an enclosure or room shall have a sign which—

(a) designates ‘restricted access’ stating that access is permitted only for authorized personnel; and

(b) is mounted either adjacent to the enclosure or on all doors to the room where the battery system is located.


Signs relating to PPE requirements and the voltage and current of the battery systems shall be located adjacent to the restricted access sign.

NOTE: Example signs are shown in Appendix B; PPE sign in Figure B4 and current and voltage signs in Figures B5 and B6.

5.6 VOLTAGE AND CURRENT

A sign stating voltage and current shall be mounted—

(a) either adjacent to the enclosure or on all doors to the room; and

(b) at the isolation point for all battery systems where the voltage and current sign cannot be read from the isolator.

The sign shall be white lettering on a red background. This sign shall state the following:

(i) Battery system (specify location).

(ii) Short-circuit current (specify current) A.

(iii) Maximum d.c. voltage (specify voltage) V.

For systems over 600 V, the above signage requirements apply plus an additional line shall be added to the sign stating ‘Hazardous d.c. Voltage’.

NOTE: See Appendix B Figure B5, B6 and B14 for examples.

Where multiple battery systems are installed—

(A) the voltage specified shall be the maximum voltage present; and

(B) the current shall be the sum of the battery system short-circuit currents for all battery systems connected to each BESS.

Where multiple BESS are installed within one electrical installation, there shall be a sign for each BESS, which includes an identifiable number together with the total number of BESS shown, for example, BESS 1 of (insert total number of BESS), BESS 2 of (insert total number of BESS).

NOTE: See Appendix B Figure B7.

5.7 SAFETY DATA SHEET (SDS)

The SDS for the battery system shall be included within a document holder in the main metering panel, and where available, at the fire panel. The SDS shall ensure a local contact (country contact, Australia or New Zealand, as appropriate) within the document.

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5.8 EXPLOSIVE GAS HAZARD

All battery system types classified as explosive gas hazards shall have a ‘Danger, Risk of Battery Explosion’ sign installed in a prominent position when approaching the battery system. The minimum size of this sign shall be 175 175 mm. This sign shall be mounted either adjacent to the enclosure or on all doors to the room where the battery system is located.

NOTE: An example of a ‘Danger” sign is shown in Appendix B, Figure B8.

5.9 TOXIC FUME HAZARD

All battery system types classified as presenting a toxic fume hazard shall have a sign: ‘Danger, Toxic Fumes’. The sign shall specify the specific fault condition (e.g. fire) under which the fumes will be present. This sign shall also include PPE requirements for entering the room/working with the battery systems. This sign shall be mounted either adjacent to the enclosure or on all doors to the room where the battery system is located.

NOTE: Example signs are shown in Appendix B; toxic fumes sign in Figure B9 and PPE signs in Figure B4.

5.10 CHEMICAL HAZARD

All battery system types classified as chemical hazards shall carry an appropriate sign specifying what to do if the skin, eyes or other parts of the body are exposed to the chemical. This sign shall be mounted either adjacent to the enclosure or on all doors to the room where the battery system is located.

NOTE: Example of an ‘Electrolyte Burns’ sign is shown in Figure B10 in Appendix B and is particularly relevant to lead acid batteries.

5.11 ARC FLASH

All battery system types classified as having an arc flash hazard above ‘minor’ (see Table 4.2) shall carry a warning sign to indicate the dangers of arc flash. This sign shall also include PPE requirements for entering the room/working with the battery systems. This sign shall be mounted either adjacent to the enclosure or on all doors to the room where the battery system is located.

NOTE: Example signs are shown in Appendix B; arc flash sign in Figure B11 and PPE signs in Figure B4.

5.12 DISCONNECTION DEVICES

5.12.1 General

Disconnection devices shall be marked with an identification name or number according to the BESS wiring diagram. The minimum size of this sign shall be such that it can be read from a distance of 1 m.

NOTE: All switches shall clearly and reliably indicate the isolating position of the device.

The symbols ‘0’ (off) and ‘I’ (on) are deemed to satisfy this requirement.

5.12.2 Battery system switch-disconnector

The battery system switch-disconnector shall carry a sign fixed in a prominent location with the following text:

BATTERY SYSTEM ISOLATOR

The sign shall be white lettering on a red background.

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NOTES:

1 The term ‘isolator’ used in this sign is to better inform the public, although the function required of the device is a switch-disconnector (i.e. load breaking).

2 An example of this sign is shown in Appendix B Figure B12.

5.12.3 Multiple switch-disconnectors

When a battery system has more than one switch-disconnector installed, these shall be labelled and numbered according to the battery system to which they are connected.

Where there are parallel battery systems connected to the PCE(s) and multiple isolation/disconnection devices are used, the following signage shall be fixed adjacent to the PCE connected to the multiple battery systems:

WARNING: MULTIPLE BATTERY SYSTEMS

TURN OFF ALL BATTERY SYSTEM ISOLATORS TO ISOLATE EQUIPMENT

The sign shall be black lettering on a yellow background.

If there are multiple PCE’s, only one sign is required to be located beside one of the PCEs.

5.12.4 Disconnectors for DVC-B and DVC-C systems

Isolating switches, plugs or links used to separate the battery system into sections to meet the requirements of Clauses 4.3.2.6 and 4.4 shall have a warning label fixed adjacent to each disconnector. All internal isolating devices shall also be suitably identified for breaking down of the battery system to offset particular maintenance and access requirements.

The sign shall be black lettering on a yellow background.

NOTE: An example of this sign is shown in Appendix B Figure B13.

5.13 OVERCURRENT DEVICES

5.13.1 General

Overcurrent devices shall be marked with an identification name or number in accordance with the BESS wiring diagram. The minimum size of this sign shall be such that it can be read from a distance of 1 m.

All overcurrent devices shall be labelled such as the following:

(a) BATTERY SYSTEM CIRCUIT BREAKER AND ISOLATING SWITCH.

(b) BATTERY SYSTEM FUSE.

(c) BATTERY SYSTEM SWITCH FUSE AND ISOLATOR.

NOTE: An example of (a) is shown in Appendix B Figure B15.

5.13.2 Multiple overcurrent devices

When a battery system has more than one overcurrent device installed, these shall be labelled and numbered according to the battery system to which they are connected.

5.13.3 Fuse holders

Where HRC fuse holders that are separate to the switch-disconnector have been installed, each fuse holder shall carry a warning label stating not to withdraw the fuse under load. The sign shall be black lettering on a yellow background. The minimum letter size of this sign shall be 5 mm such that the text can be read from a distance of 1 m.

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5.14 BATTERY SYSTEM CABLES

For battery system cabling, which is not enclosed in conduit, permanent indelible identification shall be—

(a) provided for battery system cabling installed in or on buildings;

(b) identified by distinctive and coloured labels marked with the word ‘BATTERY’; and

(c) attached over the length of that cable at an interval not exceeding 2 m.

For battery system cabling, which is housed in a wiring enclosure or in conduit, permanent indelible identification shall—

(i) be provided for the enclosure and conduit; and

(ii) be identified by distinctive and coloured labels marked with the words ‘BATTERY’ on the exterior surface over the length of the enclosure at an interval not exceeding 2 m.

If fixed to a surface, the identification shall be visible following complete installation of the battery system.

5.15 SEGREGATION

For the purpose of segregation as required in Clause 2.9, labels to identify the different types of circuits shall be mounted beside the relevant circuits.

If the different types of circuits require labelling over a length of the cable, these labels shall be located typically every 2 m.

5.16 SHUTDOWN PROCEDURE

All BESS shall include a permanent sign detailing the shutdown procedure that sets out the sequential steps to safely shut down the BESS.

The shutdown procedure shall—

(a) be installed at the main switchboard to which the BESS is connected (and any distribution board, to which it is connected, if it is not the main switchboard), unless it is adjacent to the main switchboard; and

(b) shall be placed adjacent to and visible from the equipment to be operated in the event of a shutdown.

Where the inverter is adjacent to the switchboard it is directly connected to, the shutdown procedure may be placed within that switchboard.

Where a building has a fire panel, a sign shall be installed at the fire panel stating ‘MULTIPLE SUPPLIES’, with instructions as to the location of the BESS shutdown procedures.

The sign detailing the shutdown procedure may also include the start-up procedure.

This sign shall comprise the complete shutdown procedure for the BESS, including (but not limited to) the following:

(i) Isolation of the output of the PCE(s).

(ii) Isolation of the inputs to the PCE(s).

(iii) Isolation of the battery system(s) from the PCE(s), by opening the switch-disconnector.

All labelling of devices shall be consistent with terminology used in the shutdown procedure.

The shutdown procedure shall also include emergency telephone contact information. NOTE: Appendix B, Figure B16 is an example of this sign.

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5.17 BATTERY LABELLING

Where a battery system has individual cells or modules requiring or able to be accessed or serviced, each individual cell or module is required to have a unique identifier including the use of consistent terminology. The label shall be placed on each cell or module such that it can be read without moving the cell or module.

Where there is a BMS for the cells or modules, the labelling shall be consistent with identification from the BMS.

5.18 OTHER EQUIPMENT LABELLING

All meters, shunts and alarms shall be labelled. Labels shall match naming conventions used in inspection and maintenance documentation and system drawings.

Additional warning signs may be required when specific protection or containment systems are installed.

NOTE: Appendix B, Figure B17 is an example of this sign.

5.19 SPILL CONTAINMENT

Safety signs shall be installed informing the actions that shall be undertaken in the event of a chemical spillage or leak.

NOTE: See Appendix B, Figure B18 for an example sign.

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S E C T I O N 6 C O M M I S S I O N I N G A N D I N D U C T I O N

6.1 GENERAL

After installation, a battery system shall be commissioned in accordance with the manufacturer’s instructions and the requirements of this Section. The specific requirements shall be dependent on the battery type and the overall system configuration.

6.2 VERIFICATION

6.2.1 General

Verification shall occur prior to energizing and placing the installation into service. The following requirements are minimum levels of safety inspection and testing to meet the safety requirements for the installation. Upon completion of the verification process a report shall be provided for inclusion in the system documentation (see Section 8).

6.2.2 Initial verification and visual inspection

All system shutdown and start up notifications shall be verified to match system diagrams and system labelling.

Signs, labels and markings are installed and applied correctly in accordance with the requirements of Section 5.

Any system risk-reduction isolation devices shall be verified to address requirements such as reduction in d.c. arc flash rating for the purposes of maintenance and future work.

The battery cells or modules terminal connections should be checked to ensure they are tightened to the recommended torque settings.

Battery housing shall be verified to ensure it is suitable for the battery type, for the environment in which the battery system is installed and is able to be secured against unauthorized access.

All necessary ancillary safety devices and equipment are installed.

6.3 TESTING

The testing of the installation shall be performed in accordance with the requirements of the manufacturer.

Where the installation has a separate battery system, battery polarity shall be tested prior to connection to PCE. Testing shall ensure no inadvertent connections between floating or isolated battery systems and earth.

The following measurements should be undertaken and results recorded in the commissioning documentation that should be included in the documentation (see Section 8):

(a) Total battery system voltage.

(b) Individual battery or battery module voltages, if applicable.

(c) Other suitable measurements, where applicable, such as specific gravity readings of individual battery cells, impedance test results of individual battery cells or initial state of health.

(d) Overall battery system voltage drop from cabling at maximum rated discharge current.

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6.4 COMMISSIONING

System commissioning shall verify the operation of the system as a whole and shall in particular verify the ability for the battery system to charge and discharge.

At installation commissioning, all d.c. connections shall be tested whilst the system is operating at full discharge or charge current to ensure there are no poor connections.

Programming for the control of the battery system shall be verified (whether this is done through the PCE directly or through a data connection or host computer connection).

Where charge and discharge parameters are required to be set as part of the installation, the parameters shall be verified and recorded.

The system shutdown procedure shall be tested to ensure this results in safe shutdown of the installation.

Any initiation commissioning requirements of the manufacturer shall be followed.

6.5 SYSTEM OWNER INDUCTION

An induction shall be provided to the system owner or nominated representative. This induction shall include the following:

(a) Demonstration of the system shutdown and start up procedures including review of shutdown procedure sign.

(b) Introduction to the system documentation provided as part of the installation (see requirements of Section 8).

(c) Provision of detailed information for any alarm features included in the system.

(d) Clear information on contact details for provision of assistance.

(e) Information pertaining to the access to specific data or hosted system information including user logins, available apps or programs.

(f) Basic operation and design principals.

(g) Periodic inspection checklist requirements.

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S E C T I O N 7 I N S P E C T I O N A N D M A I N T E N A N C E

7.1 GENERAL

The manufacturer’s instructions and the battery system’s SDS shall provide documented information relating to the battery system type and the inspections and maintenance required for the battery system type as well as qualifications that may be required for specific maintenance tasks. These instructions shall also provide a schedule for the tasks required for maintenance.

7.2 INSPECTIONS

Regular inspections may identify issues or changes in the battery system that indicate the need for maintenance or remedial work. Regular inspections should be based on a checklist provided to the system owner.

Inspections should be recorded and should consider a review of items such as the battery enclosure and access to the battery enclosure, any battery ventilation, labels, signage and documentation, battery terminals where accessible, review of any changes surrounding the battery system that may affect the battery system temperature or accessibility, any deformities in the battery enclosure or housing, checking the online systems or system readouts for battery state of health or battery voltages, any alarms, etc.

7.3 MAINTENANCE

7.3.1 General

Proper maintenance will prolong the life of a battery system and will help to ensure that it is capable of satisfying its design requirements. A suitable battery system maintenance program will serve as a valuable aid in determining the state of health of the battery and the need for battery replacement, or in locating system faults.

Only authorized personnel shall perform battery system maintenance procedures. Maintenance procedures shall follow the requirements set out in system documentation at intervals as required by the system documentation. All appropriate system shut downs shall be followed when performing system maintenance. All maintenance and corrective actions shall be recorded with a copy provided to the system owner or directly inserted within the system owner’s documentation.

Safety precautions required to conduct maintenance services for a battery system depend on the type of battery installation; the battery type, the system maximum d.c. voltage, the battery hazards and the enclosure. Maintenance shall be carried out in accordance with:

(a) The manufacturer’s requirements.

(b) The product SDS.

(c) The checklist and instructions provided in the system documentation (see Section 8).

(d) Applicable safety requirements listed in this Section.

Maintenance performed on any battery system shall be carried out following requirements for:

(i) Suitable tools (such as insulated tools, appropriately d.c. rated meters, thermal imaging devices).

(ii) Personnel protective equipment (e.g. face mask, cal-rated full length clothing).

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(iii) Any additional protective or safety equipment required by the manufacturers (e.g. safety shower or eye wash in near proximity, appropriately rated rescue kit).

(iv) Additional safety precautions (e.g. smoking, naked flame, fresh air flush, exclusion of heating devices, battery system voltage reduction through isolation devices to reduce d.c. arc flash risk).

Due to risks with short-circuit current on many battery systems, the use of any test metering across the system or subsets of the system shall include appropriate fusing or protection.

7.3.2 Maintenance tasks

The following items are examples of maintenance tasks to be undertaken regularly on a battery system:

(a) Review any system inspection checklists and take into account when planning maintenance procedures.

(b) Clean battery cells or modules and battery system enclosure—ensure free from vermin and debris.

(c) Check battery system’s terminals for secure connection and for any terminal growth, discolouration or corrosion.

(d) Check battery system voltages.

(e) Ensure the battery system’s switch-disconnectors operate safely and in accordance with their ratings.

(f) Inspect cabling to ensure there is no damage.

(g) Ensure all signage and labelling are in place.

(h) Inspect any ventilation to ensure this is meeting requirements.

(i) Review battery system operation and battery system state of health.

(j) Inspect battery cells or modules for any deformities or signs of extreme temperatures.

(k) Review any system logs (on line or via host computer) to review any abnormal operation.

(l) Check operation of any alarms.

(m) Thermal tests of d.c. switches and d.c. connections.

(n) Review torque of battery cell or module connections.

(o) Review specific gravity of battery cells or modules.

(p) Perform periodic maintenance on mechanical devices (fans or pumps).

(q) Perform a battery system test cycle.

(r) Perform battery cell or module impedance tests.

(s) Review any spill containment devices.

(t) Update safety sheet to ensure information contained is current and in any instance all details is up to date with contact details, and is replaced with latest version at least every 5 years.

(u) Review battery system in relation to other changes that may have taken place on site and how this may influence system performance and system safety.

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(v) Review any inspection information, review maintenance equipment.

(w) Update, review, test or certify any firefighting or fire detection devices installed as part of the battery system as required under legislation or to meet requirements of manufacturer.

7.3.3 Personnel protective equipment

The following personnel protection equipment for safe handling of the battery system and protection of personnel may be required in the maintenance of the battery system:

(a) Combination overalls (acid resistant).

(b) Dust coat (acid resistant).

(c) Bib apron (PVC).

(d) Boots (PVC or rubber).

(e) Gloves (PVC fabric base).

(f) Face shield or goggles.

(g) Breathing apparatus.

(h) Cal rated clothing to a suitable level.

7.3.4 Tools

The following tools for safe handling of the battery system and protection of personnel may be required in the maintenance of battery system:

(a) Cell lifting devices of adequate capacity.

(b) Insulated torque wrenches.

(c) d.c. rated meters.

(d) Insulated tools.

(e) Thermal imaging devices.

(f) Hydrometer.

(g) Impedance tester.

(h) Thermometers.

NOTE: There may be specific certification levels required for tools in relation to insulation levels or resistance to particular chemicals.

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S E C T I O N 8 D O C U M E N T A T I O N

8.1 GENERAL

At the completion of the installation of a battery system or a battery energy storage system, documentation shall be provided in accordance with the requirements of this section. This documentation shall ensure that key system information is readily available to customers, inspectors, maintenance service providers and emergency service personnel.

8.2 SYSTEM MANUAL

A manual, complete with the following items, shall be provided:

(a) Battery system information including:

(i) Total battery storage capacity.

(ii) Battery cell or battery system manufacturer.

(iii) Battery cell or battery system model.

(iv) Standards (Australian/New Zealand or international) to which products have been certified (e.g. UL 1973, IEC 62116 or as applicable).

(v) Australian/New Zealand address and contact details for the manufacturer representative (or deemed equivalent).

(vi) UN Code for the battery cell or battery system.

(vii) Description of battery chemistry.

(viii) Commissioning date.

(ix) Location of battery system including address of property and location within the property.

(x) Name and contact details of owner/operator.

(xi) Installer address and contact details.

(b) A complete list of installed equipment, with model description and serial numbers.

(c) System performance and operation configuration: system output performance including expected operating response based on programming, expected life of battery system (including information of state of health where provided by the system), end of life system parameters and expected operational life.

(d) Operating instructions (systems and components): a short description of the function and operation of all installed equipment.

NOTE: More detailed information should be available from the manufacturer’s documentation [see Item (j)].

(e) Operational instructions for response requirements to alarms including earth fault alarms, battery management system alarms, smoke alarms, ventilation alarms and any other alarms that may be required as part of the installation.

(f) Description of any state of health measurements, where provided.

(g) Shutdown and isolation procedure for emergency and maintenance that shall ensure safe de-energization of system components as required and to ensure battery system risk management where appropriate (see Clause 5.16).

(h) Start-up procedure.

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(i) Procedure for verifying the system’s correct operation and what to do in the case of a system failure. Details about alarm systems installed as part of the system and in addition to the system.

(j) Maintenance procedures and timetable: maintenance procedures, a checklist for the installed equipment and timetable for these tasks. This shall include hazard mitigation requirements for maintenance tasks.

(k) Commissioning records and installation checklist: A record of the initial system settings at the time of system installation and commissioning checklists for quality assurance (including documentation in accordance with commissioning Section 6).

(l) Warranty information: A statement of the system warranty period, any limitations and equipment warranties.

(m) System connection diagram: A diagram showing the electrical connections of the battery system with the PCE(s). All diagram labels shall match labels provided as per Section 5.

NOTE: In larger installations separate schematic circuit and wiring diagrams should be provided.

(n) Equipment manufacturer’s documentation, data sheets, safety data sheets for batteries and handbooks—for all equipment supplied. Where systems have an Ethernet or other form of data interface, all information on connection requirements and system operating manuals shall also be provided.

(o) Contact personnel for installation queries and system support.

(p) Design parameters by which the system design was carried out for system operation.

(q) Design parameters by which the system design was carried out for risk management (e.g. location requirements, ventilation requirements—for toxic fumes, explosive gas ventilation or cooling requirements, isolation requirements, voltage drop over battery system, etc.) including details of any specific additional devices provided (e.g. smoke detectors, firefighting equipment, personnel protective equipment, maintenance equipment, e.g. like a battery test kit with hydrolyser, face mask, etc.).

(r) Specific requirements to address all risks shall be documented, for example, the action to take when toxic fumes are present.

(s) List of any spare parts that have been provided (e.g. fuse replacement cartridges).

(t) Where required, copy of the notification provided to the relevant state-based ESS Hazardous Chemical Register Authority or other BESS system register to advise of required system information.

(u) Decommissioning information for battery replacement or battery removal (including recommendations for battery recycling).

Where multiple battery systems or BESS are installed within the one installation, documentation should be clear with consistent terminology.

8.3 SYSTEM AND BATTERY SYSTEM RECORD BOOK

The battery system manufacturer’s instructions shall advise the system owner/operator—

(a) how to maintain the battery system; and

(b) whether a record of the battery system’s performance over time is required separately or if this is managed by on-board devices or hosted devices.

The system owner/operator shall be provided with either—

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(i) a hard copy logbook or online access to an electronic copy logbook for ongoing recording of battery system operating parameters, system parameters and servicing frequency; or

(ii) a logbook function provided as part of the battery system’s battery management system (BMS). This logbook function shall be accessible via a host computer or an external device for the system owner and shall provide a historical record of battery health and operating parameters that have influence on the battery warranty.

The logbook function should record the battery system’s parameters periodically (at least monthly averages), for which examples are as follows:

(A) Number of cycles.

(B) Battery state of health.

(C) Voltages (maximum, minimum and mean for the interval).

(D) Temperatures (maximum, minimum and mean for the interval).

(E) Maximum charging and discharging currents.

(F) System continuity data, e.g. when and for how long the battery system had been disconnected from a charging source.

(G) Battery cell balancing history.

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APPENDIX A

DECISIVE VOLTAGE CLASSIFICATION (DVC)

(Informative)

The level of shock hazard is informed by the decisive voltage classification. If the battery is within the DVC-A voltage range, and the port to which it is connected is also DVC-A, then the battery is considered relatively safe from the point of view of electric shock but it still may constitute an energy hazard.

However, if the battery system voltage is within the DVC-A voltage range (e.g. 48 V) but the port to which it is connected is considered DVC-C, the whole battery system becomes DVC-C. The port may be classified as DVC-C simply because the PCE and hence the battery system, although of a DVC-A voltage, is effectively connected to DVC-C level voltage (via the grid or PV array with an open-circuit voltage Voc, rated at DVC-C.

The applicable DVC classification is always the highest classification applicable to any of the equipment connected to the battery system, even if the battery system itself is a lower classification.

The use of DVC port classifications therefore informs the designer/and or installer on the safety measures required to be implemented for the battery system, in terms of electrical protection and enclosures and interlocks.

Where the DVC classification of a port of a piece of equipment connected to a battery system is not available (as may be the case for a charge controller), consideration must be given to the technology of the piece of equipment. If the charge controller has an input voltage greater than DVC-A, and does not provide the equivalent of double insulation/separation between the battery port and the input voltage, the battery system must be classified to be a higher classification (e.g. DVC-B or DVC-C), according to the voltage classification of the input voltage of the charge controller.

If a battery system is either DVC-B or DVC-C it should be treated as an LV installation as defined in AS/NZS 3000.

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APPENDIX B

SAFETY SIGNS

(Informative)

B1 UN NUMBER IN BATTERY TYPE SIGN

The UN number refers to the type of chemical within the battery system. This number links to SAA/SNZ HB 76 which is used by first responders in the case of an emergency. SAA/SNZ HB 76 provides information on how to handle the hazard and respond. Table B1 provides the UN numbers for the most common battery types.

TABLE B1

UN NUMBER OF BATTERY TYPES

UN number Battery chemical type

UN 3480 Lithium ion (including ion polymer)

UN 3090 Lithium metal batteries

UN 2794 Flooded lead acid battery

UN 2800 Valve regulated lead acid battery

UN 3496 Nickel-metal hydride battery

UN 2794 Nickel cadmium battery

UN 3292 Sodium ion batteries

B2 TYPICAL SIGNS

ESUN No: 3480

NOTE: Insert UN number to suit battery type.

FIGURE B1 EXAMPLE SIGN FOR ENERGY STORAGE LABEL REQUIRED AT MAIN METERING PANEL AND MAIN SWITCHBOARD (SEE SECTION 5.3)

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EXHIBITION STREET

LIT

TL

E B

OU

RK

E S

TR

EE

T

TENANCY

TENANCY

EMERGENCY EVACUATION DIAGRAM

EXIT EXIT

Inver ter

LocationMain

Switchboard

Battery

System

Location

Fire stair AFire stair B

N

You are

here

EXITEMERGENCYEXIT

FIRE HOSEREEL

FIREHYDRANT

WARDENINTERCOM PHONE

MANUALCALL POINT

FIRE EXTINGUISHER(DRY CHEMICAL)

DON’T USELIFTS DURINGEMERGENCY

FIGURE B2 TYPICAL SIGN FOR BATTERY SYSTEM LOCATION TO BE PLACED AT THE MAIN METERING PANEL AND/OR FIRE/PANEL (SEE CLAUSE 5.4)

RESTRICTED ACCESSAUTHORIZED

PERSONNEL

ONLY

FIGURE B3 EXAMPLE SIGN FOR RESTRICTED ACCESS (SEE CLAUSE 5.5)

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PROTECTIVE

CLOTHING

MUST BE WORN

FACE SHIELD

MUST BE WORN

FIGURE B4 EXAMPLE SIGNS OF SPECIFIC PPE REQUIREMENTS (SEE CLAUSES 5.5, 5.9 AND 5.11)

BATTERY SYSTEM (specify location)

SHORT CIRCUIT CURRENT (specify) A

MAX DC VOLTS (specify) V

FIGURE B5 TYPICAL SIGN FOR BATTERY SYSTEM WITH VOLTAGE LESS THAN 600 V D.C. (SEE CLAUSE 5.6)

BATTERY SYSTEM (specify location)

SHORT CIRCUIT CURRENT (specify) A

MAX DC VOLTS (specify) V

HAZARDOUS d.c. VOLTAGE

FIGURE B6 TYPICAL SIGN FOR BATTERY SYSTEM WITH VOLTAGE GREATER THAN 600 V D.C. (SEE CLAUSE 5.6)

MULTIPLE BESS SUPPLIES

BESS # 1/4

SHORT CIRCUIT CURRENT A

MAXIMUM D.C. VOLTS V

FIGURE B7 TYPICAL SIGN FOR BATTERY SYSTEM HAVING MULTIPLE BESS’ INSTALLED WITHIN ONE ELECTRICAL INSTALLATION WHERE EACH INDIVIDUAL

BESS SHALL BE IDENTIFIED. FIGURE B7’S EXAMPLE SHOWS BESS #1/4, MEANING THIS IS BESS NO.1 OF A TOTAL OF 4 BESS. (SEE CLAUSE 5.6)

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RISK OF BATTERY EXPLOSION

DANGER

NO SMOKINGSPARKSFLAMES

FIGURE B8 EXAMPLE SIGN FOR EXPLOSION HAZARD (SEE CLAUSE 5.8)

TOXICFUMES

FIRE WILL CAUSE TOXIC FUMES

DANGER

FIGURE B9 EXAMPLE SIGN FOR TOXIC FUMES HAZARD (SEE CLAUSE 5.9)

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ELECTROLYTE BURNSImmediately wash affected area with plenty of water then...

SKIN BURNS1. If possible remove, or saturate

contaminated clothing

with water.

2. If patient is distressed, take

patient to doctor.

EYE BURNS1. Immediately wash eyes with large

amounts of water using

emergency eyewash bottle

2. All cases of eye burn, after

rendering first aid, take patient

immediately to a doctor.

NOTE: Doctor must be advised of type of burn(a) Lead/acid battery—dilute sulphuric acid electrolye.(b) Nickel/cadmium battery—potassium hydroxide alkali electrolyte.

PRECAUTION: 1. Always wear protective clothing when dealing

with electrolyte.

FIGURE B10 EXAMPLE SIGN FOR ELECTROLYTE BURNS (SEE CLAUSE 5.10)

WARNING!Arc Flash & Shock HazardAppropr iate PPEand tools requiredwhi le work ing on this equipment.

FIGURE B11 EXAMPLE SIGN FOR ARC FLASH HAZARD (SEE CLAUSE 5.11)

BATTERY SYSTEM

ISOLATOR

FIGURE B12 TYPICAL BATTERY SYSTEM ISOLATOR SIGN (SEE CLAUSE 5.12.2)

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WARNINGDO NOT DISCONNECT

UNDER LOAD

FIGURE B13 WARNING SIGN FOR ISOLATION SWITCHES FOR BATTERY SYSTEMS ABOVE DVC-A (SEE CLAUSE 5.12.4)

WARNING HAZARDOUS d.c.

VOLTAGE

FIGURE B14 EXAMPLE OF HAZARDOUS D.C. VOLTAGE >600 V LABEL (SEE CLAUSE 5.6)

BATTERY SYSTEM CIRCUIT

BREAKER AND

ISOLATING SWITCH

FIGURE B15 GENERAL INFORMATION FOR OVERCURRENT DEVICE LABELLING (SEE CLAUSE 5.13)

SHUTDOWN PROCEDURE

INSERT APPROPRIATESTEPS FOR

SAFE SHUTDOWN

In case of emergency call 000. For general system support call 1800 XXX XXX

FIGURE B16 SHUTDOWN PROCEDURE NOTICE (SEE CLAUSE 5.16)

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THIS ENCLOSURE IS PROTECTED

BY AN ABC AEROSOL FIRE

SUPPRESSION SYSTEM. OPEN

DOORS WITH CARE AND

VENTILATE COMPLETELY

AFTER DISCHARGE.

FIGURE B17 FIRE SYSTEM LABELLING (SEE CLAUSE 5.18)

IN THE EVENT OF LIQUID

DETECTED IN THE BUND,

USE LABELLED SPILL KIT

AND PPE TO REMOVE LIQUID.

REPORT FAILURE IMMEDIATELY

TO SUPPLIER

FIGURE B18 SPILL SAFETY SIGN LABELLING (SEE CLAUSE 5.19)

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APPENDIX C

METHOD OF DETERMINING INTERNAL RESISTANCE OF LEAD ACID BATTERIES

(Informative)

C1 SCOPE

This Appendix sets out a method of determining the internal resistance of a battery.

C2 PRINCIPLE

At least three lead acid cells are connected in series, allowed to stand in an open circuit condition, and then momentarily discharged at the 3 h rate and the 30 min rate.

C3 PROCEDURE

The procedure is as follows:

(a) Prior to testing, fully charge the battery and let stand in an open-circuit condition for a period not less than 12 h and not more than 24 h.

(b) Connect in series at least three cells, randomly selected from those under supply, and test them as one battery.

(c) At normal ambient temperature, discharge the battery at the 3 h rate (E1, I1) and hold momentarily, then increase current to the 30 min rate (E2, I2) and hold momentarily. Measure the overall terminal potential difference in volts at the respective currents.

(d) Calculate the internal resistance, in ohms, from the following equation:

1 2

2 1

E ER

n I I

. . . C1

where

R = internal resistance of a cell

E1 = battery terminal voltage at the 3 h rate of discharge

E2 = battery terminal voltage at the 30 min rate of discharge

n = number of cells in the battery

I2 = discharge current at the 30 min rate

I1 = discharge current at the 3 h rate NOTE: In order to obtain accurate and repeatable values, the readings needs to be taken rapidly with fast-responding instruments having an accuracy of not less than Class 1 or with suitable accurate high-speed recording equipment.

C4 REPORT

The report should contain the following:

(a) The internal resistance of a cell, in ohms.

(b) Reference to this test method, i.e. AS 5139, Appendix C.

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APPENDIX D

BARRIER REQUIREMENTS FOR BATTERY SYSTEMS WITH VOLTAGE GREATER THAN DVC-A

(Normative)

– +

> 2500 mm> 60 V

FIGURE D1 MINIMUM DISTANCE BETWEEN TERMINALS WHEN POTENTIAL DIFFERENCE GREATER THAN DCV-A

– +

Barr ier required to preventtouching greater than 60 V atany one t ime

< 2500mm> 60 V

FIGURE D2 BARRIER REQUIREMENTS

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APPENDIX E

MINIMUM CLEARANCES WITHIN BATTERY ROOMS (SHOWING TYPICAL LAYOUT)

(Normative)

(Layout based on unshrouded l ive sur faces)

Single row bat terySingle row bat tery

Dimensions in Mi l l imetres

- Terminal

Double row bat teryDouble row bat tery

Bat tery

Bat tery chargers andassociated equipment

1000 min.

1000 min.

60 V maximumwithout barr iers

1000 min.

25 min

25 min.

25 min.

60 V maximumsect ion vol tage

1000 min.

60 V maximumsect ion vol tage

Barr ier

Inter-rowbarr ier

See c lause 4.3.5.3

FIGURE E1 MINIMUM CLEARANCES IN BATTERY ROOM

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300 mm min.

FIGURE E2 CLEARANCES FOR FLOODED CELLS/BATTERIES

75 mm min.

FIGURE E3 CLEARANCES FOR OTHER TYPES

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APPENDIX F

SIZING EARTH CABLE EXAMPLE

(Informative)

F1 SIZING THE BATTERY EARTH CABLE

The earth cable in an earthed battery system should be sized according to AS/NZS 3000:2007 Clause 5.3.3.1.2, which states that the cable cross-sectional area is required to be determined either—

(a) from AS/NZS 3000:2007 Table 5.1 in relation to the cross-sectional area of the largest active conductor supplying the portion of the electrical installation to be protected; or

(b) by calculation in accordance with AS/NZS 3000:2007 Clause 5.3.3.1.3.

The cable to run from a battery to main battery fuse for a particular BESS has been selected. The ratings are as follows:

(i) Cross sectional area ....................................................................................... 70 mm2.

(ii) Cable type ................................................... flexible copper with R-HF-90 insulation.

(iii) Fuse .................................................................................................................. 160 A.

(iv) Minimum constant current carrying capacity ..................................................... 178 A.

F2 METHOD 1

The size of the earth cable can be determined by cross-referencing the size of the battery fuse cable in column 1 of Table 5.1 from AS/NZS 3000:2007. Column 2 of Table 5.1 shows that a 25 mm2 copper earth cable could be used.

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TABLE F1

MINIMUM COPPER EARTHING CONDUCTOR SIZE

Nominal size of active

conductor mm2

Nominal size of copper earthing conductor

mm2

With copper active conductors

With aluminum active conductors

1 1.5 2.5

1 1.5 2.5

— — —

4 6

10

2.5 2.5 4

— — —

16 25 35

6 6

10

4 6 6

50 70 95

16 25 25

10 10 16

120 150 185

35 50 70

25 25 35

240 300 400

95 120

120

50 70

95

500 630

120 120

95 120

F3 METHOD 2

The equation given in AS/NZS 3000:2007 Clause 5.3.3.1.3 for sizing an earth cable is as follows:

2 2S I t K . . . F1

where

S = cross-sectional area of protective earthing conductor, in mm2

I = the value of the fault current in amperes that would flow through theovercurrent device of the circuit concerned in the event of a short-circuit of negligible impedance

t = the disconnecting time of the overcurrent protective device in seconds, corresponding to the value of fault current I

K = factor dependent on the material of the protective earthing conductor, theinsulation and the start and finish temperatures of the earthing conductor

NOTE: Values for K come from Table 52 of AS/NZS 3008.1.1:2017.

For this example:

(a) I .................................................................................................................... 13000 A.

(b) t .......................................................................................................................... 0.1 s.

(c) K ......................................................................................................................... 159.

NOTE: Value for K is based on R-HF-110 insulation, copper conductors, start 60°C, finish 250°C.

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The CSA of the earth cable is then:

2

2

13000 13000 0.1

159

81.76 mm

S

. . . F2

From Table 5.1, a minimum 95 mm2 cable is required for the battery earth.

F4 SOLUTION

The size of the earth cable should be the larger of the result from each of the above methods. Therefore, the battery earth cable should have a CSA at least 95 mm2.

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APPENDIX G

BATTERY ENCLOSURES EXAMPLES FOR BATTERY TYPES CLASSIFIED AS EXPLOSION GAS HAZARDS

(Informative)

Examples of acceptable arrangements for housing and ventilation of batteries are shown in Figures G1 to G4. This is not an exhaustive set of possible arrangements.

Elevat ion

Plan

Elevat ion

Plan

Bat teryarea

Bat tery area

Wall

Wal l

100 mm





NOTES:

1 This is a dedicated battery system or BESS room that is secured to prevent unauthorised entry.

2 The Battery system or BESS room is ventilated externally.

Values for K come from Table 52 of AS/NZS 3008.1.1:2017.

FIGURE G1 TWO EXAMPLE BATTERY AREAS INSTALLED IN A DEDICATED EQUIPMENT ROOM SHOWING CLEARANCES FROM EQUIPMENT

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Note

*

Equipment room

Elevat ion

* Space overhead should be unenclosed or al low no hydrogen pockets to accumulate above

Enclosure for bat terywith ex ternal vent i lat ion

Bat tery enclosure

Plan

VentVent


600 mm

No equipment in th is space

600 mm


Vent

NOTE: The battery enclosure is ventilated externally

FIGURE G2 EXAMPLE BATTERY ENCLOSURE WITHIN A ROOM WHERE THE BATTERY ENCLOSURE IS VENTED TO OUTSIDE THE BUILDING

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Note 1

Bat tery enclosure

Electronic equipment

Air in lets

Air out lets(on rear)

NOTES:

1 The battery enclosure is vented externally

2 Cross flow ventilation

3 The battery and electronic inlet vents are on different sides to the outlet vents.

4 The barrier between battery enclosure and electronics is sealed to prevent hydrogen ingress.

FIGURE G3 EXAMPLE BATTERY ENCLOSURE WITH EQUIPMENT ENCLOSURE IMMEDIATELY ADJACENT

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Depth of enc losure not greater than 2 rows of cel ls or b locks

Sloping internal cei l ing ofenclosure designed to ensure al l hydrogen escapingfrom the bat tery is d irected to the ex ternal vent

Lengths of vents at least75% of the enclosure faceand central ly located

Bat tery enclosure withintake and out let ventson the same wal l

FIGURE G4 EXAMPLE BATTERY ENCLOSURE WITH THE INTAKE AND OUTLET VENTS ON THE SAME WALL

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APPENDIX H

INSTALLATION REQUIREMENTS

(Normative)

Bat terysystem

or BESS

Floor of bui ld ing

Floor barr ier shal l ex tend a minimum of600 mm of 60 minute f i re rated mater ia lfrom the lower ex tremity of the Bat terysystem or BESS

Barr ier of 60 minute f i re Rated Mater ia lprotect ing wal l: shal l ex tend for ver t ical height of 2 m minimum, i f ver t ical c learanceto eave less than 2 m, f i re barr ier shouldex tend to eave and cont inue outwards forminimum distance of 600 mm or to ex tremityof bui ld ing (whichever is less)

Top Fire Barr ier required i f ver t ical d istanceof 60 minute f i re rated mater ia l is less than2 m from top of Bat tery System or BESS

Top f i re barr ier at least 600mm from theex tremity of the bat tery system or width ofeave (whichever is less)

600 mm600 mm

FIGURE H1 GROUND-MOUNTED: FRONT VIEW AND 3D ASSEMBLY OF BATTERY SYSTEM OR BESS INSTALLED EXTERNALLY TO ANY BUILDING IN ACCORDANCE

WITH CLAUSES 4.5.3 AND 4.5.4

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Bat terysystem or BESS

Floor of bui ld ing

Wal l of bui ld ing

Floor barr ier shal l ex tend a minimum of 600 mm of 60 minute f i re rated mater ia l from the lower ex tremityof the Bat tery system or BESS

600 mm

600 mm

Barr ier of 60 minute f i re Rated Mater ia l protect ing wal l: shal l ex tend for ver t ical height of 2 m minimum,i f ver t ical c learance to eave less than 2 m, f i re barr iershould ex tend to eave and cont inue outwards forminimum distance of 600 mmor to ex tremity of bui ld ing (whichever is less)

Top Fire Barr ier required i fver t ical d istance of 60 minutef ire rated mater ia l is less than2 m from top of Bat tery Systemor BESS

Top f i re barr ier at least 600 mmfrom the ex tremity of the bat terysystem or width of eave(whichever is less)

FIGURE H2 GROUND-MOUNTED: SIDE VIEW OF BATTERY SYSTEM OR BESS INSTALLED EXTERNALLY TO ANY BUILDING IN ACCORDANCE WITH

CLAUSES 4.5.3 AND 4.5.4

Wall of bui ld ing


600 mm

600 mm 600 mm

Barr ier of 60 minute f i re Rated Mater ia l protect ing wal l; shal l ex tend for ver t ical heightof 2 m minimum

Barr ier of 60 minute f i re Rated Mater ia l on f loor below bat tery system to ex tend 600 mm aroundouter ex tremit ies ofBat tery System or BESS

FIGURE H3 GROUND-MOUNTED: PLAN VIEW OF BATTERY SYSTEM OR BESS INSTALLED EXTERNALLY TO ANY BUILDING IN ACCORDANCE WITH

CLAUSES 4.5.3 AND 4.5.4

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Wall of bui ld ing


600 mm

600 mm

FIGURE H4 PLAN AND FRONT VIEWS OF BATTERY SYSTEM OR BESS INSTALLED EXTERNALLY IN THE CORNER OF A BUILDING

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APPENDIX I

TYPICAL BATTERY STANDS

(Informative)

This Appendix shows typical cell arrangements only. The additional bracing required for seismic (earthquake) conditions is not shown.

FIGURE I1 SINGLE-ROW, SINGLE-TIER

FIGURE I2 DOUBLE-ROW, SINGLE-TIER

FIGURE I3 DOUBLE ROW, SINGLE TIER STEPPED

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FIGURE I4 SINGLE ROW, DOUBLE TIER

FIGURE I5 DOUBLE ROW, DOUBLE TIER

FIGURE I6 DOUBLE ROW, DOUBLE TIER STEPPED

FIGURE I7 PALLET STANDS

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APPENDIX J

DEGREES OF PROTECTION OF ENCLOSED EQUIPMENT

(Informative)

The degree of protection of an item of enclosed equipment is expressed as an IP (International Protection) rating, in accordance with AS 60529.

The ‘IP’ rating is usually written as ‘IP’ followed by two numbers and, sometimes, an additional letter. The first number, from 1 to 6, designates a degree of ‘protection against solid objects’, and ‘protection of persons against access to hazardous parts’. See Table J1 for guidance and examples.

The second number, from 1 to 8, designates a degree of ‘protection against entry of water with harmful effects’. See Table J2 for guidance and examples.

If a specific degree of protection is not designated, an ‘X’ is used instead of either one or both numbers.

The additional letter, from A to D, when used, designates a degree of ‘protection of persons against access to hazardous parts’. See Table J3 for guidance and examples.

On infrequent occasions, a supplementary letter, H, M, S or W, is used to designate special classes of electrical equipment. See Table J4 for additional guidance.

NOTES:

1 Figure J1 gives an example to facilitate the understanding of the IP code covered by AS 60529.

2 See AS 60529 for test results.

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TABLE J1

FIRST NUMERAL—PROTECTION AGAINST INGRESS OF SOLID OBJECTS

IP Requirements Example Protection of persons

against access to hazardous parts with

0 No protection Non-protected

1

Full penetration of 50 mm diameter sphere not allowed. Contact with hazardous parts not permitted

50

Back of hand

2

Full penetration of 12.5 mm diameter sphere not allowed. The jointed test finger has adequate clearance from hazardous parts

12.5

Finger

3 No penetration by access probe of 2.55 mm diameter

Tool

4 No penetration by access probe of 1.0 mm diameter

Wire

5 Limited ingress of dust permitted (no harmful deposit)

Wire

6 Totally protected against ingress of dust

Wire

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TABLE J2

SECOND NUMERAL—PROTECTION AGAINST INGRESS OF WATER

IP Requirements Example Protection from water

0 No protection Non-protected

1

Protected against vertically falling drops of water. Limited ingress permitted

Vertically dripping

2

Protected against vertically falling drops of water with enclosure tilted 15° from the vertical. Limited ingress permitted

Dripping up to 15° from the vertical

3 Protected against sprays to 60° from the vertical. Limited ingress permitted

Limited spraying

4 Protected against water splashed

Splashing from all directions

5 Protected against jets of water. Limited ingress permitted

Hosing jets from all directions

6 Protected against strong jets of water. Limited ingress permitted

Strong hosing jets from all directions

7 Protected against the effects of immersion between 15 cm and 1 m

15 cm min

Temporary immersion

8 Protected against long periods of immersion under pressure

Continuous immersion

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TABLE J3

ADDITIONAL LETTER (OPTIONAL)

IP Requirements Example Protection of persons

against access to hazardous parts with

A For use with numeral 0

Penetration of 50 mm diameter sphere up to barrier must not contact hazardous parts

50

Back of hand

B For use with numeral 0 and 1

Test finger penetration to a maximum of 80 mm must not contact hazardous parts

Finger

C For use with numeral 1 and 2

No contact of wire of 2.5 mm diameter 100 mm long with hazardous parts when spherical stop face is partially entered

Tool

D For use with numeral 2 and 3

No contact of wire of 1.0 mm diameter 100 mm long with hazardous parts when spherical stop face is partially entered

Wire

TABLE J4

SUPPLEMENTARY LETTER (OPTIONAL)

Letter Significance

H High voltage apparatus

M Tested for harmful effects because of the ingress of water when the movable parts of the equipment, e.g. the rotor of a rotating machine, are in motion

S Tested for harmful effects because of the ingress of water when the movable parts of the equipment, e.g. the rotor of a rotating machine, are stationary

W Suitable for use under specified weather conditions and provided with additional protective features or processes

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Code let ters(internat ional protect ion)

First character ist ic numeral(numerals 0 to 6, or let ter X)

Second character ist ic numeral(numerals 0 to 8, or let ter X)

Addit ional let ter (opt ional)( let ters A,B,C,D)

Addit ional let ter (opt ional)( let ters H,M,S,W)

IP 2 3 C H

NOTE: An enclosure with the designation (IP Code) IP23CH is interpreted as follows:

(2)

=

=

protects persons against access to hazardous parts with fingers; and protects the equipment inside the enclosure against ingress of solid foreign objects having a diameter of 12.5 mm and greater

(C) = protects the equipment inside the enclosure against the harmful effects because of water sprayed against the enclosure

(3) = protects persons handling tools having a diameter of 2.5 mm and greater and a length not exceeding 100 mm against access to hazardous parts (the tool may penetrate the enclosure up to its full length)

(H) = indicates that the equipment is high voltage apparatus

FIGURE J2 EXAMPLE OF ‘IP’ RATING

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APPENDIX K

FAULT CURRENT (SHORT-CIRCUIT) PERFORMANCE OF CABLES

(Informative)

K1 SCOPE

This Appendix covers the short-circuit maximum temperature rating of output conductors in a battery installation.

K2 BATTERY SHORT-CIRCUIT CURRENT

The requirements for a high discharge current for short periods have resulted in the development of cells with low internal resistance and high discharge current capability. A typical vented lead-acid stationary battery with a nominal capacity of 200 A.h is capable of delivering a short-circuit current of 2000 A.

The battery manufacturer should be consulted with regard to the sizing of battery short-circuit protection. If information regarding the short-circuit protection of a battery is not available from the manufacturer, the prospective fault level at the battery terminals should be considered to be 6 times the nominal battery capacity at the 120 h rate.

The short-circuit current rating of a battery consisting of strings of cells in parallel is the sum of the short-circuit current ratings of a group of cells comprising a single cell from each of the parallel branches. A monobloc battery consisting of a number of cells in series can be treated as a single cell for the purpose of determining short-circuit current rating.

K3 FACTORS GOVERNING THE APPLICATION OF THE TEMPERATURE LIMITS

The short-circuit temperatures given in Paragraph K6 are the actual temperatures of the current-carrying components as limited by the adjacent materials in the cable and are valid for short-circuit durations of up to 5 s. These temperatures will only be obtained in practice if non-adiabatic heating is assumed (i.e. if an appropriate allowance is made for heat loss into the dielectric during the short circuit) when calculating the allowable short-circuit current for a given time (not longer than 5 s). The use of the adiabatic method (i.e. when heat loss from the current-carrying component during the short circuit is neglected) gives short-circuit currents that are on the safe side. The 5 s period is the limit for the temperatures to be valid, not for the application of the adiabatic calculation method. The time limit for the use of the adiabatic method has a different definition, being a function of both the short-circuit duration and the cross-sectional area of the current-carrying component.

For thermoplastic insulating materials, the limits need to be applied with caution when the cables are either directly buried or securely clamped when in air. Local pressure due to clamping or the use of an installation radius less than 8 times the cable’s outside diameter, especially for cables that are rigidly restrained, can lead to high deforming forces under short-circuit conditions. Where these conditions cannot be avoided, it is suggested that the limit be reduced by 10°C. The limits quoted are based on average hardness grades of PVC and some adjustment may be necessary for other grades, especially those compounded for improved low-temperature properties. Li

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NOTES:

1 Caution should be exercised when using the limits recommended for thermosetting materials on large conductors because the high mechanical forces combined with any residual characteristics could result in deformation sufficient to cause failure.

2 Caution may be needed with total cross-sectional areas in the region of 1000 mm2 when using the conductor temperatures specified for impregnated paper, butyl, cross-linked polyethylene (XLPE) and ethylene propylene rubber (EPR) insulation and the cable is sheathed with a lower-temperature material.

3 Information on the short-circuit performance of mineral-insulated metal sheathed cables is not included in this Standard and reference should be made to the manufacturer’s instructions.

K4 CALCULATION OF PERMISSIBLE SHORT-CIRCUIT CURRENTS

The following adiabatic method, which neglects heat loss, is accurate enough for calculating permissible conductor and metallic sheath short-circuit currents for the majority of practical cases and any error is on the safe side. However, for thin screens, the adiabatic method indicates much higher temperature rises than actually occur in practice and thus needs to be used with some discretion.

The generalized form of the adiabatic temperature rise equation, which is applicable to any starting temperature is as follows:

2 2 2I t K S . . . K1

where

I = short-circuit current (r.m.s. over duration), in amperes

t = duration of short circuit, in seconds

K = constant depending on the material of the current-carrying component, the initial temperature and the final temperature

NOTE: Refer to Table K1 for values of constant (K).

S = cross-sectional area of the current-carrying component, in square millimetres NOTE: For conductors and metallic sheaths it is sufficient to take the nominal cross-sectional area but in the case of screens, this quantity requires careful consideration.

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10

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TABLE K1

VALUES OF CONSTANT K FOR DETERMINATION OF PERMISSIBLE SHORT-CIRCUIT CURRENTS

Initial temperature

of conductor

Constant (K)

Final temperature of conductor, °C

Copper Aluminium Lead Steel

°C 140 150 160 220 250 350 130 150 160 250 130 150 250 130 150 170

130 37.2 52.2 63.6 106 121 155 — 34.5 42.0 79.6 — 9.5 22.0 — 18.9 26.3

125 45.7 58.6 68.9 109 123 158 17.6 38.7 45.5 81.5 4.8 10.7 22.5 9.6 21.2 28.0

90 85.6 93.1 99.9 131 143 173 50.9 61.5 66.0 94.5 14.1 17.0 26.1 27.9 33.7 38.4

85 90.1 97.3 104 134 146 173 54.2 64.3 68.6 96.3 15.0 17.8 26.6 29.8 35.2 39.7

80 94.4 101 108 137 149 178 57.4 67.0 71.1 98.1 15.9 18.5 27.1 31.5 36.7 41.1

75 98.7 105 111 140 151 180 60.4 69.6 73.6 99.9 16.7 19.2 27.6 33.2 38.2 42.4

70 103 109 115 143 154 182 63.4 72.2 76.0 102 17.5 19.9 28.1 34.8 39.6 43.6

65 107 113 119 146 157 185 66.2 74.7 78.4 104 18.3 20.6 28.6 36.4 41.0 44.9

60 111 117 122 149 159 187 69.0 77.2 80.8 105 19.1 21.3 29.1 38.0 42.4 46.2

55 115 120 126 152 162 189 71.8 79.6 83.1 107 19.8 22.0 29.6 39.5 43.7 47.4

50 118 124 129 155 165 192 74.4 82.0 85.5 109 20.6 22.7 30.1 41.0 45.1 48.7

45 122 128 133 158 168 194 77.1 84.4 87.7 111 21.3 23.3 30.6 42.4 46.4 49.9

40 126 131 136 160 170 196 79.6 86.8 90.0 113 22.0 24.0 31.1 43.9 47.7 51.1

35 130 135 140 163 173 199 82.2 89.1 92.3 114 22.7 24.6 31.6 45.3 49.1 52.4

30 133 138 143 166 176 201 84.7 91.5 94.5 116 23.4 25.3 32.1 46.7 50.4 53.6

25 137 142 146 169 179 204 87.2 93.8 96.8 118 24.1 25.9 32.6 48.1 51.7 54.8

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K5 INFLUENCE OF METHOD OF INSTALLATION

When it is intended to make full use of the short-circuit limits of a cable, consideration should be given to the influence of the method of installation. An important aspect concerns the extent and nature of the mechanical restraint imposed on the cable. Longitudinal expansion of a cable during a short circuit can be significant and when this expansion is restrained the resultant forces are considerable.

Where cables are installed in air, provision should be made so that expansion may be absorbed uniformly along the length by snaking rather than permitting it to be relieved by excessive movement at a few points only. Fixings should be spaced sufficiently far apart to permit lateral movement of multi-core cables or groups of single-core cables.

Where cables are buried directly in the ground, or have to be restrained by frequent fixing, then provision should be made to accommodate the resulting longitudinal forces on terminations and joint boxes. Sharp bends should be avoided because the longitudinal forces are translated into radial pressures at bends in the cable route and these may damage thermoplastic components of the cable such as insulation and sheaths. Attention is drawn to the minimum bending radius specified by the appropriate installation regulations. For cables in air, it is also desirable to avoid fixings at a bend which may cause local pressure on the cable.

K6 MAXIMUM PERMISSIBLE SHORT-CIRCUIT TEMPERATURES

K6.1 General

Taking into account the recommendation given in Paragraph K3, the temperature values given in Tables K2 to K4 are—

(a) the actual temperatures of the current-carrying components; and

(b) the limits specified for short-circuits of up to 5 s duration.

K6.2 Insulating materials

The temperature limits given in Table K2 are for all types of conditions when in contact with the insulating materials specified.

TABLE K2

TEMPERATURE LIMITS FOR INSULATING MATERIALS IN CONTACT WITH CONDUCTORS

Material Temperature limit °C

Paper 250

PVC – V -75, zV-90 and V-105

– up to and including 300 mm 160

– greater than 300 mm 140

Elastomer and R75 200

XLPE and R-EP-90 250

Silicone rubber, R-S-150 350

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K6.3 Outer sheath and bedding materials

The temperature limits given in Table K3 are for the outer sheath and bedding materials comprising a continuous screen/sheath or a complete layer of armour wires. These temperatures are for materials where there is no electrical or other requirements necessary, i.e. screen/sheath/armour temperature limits when in contact with the outer sheath materials but thermally separated from the insulation by layers of suitable material of sufficient thickness. If thermal separation is not provided, the temperature limits of the insulation should be used if it is lower than that of the sheath.

TABLE K3

TEMPERATURE LIMITS FOR OUTER SHEATH AND BEDDING MATERIALS

Material Temperature limit °C

PVC – V-75, V-90 and V-105 200

Polyethylene 150

R-CPS-90 220

K6.4 Conductor and metallic sheath materials and components

The temperature limits specified in Table K4 apply to the conductor and metallic sheath materials and components.

NOTE: Limitations of materials in contact with these metals should also be considered.

TABLE K4

TEMPERATURE LIMITS FOR CONDUCTOR AND METALLIC SHEATH MATERIALS AND COMPONENTS

Metals Condition Temperature limit °C

Copper and aluminium

Conductor only* †

Welded joint †

Exothermic welded joint 250†

Soldered joint 160

Compression (mechanical deformation) joint

250‡

Mechanical (bolted) joint §

Lead 170

Lead alloy 200

Steel †

* Includes concentric neutral conductors † Limited by the material it is in contact with ‡ Temperature of adjacent conductor; actual joint will be at a lower temperature § Refer to manufacturer’s recommendations

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APPENDIX L

D.C. CIRCUIT PROTECTION APPLICATION GUIDE

(Informative)

L1 SCOPE

This Appendix provides guidance for the selection of circuit protection and switching devices which are operated on a d.c. supply that would be deemed to satisfy the design, equipment selection and installation criteria of this Standard.

L2 GENERAL

A d.c. supply is a constant or continuous current flow and to interrupt this current flow by a switch contact or over current device, a single contact with a very large air gap with good arc suppression or control is needed.

In order to make this air gap as large as possible, for voltages above 60 V d.c., the use of multiple switch contacts in series are often used.

L3 ARC SUPPRESSION

When a contact carrying d.c. current is opened, an arc is formed between each set of contacts as they are opened, and to increase the resistance of the arc and to reduce the current flow to zero as quickly as possible, an arc chute for each set of contacts is used to increase the length of the arc, cool the arc and to increase the arc resistance until the current flowing is reduced to zero.

In some devices, but not all, the use of a permanent magnet in each arc chute assembly is used to assist in drawing of the arc into the arc chute to increase the length and resistance of the arc until the current flow is reduced to zero.

L4 SWITCHGEAR TYPES

L4.1 Polarized

When the d.c. load current can flow in only one direction in normal or fault conditions, the use of polarized devices is possible.

Polarized devices are fitted with a permanent magnet to assist in the magnetic deflection of the arc into the switchgear arc chute to increase the arc length when the device contacts are opening. To be able to perform this deflection function, the magnetic field in the load carrying parts of the device should be such that the magnetic field of the magnet is arranged for the maximum deflection force. The correct external polarity connections of the device will ensure correct operation of the arc deflection forces.

A typical application of a polarized over current device is a distribution switchboard providing a supply to d.c. operated equipment. This configuration will only allow load current to flow in one direction.

L4.2 Non-polarized type

When it is possible that the d.c. load current could flow in either direction in normal or fault conditions, the use of non-polarized devices is necessary.

As the d.c. current is able to flow in two directions, this means a magnetic field from a fixed magnet is not able to be used.

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A typical application use of a non-polarized type device is a battery overcurrent device in which the current flow can be in two different directions; the battery charge current when being float charged, and the battery when being discharged by the load and when no output from the d.c. charging source is available.

L5 CERTIFIED D.C. RATINGS

L5.1 General

All d.c. isolating switches, contactors and overcurrent devices should be certified by the device manufacturer as being suitable for operation on a d.c. supply. The maximum current and voltage ratings specified by the manufacturer should not be exceeded and the multiple series contact arrangement detailed in the manufacturer’s instructions should be used.

For operating voltages above 60 V d.c. (ELV) this will usually require the use of two or more contacts in series to achieve the specified operating voltage and current ratings.

L5.2 Earthed d.c. supply

The d.c. supply may be operated as a separated (isolated) supply. All switching or overload devices should operate in all unearthed conductors; all multi-pole devices should be linked together so that all contacts will operate substantially together.

One pole of the d.c. supply may be earthed. Any switching device may operate in the unearthed conductor only.

Exception: A multi-pole device is permitted in all conductors (including the earthed conductor) in this application. All contacts should be linked together so that all contacts operate substantially together.

L6 PROVISION OF ISOLATION AND OVERCURRENT PROTECTION

The applicable requirements of Sections 2 to 4 of this Standard apply for the provision of isolation and over current protection of the d.c. system.

Exception: Earth leakage protection by use of RCDs is not required, as no suitable protection devices are currently available.

L7 SWITCHBOARD LOCATIONS

AS/NZS 3000 specifies requirements for the location of switchboards containing a main switch and over current devices.

L8 FINAL SUBCIRCUIT WIRING AND FITTINGS

All wiring for the direct current system should be suitable for use on a d.c. supply. The requirements for installation are specified in AS/NZS 3000 and Sections 3 and 4 of this Standard.

If twin cables are not used, all single cables should be positioned in close proximity of each other to provide cancellation of the magnetic field when d.c. current is flowing.

Segregation of 25 mm minimum should be maintained from all d.c. cabling to the a.c. wiring in switchboards and cabling within the installation.

The use of fittings designed solely for use on LV a.c. electrical installations only should not be used for d.c. installations.

All d.c. socket outlets should be provided with a d.c. rated control switch.

The plugs of a.c. operated equipment should not be able to enter socket outlets connected to the d.c. distribution system, or vice versa.

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NOTE: AS/NZS 3112 contains a specific plug and socket-outlet arrangement recommended for ELV applications.

Plugs and socket-outlets for SELV and PELV systems do not have an earthing contact or pin.

L9 INVERTERS

If the d.c. supply system has an inverter providing a 230 V a.c. supply output, unless the inverter a.c. output is not permanently marked as providing full electrical isolation from the d.c. input to the a.c. output, all parts of the d.c. supply system should be insulated and screened from touch for 230 V a.c. operation.

An inverter that does not provide for full electrical isolation between the d.c. input and a.c. output, is considered to be ‘transformer-less’ or a ‘non-isolated’ design, and under some fault conditions can result in the d.c. supply being raised to the potential of the a.c. output.

For a.c. only switch contacts and overcurrent device contacts, all contacts have a small air gap to ensure the a.c. arc supply current through the load current drops down to zero, twice for every cycle of the supply voltage until the arc is extinguished. The use of a.c. only contacts on a d.c. supply are unable to reduce the arcing that occurs with a d.c. supply current which increases the arc resistance to a point that no current flows. In many cases the arcing will cause the d.c. current to continue to flow, which may permanently destroy the a.c. only switch or overload the contacts.

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APPENDIX M

ARC FLASH CALCULATION

(Informative)

M1 OVERVIEW

Arc flash occurs when electrical current passes through the air between electrified conductors when there is insufficient isolation or insulation to withstand the applied voltage.

Currently NFPA 70E-2015 is the only international standard that provides guidance on d.c. arc flash. NFPA 70E-2015 Annex D summarizes calculation methods for calculating arc flash incident energy and arc flash boundaries. Two methods for d.c. arcs are provided:

(a) Maximum power methodology (Doan method).

(b) Detailed arcing current and energy calculation method (Ammerman method).

While both methods are accepted by the industry, the two methods yield different results. The Doan method is more widely used since it is easier to calculate, but considered conservative in incident energy estimations. The Ammerman method is more detailed and accurate in the calculation of incident energy compared with Doan, however the Ammerman equations cannot be easily solved.

Due to its ease in calculations, the Doan Method is used in this Standard. Further information on this method can be obtained from the Paper: ‘Arc Flash Calculations for Exposures to DC Systems’ by Daniel R Doan in the Publication: IEEE Transactions on Industry Applications, Volume 46 Number 6 November/December 2010.

The Doan formula for arc flash energy is provided below and it is then transposed to determine the arc flash boundary.

M2 ARC FLASH INCIDENT ENERGY

The arc flash incident energy for battery systems, having system voltages equal to or less than 1000 V d.c., is calculated using the following formula:

IEm = 0.01 Vsys Iarc (Tarc D2) MF . . . M1

where

IEm = estimated d.c. arc flash incident energy at the maximum power point in cal/cm2

Vsys = system voltage in volts

Iarc = arcing current in amps

Tarc = arcing time in seconds

D = working distance in cm


while

Iarc = 0.5 Ibf

where

Ibf = battery system prospective fault (short circuit) current in amps

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M3 ARC FLASH INCIDENT PROTECTION BOUNDARY

The arc flash protection boundary is the distance at which incident energy equals 5 J/cm2 (1.2 cal/cm2).

The arc flash protection boundary can be determined using the following equation:

AFB = SQRT (0.0083 Vsys Iarc Tarc MF) . . . M2

or

AFB = SQRT ((0.01 Vsys Iarc Tarc MF)/1.2)

where

AFB = arc flash protection boundary in cm

Vsys = system voltage in volts

Iarc = arcing current in amps

Tarc = arcing time in seconds


while

Iarc = 0.5 Ibf

where

Ibf= battery system prospective fault (short circuit) current in amps

M4 EXAMPLE CALCULATIONS

Example 1: No Fusing within the string

A 48 V battery system has a prospective fault current of 6 kA. There is no fusing within the battery string. When there is no string fusing, assume that the arcing time is 2 seconds.

Assume:

1 The working distance is 45 cm.

2 The system is located in an enclosure with a multiplying factor of 3.

Iarc = 0.5 Ibf . . . M3

= 0.5 6000 A

= 3000 A

The arc flash incident energy is:

IEm = 0.01 Vsys Iarc (Tarc/D2) MF . . . M4

= 0.01 48 3000 (2/452) 3

= 4.27 cal/cm2

The arc flash protection boundary is:

AFB= SQRT ((0.01 Vsys Iarc Tarc MF)/1.2) . . . M5

= SQRT ((0.01 48 300 2c 3)/1.2)

= 84.85 cm

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Example 2: Fusing within the string

This example uses the same system details as for Example 1, however this system has string fusing. The arc flash time would equal the clearing time by the fuse for the prospective fault current of 6000 A. This would be obtained by referring to the arcing time graphs for the particular fuse being used. For this example, assume it is 0.1 second, although in reality it would be less than this, possibly as low as 0.01 seconds.

The arc flash incident energy is:

IEm = 0.01 Vsys Iarc (Tarc/D2) MF . . . M6

= 0.01 48 3000 (0.1/452) 3

= 0.213 cal/cm2

The arc flash boundary is:

AFB= SQRT ((0.01 Vsys Iarc Tarc MF)/1.2) . . . M7

= SQRT ((0.01 48 3000 0.1 3)/1.2)

= 18.9 cm

Tables M1 to M4 provide incident arc flash energy and arc flash boundary distance for various voltages and fault current levels with and without inter-string protection.

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TABLE M1

ARC FLASH INCIDENT ENERGY AND ARC FLASH PROTECTION BOUNDARY DISTANCES FOR 24 V BATTERY SYSTEMS

Inter-string1 protection (see Note)

DC arc voltage

Bolted Fault current at point

of activity kA

Arcing time

seconds

Multiplying factor

Incident energy cal/cm2

Arc flash boundary

cm

No 24 3 2 3 1.067 42.43

24 6 2 3 2.133 60.00

24 9 2 3 3.200 73.48

24 12 2 3 4.267 84.85

24 15 2 3 5.333 94.87

24 18 2 3 6.400 103.92

24 21 2 3 7.467 112.25

24 24 2 3 8.533 120.00

24 27 2 3 9.600 127.28

24 30 2 3 10.667 134.16

Yes 24 3 0.1 3 0.053 9.49

24 6 0.1 3 0.107 13.42

24 9 0.1 3 0.160 16.43

24 12 0.1 3 0.213 18.97

24 15 0.1 3 0.267 21.21

24 18 0.1 3 0.320 23.24

24 21 0.1 3 0.373 25.10

24 24 0.1 3 0.427 26.83

24 27 0.1 3 0.480 28.46

24 30 0.1 3 0.533 30.00

NOTE: Bolted faults at the terminals to the battery system (prior to fusing or circuit-breaker protection) can be significantly reduced by inserting inter-string protection.

TABLE M2

ARC FLASH INCIDENT ENERGY AND ARC FLASH PROTECTION BOUNDARY DISTANCES FOR 48V BATTERY SYSTEMS

Inter-string

protection (see Note)

DC arc voltage

Bolted fault current at

point of activity

kA

Arcing timeseconds

Multiplying factor


Arc flash boundary

cm

No 48 3 2 3 2.133 60.00

48 6 2 3 4.267 84.85

48 9 2 3 6.400 103.92

48 12 2 3 8.533 120.00

48 15 2 3 10.667 134.16

48 18 2 3 12.800 146.97

48 21 2 3 14.933 158.75

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48 24 2 3 17.067 169.71

48 27 2 3 19.200 180.00

48 30 2 3 21.333 189.74

Yes 48 3 0.1 3 0.107 13.42

48 6 0.1 3 0.213 18.97

48 9 0.1 3 0.320 23.24

48 12 0.1 3 0.427 26.83

48 15 0.1 3 0.533 30.00

48 18 0.1 3 0.640 32.86

48 21 0.1 3 0.747 35.50

48 24 0.1 3 0.853 37.95

48 27 0.1 3 0.960 40.25

48 30 0.1 3 1.067 42.43

TABLE M3


Inter-string

protection

DC Arc voltage


point of activity

kA

Arcing time

seconds

Multiplying factor


Arc flash boundary

cm

No 120 3 2 3 5.333 94.87

120 6 2 3 10.667 134.16

120 9 2 3 16.000 164.32

120 12 2 3 21.333 189.74

120 15 2 3 26.667 212.13

120 18 2 3 32.000 232.38

120 21 2 3 37.333 251.00

120 24 2 3 42.667 268.33

120 27 2 3 48.000 284.60

120 30 2 3 53.333 300.00

Yes 120 3 0.1 3 0.267 21.21

120 6 0.1 3 0.533 30.00

120 9 0.1 3 0.800 36.74

120 12 0.1 3 1.067 42.43

120 15 0.1 3 1.333 47.43

120 18 0.1 3 1.600 51.96

120 21 0.1 3 1.867 56.12

120 24 0.1 3 2.133 60.00

120 27 0.1 3 2.400 63.64

120 30 0.1 3 2.667 67.08

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TABLE M4


Inter-string

protection

DC arc voltage


point of activity

kA

Arcing time

seconds

Multiplying factor


Arc flash boundary

cm

No 350 3 2 3 15.556 162.02

350 6 2 3 31.111 229.13

350 9 2 3 46.667 280.62

350 12 2 3 62.222 324.04

350 15 2 3 77.778 362.28

350 18 2 3 93.333 396.86

350 21 2 3 108.889 428.66

350 24 2 3 124.444 458.26

350 27 2 3 140.000 486.06

350 30 2 3 155.556 512.35

Yes 350 3 0.1 3 0.778 36.23

350 6 0.1 3 1.556 51.23

350 9 0.1 3 2.333 62.75

350 12 0.1 3 3.111 72.46

350 15 0.1 3 3.889 81.01

350 18 0.1 3 4.667 88.74

350 21 0.1 3 5.444 95.85

350 24 0.1 3 6.222 102.47

350 27 0.1 3 7.000 108.69

350 30 0.1 3 7.778 114.56

The tables above illustrate that the addition of appropriate inter-string and battery system terminal protection can significantly influence the level of incident energy potential from an arc event.

M5 EFFECTS BY DIFFERENT FAULTS

The calculations above and the Tables M1 to M4 are all based on the fault occurring where the battery system voltage is applied to the arc. Figures M1 to M3 provide the actual voltages and currents that would be applied to the arc flash incident energy calculations for different types of faults for three scenarios:

(a) Figure M1—No protection.

(b) Figure M2—String protection.

(c) Figure M3—String and inter-string protection.

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Str ing 1

Str ing 2

Str ing M

Cel lmodule

3

Cel lmodule

N

Cel lmodule

2

Cel lmodule

1

Cel lmodule

3

Cel lmodule

N

Cel lmodule

2

Cel lmodule

1

Cel lmodule

3

Cel lmodule

N

Cel lmodule

2

Cel lmodule

1

DC

bu

s

S tr ing Faul tSame as DC bus faul t

DC Bus Faul tVarc = DC bus vol tageIarc = Summation of string fault currentsTarc = 2 seconds (no c lear ing device)

Single cel l /module faul tVarc = Cel l /module vol tageIarc = Cel l module faul t currentTarc = 2 seconds (no c lear ing device)

Mult ip le Cel l /Module Faul tVarc = Voltage of number cells/modulesIarc = M × str ing faul t currentTarc = 2 seconds (no c lear ing device)

FIGURE M1 EXAMPLES OF VARIOUS FAULTS WITH NO PROTECTION

Str ing 1

Str ing 2

Str ing M

DC

bu

s

DC bus faul tVarc = DC bus vol tageIarc = Summation of string fault currentsTarc = Clearing time of protective device

Str

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pro

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Str

ing

pro

tec

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nd

ev

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Str

ing

pro

tec

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nd

ev

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Mul t ip le cel l /module faul t

Cel lmodule

3

Cel lmodule

N

Cel lmodule

2

Cel lmodule

1

Cel lmodule

3

Cel lmodule

N

Cel lmodule

2

Cel lmodule

1

Cel lmodule

3

Cel lmodule

N

Cel lmodule

2

Cel lmodule

1



Str ing faul t (on bus s ide of protect ion device)Same as DC bus faul t

Str ing faul t (on str ing s ide of protect iondevice) Assume the worst case inc identenergy wi l l be from the str ing and wi l ldominate the contr ibut ion from the DC bus.Varc = Str ing faul tIarc = Str ing faul t currentTarc = 2 seconds (no c lear ing device)

FIGURE M2 EXAMPLES OF VARIOUS FAULTS WITH STRING PROTECTION

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Str ing 1

Str ing 2

Str ing M

DC

bu

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DC bus faul tVarc = DC bus vol tageIarc = Summation of string fault currentsTarc = Clearing time of protection device

Str

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Mul t ip le cel l /module faul tM

id-s

trin

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Mid

-str

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pro

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ev

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Mid

-str

ing

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3

Cel lmodule

N

Cel lmodule

2

Cel lmodule

1

Str

ing

pro

tec

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nd

ev

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Str

ing

pro

tec

tio

nd

ev

ice

Cel lmodule

3

Cel lmodule

N

Cel lmodule

2

Cel lmodule

1

Cel lmodule

3

Cel lmodule

N

Cel lmodule

2

Cel lmodule

1


Mult ip le cel l /module faul tVarc = Voltage of number cells/modulesIarc = M x str ing faul t currentTarc = 2 seconds (no c lear ing device)

Str ing faul t (on bus s ide of protect ion device)Same as DC bus faul t

Mid-Str ing faul tAssume the worst case inc ident energy wi l l be fromthe str ing and wi l l dominate the contr ibut ion from the DC bus.Varc = Str ing faul t / 2Iarc = Str ing faul t currentTarc = 2 seconds (no c lear ing device)

FIGURE M3 EXAMPLES OF VARIOUS FAULTS WITH STRING AND INTER-STRING PROTECTION

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APPENDIX N

RISK ASSESSMENT

(Informative)

N1 SAFETY RISK ASSESSMENT FOR BESS AND BATTERY SYSTEMS

N1.1 General

This Appendix provides guidance regarding a qualitative approach to risk assessment relating to the safety of BESS and Battery Systems; to ensure not only that measures are put in place and considered as part of the safe installation of the BESS, but also for the life of the system. A risk assessment is an analytical process intended to ensure that safety hazards are properly identified and analysed with regard to their consequence and the likelihood of their occurrence. Appropriate protective measures can then be implemented and maintained. The risk assessment should include a comprehensive review of the hazards, the foreseeable tasks, and the protective measures that are required in order to maintain a tolerable level of risk including the following:

(a) Identifying and analysing hazards.

.1.a.i.A.1 Identifying tasks to be performed.

(b) Documenting hazards associated with each task.

(c) Estimating the risk for each hazard/task pair.

(d) Determining the appropriate protective measures needed to reduce the level of risk to as low as reasonably possible.

Risk assessment is a necessary factor at all stages of a battery system’s life; design and installation, as well as operation, maintenance through to decommissioning. Appropriate information needs to be supplied by the customer, product manufacturers and suppliers for the risk assessment to be comprehensive. Whilst this Standard covers typical hazards associated with the installation of a battery system or BESS, if there are other hazards particular to the location or the type of system being installed, these should also be included. The examples in Paragraph N2 relate to the installation of the battery system itself; it would be considered advisable that the risk assessment include appropriate additional standards and the local workplace health and safety regulations with respect to development of a risk assessment for the entire installation (be it a full BESS), and the incorporation of other parts such as a photovoltaic (PV) array. Appropriate work method statements/job safety analysis should be part of the installation and maintenance of battery systems and should be specifically referred to as part of the control measures in any risk management and used for installation works.

N1.2 Risk assessment principles for battery systems

A hazard is any source of potential damage, harm or adverse health effects on a person, property of the environment. Hazards arise from the physical work environment, equipment and materials used, work tasks and how they are performed, work design and management.

A risk is the possibility or likelihood that harm might occur when exposed to the hazard and the severity of that harm. The risk is a measure of the consequence and the likelihood—the likelihood of injury, illness or damage to property or the environment arising from exposure to hazards. A risk assessment allows us to identify risks from hazards in a workplace or work process and helps use to determine:

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(a) The severity of the risk.

(b) Whether existing control measures are effective.

(c) What action needs to be taken to control, monitor and review the risk.

Control measures are undertaken to reduce the risk to an acceptable level—as low as reasonably practicable. In battery systems and electrical systems it is not possible to eliminate all risks and we can not prevent people from making mistakes. We therefore apply as many controls as reasonably practicable to minimize the potential for harm, balancing the implementation of controls against the benefits received in mitigating a risk to a level consistent with risk appetite or acceptability. Once the control methods have been put in place, it is important to monitor and review implemented controls to evaluate their effectiveness.

Likelihood and consequence measures may be different for different situations and the requirements of a particular site may need to be incorporated into the risk assessment process. For the purposes of the examples in Paragraph N2, the consequence Table N1 is used as an example to grade the impact levels in relation to hazards. Table N2 describes the levels of expected likelihood used for the purposes of this series of typical risk assessments.

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TABLE N1

TYPICAL RISK CONSEQUENCE TABLE

Consequence/impact category

Consequence/impact rating definitions

Catastrophic Major Moderate Minor Insignificant

Health and safety Any fatality of staff, contractor or public

Non-recoverable occupational illness or permanent injury

Injury or illness requiring medical treatment by a doctor

Injury requiring first aid No or minor injury

Injury or illness requiring admission to hospital

Dangerous / reportable electrical incident

Circumstances that lead to a near miss

Environmental High, long term or widespread impact (spill, emission, or habitat disturbance) to sensitive environment (national park, world heritage listed area, site of special significance, potable water)

Substantial impact—large spill or emission not contained on site or requiring Emergency Services attendance

Moderate impact—Spill or emission not contained on site with clean up needed

Minor cleanup/rectification—spill or emission not contained on site

Small spill or emission that has no impact on site or installation

Environmental agency response with significant fine

Major loss of habitat or impact on biodiversity

Death or destruction of protected flora or fauna Minor impact on biodiversity

Clean up requires no special equipment and has no potential impact

Long term recovery of environment to pre-incident state not likely

Any spill into sensitive area (wet tropics, fish habitat, potable water supply)

Environment likely to recover to pre-incident state in short to medium term

Environmental nuisance (short term impact) caused by noise, dust, odour, fumes, light

Recovery of environment likely but not necessarily to pre-incident state

Environment expected to fully recover to pre-incident state

Financial Impact to 100% or more of the value of the project or property

Impact to at least 50% or more of the value of the project or property



Impact to at least 0.5% to 2% of the value of the project or property

(continued)

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Consequence/impact category

Consequence/impact rating definitions

Catastrophic Major Moderate Minor Insignificant

Reputation Extremely critical and sustained negative publicity

Reputational consequences for company

Community or customer outrage

Negative questions at industry, council or government level

Public awareness may exist but there is little public concern

Legal action Intense community action External agency involvement (e.g. ACCC)

Adverse local media reports Customer issue easily resolved

Highly critical and sustained negative publicity

Sustained negative publicity and media coverage

Local issue resolved promptly

Legal and regulatory

Loss of operating licence

Breach of licences, legislation or regulations leading to prosecution

Breach of licences, legislation or regulations leading to:

Breach of licences, legislation, regulations, policies or guidelines leading to:

Breach of licences, legislation regulations, policies or guidelines leading to an administrative resolution

No issues

(a) Contravention notice from authorities; or

(a) Warning Notice, or

(b) Court order; or (b) Fine of up to $1000; or

(c) Fine over $1000 (c) Enforceable

Undertakings

Asset impact Equipment destruction, repair not possible, asset repair greater than original cost of works

Equipment damage repaired at a cost of between 50% and 100% of original cost of works



Simple equipment damage with no or same day repair at a cost of less than 2% of original cost of works

TABLE N1 (continued)

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The following likelihood table (Table N2) is provided as an example of definitions of likelihood of occurrence ratings.

TABLE N2 LIKELIHOOD OF OCCURRENCE RATING

Likelihood rating Definition of likelihood of occurrence rating

Almost certain Probability of occurrence—greater than 90%

Expected to occur whenever system is accessed or operated

The event is expected to occur in most circumstances

Likely Probability of occurrence—60% – 89%

Expected to occur when system is accessed or operated under typical circumstances

There is a strong possibility the event may occur

Possible Probability of occurrence—40% – 59%

Expected to occur in unusual instances when the system is access or operated

The event may occur at some time

Unlikely Probability of occurrence—20% – 39%

Expected to occur in unusual instanced for non-standard access or non-standard operation

Not expected to occur, but there is a slight possibility it may occur at some time

Rare Probability of occurrence—1% – 19%

Highly unlikely to occur in any instance related to coming in contact with the system or associated systems

Highly unlikely, but it may occur in exceptional circumstances, but probably never will.

And finally, the level of risk is a measure of the consequence and the likelihood. Table N3 demonstrates the outcome of these measures. Generally it would be recommended that where an inherent risk (a risk prior to the implementation of control measures) is greater than very low, that this risk be reviewed to determine what control measures can be put in place to reduce the risk (this is considered the residual risk). Residual risks that remain greater than ‘low’ should be discussed with the system owner and operator and anyone involved in the installation of the system. The risk assessment and risks management processes are to be documented with this information kept as part of the system operating manual (Section 8). The following five level risk matrix (Table N3) should be used for the purposes of any risk assessment.

TABLE N3 RISK MATRIX TABLE

Consequence (how serious)

Likelyhood (how often)

Rare Unlikely Possible Likely Almost certain

Catatropic Medium High High Extreme Extreme

Major Medium Medium High High Extreme

Moderate Low Medium Medium High High

Minor Very low Low Medium Medium Medium

Insignificant Very low Very low Low Medium Medium

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Adopted control measures should consider the most effective options, starting with elimination and ending with personal protective equipment. The most effective way to manage a risk is to remove the risk entirely. As this is often not possible, the hierarchy of control measures suggest the next most appropriate methods of control. See Figure N1.

Inc

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e c

on

tro

l

EliminationRemove danger

completely

SubstitutionUse al ternat ives that do

not have the r isk

Engineering Controls / IsolationSeparate hazard or design to protect

people from hazard

Administrat ive ControlsTraining, s ignage, instruct ions

Personal Protective EquipmentGloves, aprons, safety g lasses, Cal rated c lothing

FIGURE N1 CONTROL MEASURES AND EFFECTIVENESS

To conduct the risk assessment for a BESS or battery system installation, a description of the BESS or battery system is required including general characteristics such as:

(i) Battery chemistry, battery system voltage, short circuit current of the battery and battery system, DVC characteristics considerate of the PCE, operating options/modes of PCE.

(ii) Application type—stand-alone or grid connected.

(iii) Installation—location, environmental factors, enclosures, site.

(iv) Protection and isolation measures.

The risk assessments should consider aspects dealt with in design, installation (including commissioning) and ongoing operation and maintenance, as each area may require specific risk controls.

N2 RISK ASSESSMENT EXAMPLES

N2.1 Example 1—Domestic installation

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TABLE N4 EXAMPLE 1: DESIGN PARAMETERS

Battery system installation: 2 packaged battery systems (each package contains batteries, monitoring/control system and BMS)—individual batteries are not serviceable/accessible

Battery type: Lithium iron phosphate (fire hazard level 1)

Nominal system voltage: 48 V

Maximum system voltage: 57.5 V

Prospective short circuit current rating per unit:

12 kA

PCE battery port rating: 60 V d.c. (DVC-A) electrically isolated from grid

Electrical connection: Two strings in parallel

Earthing: Floating battery bank, metal enclosure earthed

Enclosure: Both units installed within a fire rated enclosure (60/60/60) in a carport detached from domestic residence (>1 m)

Metal cabinet, powder coated against corrosion, elevated floor for battery mounting away from concrete, lockable with double front opening doors for full access to individual battery system packages, enclosure designed to ingress protection level IP33

Approval of design for enclosure approved by battery system manufacturer to suit ventilation, mounting and installation requirements

Enclosure secured to floor and rear wall of car port

Overall battery enclosure weight: 190 kg

String isolation: Using switch disconnector circuit breakers on each string installed in labelled circuit panel mounted on external wall of battery enclosure

Installation location: Out of sun and weather, in Brisbane Queensland. Enclosure floor mounted on existing concrete floor. Ceiling to carport has overhead fluorescent lighting and during day there is good natural lighting

Arc flash considerations: Enclosure multiplying factor of 3

Arc flash potential per unit 9.9 cal/cm2

Circuit breaker response time 0.05 seconds (max)—from time/current response curve particular to the chosen circuit breaker

There is no possibility for inter-string protection. Each unit has a circuit breaker installed adjacent to the battery system terminals and these circuit breakers are separated by a distance of over 500 mm.

Specific design considerations for this installation:

Protection against potential car impact using bollards

The PCE is mount adjacent and to the side of the battery enclosure. The PCE is mounted directly on the wall to manufacturer’s requirements

Voltage drop design less than 2% based on full rated inverter current and the potential for only one battery string to be operational

Cabling to each system is of same impedance (same length and same size cable)

System installed with good access for trolleys and clearance for working

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Following is the d.c. arc fault calculations considerate of the various access and activities possible for this system.

TABLE N5

EXAMPLE 1: LITHIUM BATTERY ARC FAULT SCENARIOS

Work activity (see Figure N2)

Detail of possible worst

case fault contribution

DC arc flash parameters

Maximum power

method (doan)

Risk rating

DC arc voltage


point of activity kA

Arcing time

second

Multi-plying factor


Consequence Likelihood Risk Arc flash boundary

cm

Arc flash PPE

required? Controls to implement

Fault 1—Work external to enclosure between system circuit breaker and PCE—possible d.c. bus short

Full fault contribution from both strings. String and system circuit breakers act to reduce arc fault incident energy

57.5 24.00 0.05 1 0.17 Insignificant Unlikely Very low 16.96 No Isolation of batteries by string and system circuit breakers will remove this risk. Where live work is required, circuit breakers provide significant protection from arc fault. Standard electrical practices should be used. No specific further arc flash mitigation controls required. Whilst working external to battery enclosure, doors to enclosure should remain closed

Fault 2—Work external to enclosure between system circuit breaker and string circuit breakers—possible d.c. bus short

Full fault contribution from both strings. String circuit breakers act to reduce arc fault incident energy

57.5 24.00 0.05 1 0.17 Insignificant Unlikely Very low 16.96 No

(continued)

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Maximum power

method (doan)

Risk rating

DC arc voltage



Arcing time

second

Multi-plying factor



cm

Arc flash PPE


Fault 3—Work internal to enclosure on load side of string circuit breaker—possible d.c. bus short

Fault contribution from both strings as strings not isolated

57.5 24.00 0.05 3 0.50 Insignificant Rare Very low 29.37 No Prior to commencement of work within the enclosure, the system circuit breaker should be opened. Upon opening the enclosure, the string circuit breakers should be opened. To operate string circuit breakers within the enclosure PPE level 3 is required. Where live work is required as there is no ability to rule out worst case faults, PPE level 3 is required. Insulated tools must be used. Standard electrical practices should be used

Fault 4—Work internal to enclosure on load side of string circuit breaker—possible d.c. short

Fault contribution from only one string as strings isolated

57.5 12.00 0.05 3 0.25 Insignificant Unlikely Very low 20.77 No

Fault 5—Work internal to enclosure on load side of string circuit breaker—possible connection between two battery strings

Requires two faults to exist and dependent where these fault are, the worst case is depicted

57.5 24.00 0.05 3 0.50 Insignificant Rare Very low 29.37 No

(continued)


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Maximum power

method (doan)

Risk rating

DC arc voltage



Arcing time

second

Multi-plying factor



cm

Arc flash PPE


Fault 6—Work internal to enclosure on battery side of string circuit breaker—possible d.c. bus short

Fault contribution from one battery system with no acknowledged fault protection device

57.5 12.00 2 3 9.91 Major Unlikely Medium 131.34 Yes

Fault 7—Work internal to enclosure and experience fault within the pre-packaged battery system

Fault contribution from one battery system with no acknowledged fault protection device

57.5 12.00 2 3 9.91 Major Rare Medium 131.34 Yes


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Figure N2 provides a typical circuit diagram showing the battery connections and potential scenarios for arc flash as described in Table N5.

Str ing 1Str ing 1

Str ing 2Str ing 2Faul t 7

Faul t 5

Faul t 6

Faul t 3(no isolat ion)

Faul t 3(no isolat ion)

Faul t 2

Faul t 1

PCE+ – + – + –

+ – + – + –

Lockable fire rated bat tery enclosureLockable fire rated bat tery enclosure

Fault 4(one str ing isolated)

Faul t 4(one str ing isolated)

FIGURE N2 EXAMPLE 1: TYPICAL CONFIGURATION AND POSSIBLE D.C. ARC FAULT SCENARIOS

The risk assessment (Table N6) has been developed and references the particular hazards as may be applicable in the installation, as specified in this Standard. Additional requirements under individual workplace and regulatory requirements should not be substituted by this matrix. Inherent risk and residual risk measures are qualitative assessments.

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TABLE N6

EXAMPLE 1: RISK ASSESSMENT

Tasks (inherent risk level) Hazard Control measures Clause

referencesResidual

consequence Residual

likelihood

Residual risk (after control

measures implemented)

Installation—key hazards in installation are electrical, energy, fire, toxic gasses and mechanical

Installation competence general (high)

General Installation carried out by licenced persons with additional appropriate accreditation and training in the products being installed

4.2.1 Insignificant Rare Very low

Lifting heavy items

(high) Mechanical

Lifting equipment used

Work practices set out requirements for manual handling

Two men lift where appropriate

4.8 Minor Possible Medium

Installation environment general

(medium) Work practices

Fan used

Breaks taken

Manage rest vs work time

Shaded, cool area for breaks

Cold water available on site

General work practices

Insignificant Unlikely Very low

Electrical work

(high) Electrical and energy

De-energize where possible

LV rescue kit on hand for live work

Work procedure requires 2 persons attending for any live work including d.c. connections from battery systems.

Batteries are always live but system has recessed terminals and terminal covers that will be used during installation work

Appropriate system design—see Table N4

Adopt arc flash control measures noted in Table N5

Work practices are in place for all electrical work

General electrical practice

4.3 and 4.4

Minor Unlikely Low

(continued)

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referencesResidual


likelihood



Working with tools and equipment that may cause sparks or fire

(medium)

Fire hazard

No arc producing tools used with battery enclosure open

Debris to be removed prior to installation and ongoing through install process

Emergency phone on hand

SDS located at worksite throughout installation for reference

4.5 Minor Rare Very low

Work in battery enclosure

(low)

Toxic gas/chemical hazard

Prior to any work, open room and ventilate in case of toxic gas build up (for at least 2 minutes)

Check external vents prior to entering to ensure no blockages

Check for odd odours upon enter, if unsure, ventilate further


Install battery systems

(medium)

Mechanical /general/chemical hazard

All batteries inspected for any cracks, dents, deformations or splits in casing at the time of installation.

Where cracks or splits, items removed and handled with appropriate PPE protection

4.1, 4.6 and 4.8

Insignificant Rare Very low

Maintenance and General Operation

Replacement of battery or PCE (high)

Mechanical





Shutdown of system in the case of external incident or hazard

(high)

External

Signage includes safety shutdown notice and various warning signage

Instruction on safe shutdown provided to system owner

Phone number provided for assistance if required

SDS located within site switchboard

System owner informed of safety considerations for the system

Section 5 Moderate Rare Low

(continued)


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referencesResidual


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Electrical maintenance





Batteries are always live but system has recessed terminals and terminal covers that will be used during maintenance work




4.3, 4.4.and general electrical work practice

Minor Unlikely Low

Maintenance with tools and equipment that may cause sparks or fire

(medium)

Fire hazard


Debris to be removed as part of maintenance



4.1 and 4.5 Minor Rare Very low

Work in battery enclosure Toxic gas/chemical hazard

Prior to any work open room and ventilate in case of toxic gas build up (for at least 2 minutes)




Replace battery system

(medium)

Mechanical /general/chemical hazard

All batteries inspected for any cracks, dents, deformations or splits in casing


4.1, 4.6 and 4.8



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N2.2 Example 2—Stand-alone power supply for rural property

TABLE N7

EXAMPLE 2: DESIGN PARAMETERS

Battery system installation:

120 2 V VRLA battery cells (dimensions 180 mm (w) 250 mm (d) 700mm (h))

Battery type: Valve regulated lead acid batteries (fire hazard level 2). No BMS or additional control other than the PCE is required. Voltage sense leads and two battery temperature monitoring leads are installed between the battery banks and the PCE.

Nominal system voltage: 120 V

Maximum system voltage:

141 V (or 2.35 V per cell)

Prospective short circuit current rating per string:

6 kA

PCE battery port rating: DVC-C

Electrical connection: Two parallel strings each with 60 batteries

Earthing: Floating battery bank, metal battery stands earthed

Installation:

Purpose built rooms in segregated part of shed (other areas are used for vehicles and a mechanical workshop) with lockable doors. There are no facilities for this shed to be a living space. The system is well within the boundaries of the property and at least 10 metres away from the domestic dwellings on the site. Both rooms are protected from weather and any direct sunlight, insulated to reduce heat gain from the exterior and with a concrete slab floor. The batteries are installed in a separate room from balance of systems equipment. Venting of battery room is directly to exterior. Inverter and solar regulator installed in balance of systems room. Main single isolator between PCE and battery bank also installed in balance of systems room.

Battery room:

Metal frames (earthed) with wooden bases elevating battery bases away from concrete, access doors provide 1200 mm wide opening for ease of access for bringing trolley/pallet jack in. Walls and ceiling insulated (using reflective foil) to reduce heat variability. Venting is natural with vents having screens to reduce possibility for vermin to enter. Vent size calculations take into account reduced air movement due to input and output air screens and some potential dust build up. Batteries are mounted vertically, with central aisle, one string installed on each wall, batteries are 2 cells deep against each wall. Terminal covers are divided such that access is based on the 40 V blocks for servicing. The battery room walls and ceiling are lined with 60 minute fire rated materials. Lighting mounted above the aisles in the battery room. Racks do not have support sides due to additional risks that this raises in manual handling.

Overall battery enclosure weight:

9600 kg

String isolation: Using fuse switches for over current protection in each string and a single disconnector circuit breaker on the input to the PCE. Fuse switches mounted on wall in battery room below top of batteries

(continued)

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Battery system installation:

120 2 V VRLA battery cells (dimensions 180 mm (w) 250 mm (d) 700mm (h))

Inter-string isolation Two inter-string isolators are installed per string dividing each string into 3 (voltage for each subset is 40 V nominal (47 V maximum)). Isolation mounted on battery frames, below top of batteries. Isolators are no-load isolators and are clearly labelled as such.

Installation location: Out of sun and weather, in regional Tasmania. Battery racks (including wooden base) mounted on concrete floor to keep batteries away from concrete thermal mass

Arc flash considerations:

Battery room multiplying factor of 1.5

Balance of systems room multiplying factor of 1

Arc flash potential per string 6.1 cal/cm2

Fuse switch response time 0.05 seconds (max)

Circuit breaker response time 0.02 seconds (max) –from time/current response curve particular to the chosen circuit breaker


The PCE is mounted in an adjacent room to the battery room. The PCE is mounted directly on the wall to manufacturer’s requirements.

Voltage drop ensures less than 2% based on full rated inverter current and the potential for only one battery string to be operational

Cabling to each system is of same impedance (same length and same size cable)

System installed with good access for trolleys, forklifts and clearance for working


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Table N2 comprises d.c. arc fault calculations considerate of the various access and activities possible for this system.

TABLE N8

EXAMPLE 2: LEAD ACID BATTERY ARC FAULT SCENARIOS

Work activity (see Figure

N3)




Maximum power

method (doan)

Risk rating

DC arc voltage


point of activity

kA

Arcing time

seconds

Multi-plying factor



cm

Arc flash PPE


Fault 1—Work external to battery room between system circuit breaker and PCE—possible d.c. bus short

Full fault current contribution from both strings. String fuses and system circuit breaker act to reduce arc fault incident energy

141 12.00 0.02 1 0.08 Insignificant Unlikely Very low

11.87 No Isolation of batteries by string fuses and system circuit breaker will remove risks when working external to the battery room. Where live work is required, circuit breaker and fusing provides significant protection from arc fault. Standard electrical practices should be used. No specific further arc flash mitigation controls required in this room. Whilst working external to battery room, doors to battery room should remain closed.

Fault 2—Work external to battery room between system circuit breaker and battery room cable entries

Full fault contribution from both strings. String fuses act to reduce arc fault inceident energy


18.77 No

(continued)

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N3)




Maximum power

method (doan)

Risk rating

DC arc voltage


point of activity

kA

Arcing time

seconds

Multi-plying factor



cm

Arc flash PPE


Fault 3—Work internal to battery room between battery room cable entries and string fuses

Fault contribution from both strings when strings are not isolated

141 12.00 0.05 1.5 0.30 Insignificant Unlikely Very low

22.99 No Prior to commencement of work within the room, the system circuit breaker should be opened. Upon entering the room, the string fuses should be opened and then the inter-string isolators. To operate string fuse isolators within the room PPE level 2 is required. Where live work is required as there is no ability to rule out worst case faults, PPE level 2 is required. Insulated tools must be used. Standard electrical practices should be used.

Fault 4—Work internal to battery room on load side of string fuses—possible connection between two battery strings

Requires two faults to exist and dependent where these fault are, the worst case is depicted

141 12.00 0.05 1.5 0.30 Insignificant Rare Very low

22.99 No

(continued)


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N3)




Maximum power

method (doan)

Risk rating

DC arc voltage


point of activity

kA

Arcing time

seconds

Multi-plying factor



cm

Arc flash PPE


Fault 5—Work internal to battery room on battery side of fuse—possible d.c. bus short

Fault contribution from one battery system if no interstring isolators operated

141 6.00 2 1.5 6.08 Moderate Rare Low 102.83 Yes

Fault 6—Work internal to enclosure on battery side of fuse isolator, assuming inter-string isolators open

Fault contribution from smaller segment of system

47 6.00 2 1.5 2.03 Minor Unlikely Low 59.37 Yes

Fault 7—Work internal to enclosure and cell fault or short across cell terminals occurs

Fault contribution only individual cell

2.35 6.00 2 1.5 0.10 Insignificant Unlikely Very low

13.28 No

Even though, in the Example 2, shorting between the terminals of the 2 V lead acid battery cell (Fault 7) is not considered a significant arc flash risk, this does not suggest that there are no risks. If bare hands are used with uninsulated tools and a terminal short occurs; as the hands are generally within the arc flash boundary distance (in this case 13 cm distance), the impact can be considerable requiring first aid or hospitalization. As such, minimum PPE such as gloves and insulated tools are always required for battery work, regardless of the voltage or prospective short circuit current.


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Fault 7Faul t 5

Faul t 3

Faul t 2

Faul t 1

Str ing 1

Str ing 2

Fuse/switchisolators20 × 2 V

cel ls (40 V)20 × 2 V

cel ls (40 V)20 × 2 V

cel ls (40 V)

Switch disconnector

Switch disconnector

Fuse/switchisolators

PCE

Fault 6

+ –

–

+ – + –

20 × 2 Vcel ls (40 V)

20 × 2 Vcel ls (40 V)

20 × 2 Vcel ls (40 V)

Switch disconnector

Switch disconnector

+ + – + –


The risk assessment (Table N9) has been developed, and references the particular hazards noted in this Standard, as may be applicable in the installation as specified. Additional requirements under individual workplace and regulatory requirements should not be substituted by this matrix. Inherent risk and residual risk measures are qualitative assessments.

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TABLE N9 EXAMPLE 2: RISK ASSESSMENT

Tasks

(inherent risk level) Hazard Control measures Clause

references Residual


likelihood

Residual Risk (after control


Installation—key hazards in installation are electrical, energy, fire, explosive gasses and mechanical

Installation competence general

(high) General

Installation to be carried out by licenced persons with additional appropriate accreditation and training in the products being installed


Lifting heavy items

(extreme) Mechanical




Breaks taken



(medium)

Work practices

Fan used

Breaks taken




General work practices Insignificant Unlikely Very low

Electrical work

(high) Electrical and Energy









4.3 and 4.4

Minor Unlikely Low

(continued)

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Tasks


references Residual


likelihood



Installation work

(medium) Fire hazard

No arc producing tools used with battery room open

Debris to be removed prior to installation



4.1 and 4.5 Minor Rare Very Low

Installation work

(medium) Explosive Gasses

Prior to any work open room and ventilate in case of hydrogen build up (for at least 2 minutes)



No arcing devices to be used in the battery room

4.7 Minor Unlikely Low

Installation work

(medium)

Chemical/ general/ mechanical



4.1, 4.6 and 4.8 Insignificant Rare Very Low

Maintenance and General Operation

Replacement of battery or PCE (high) Mechanical






(high) External





System owner informed of safety considerations for system


(continued)


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Tasks


references Residual


likelihood



Electrical maintenance including

(high)

Electrical and Energy




Batteries are always live but system has recessed terminals and terminal covers that will be used during maintenance work





Minor Unlikely Low

Maintenance with tools and equipment that may cause sparks or arcs

(medium)

Fire hazard

No arc producing tools used with battery room open

Any debris to be removed prior to work commencement



4.1 and 4.5 Minor Unlikely Low

Battery and battery room maintenance (e.g. clean vents, check battery terminals)

(high)

Explosive gas

Prior to any work open room and ventilate in case of hydrogen build up (for at least 2 minutes)




Battery maintenance and cell replacement Chemical

All batteries inspected for any cracks, dents, deformations or splits in casing at maintenance


4.6 Insignificant Rare Very low


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N2.3 Example 3—Domestic installation packaged BESS

TABLE N10


Battery system installation: Single package BESS (OEM)

Battery type: Lithium NCA (fire hazard level1), all batteries, BMS, battery protection and inverter housed within the one metal enclosure

Nominal system voltage: 48 V d.c.

Maximum system voltage: 60 V d.c.

Prospective short circuit current rating per unit:

9 kA

PCE battery port rating: DVC-A

Electrical connection: Battery modules (x3) are required to be installed within the enclosure at the time of installation with plug in connectors (for power, control and communications). Battery module is fully sealed—no access to internal components—cells, BMS, inter-cell wiring. Fusing is only accessible part.

Earthing: Floating battery bank, metal enclosure earthed

Enclosure: Enclosure to be installed on outer wall of domestic residence, under eaves, out of weather. 60/60/60 rated material used on wall and eaves. Floor is concrete.

Metal cabinet, power coated against corrosion, elevated floor for battery mounting away from concrete. Enclosure designed to ingress protection level IP44

Front panel for user interface and basic isolation for shutdown purposes. Access to individual components only via unscrewing front panel. Base of enclosure provides space for cable entry and enables all equipment to be mounted at least 300mm off the floor. Unit installed on concrete path

Overall battery enclosure weight: 170 kg

String isolation: Pre-installed fuse, only accessible to installer or qualified personnel. The supplier has provided the time coefficients for operation of fuses for 3 parallel modules and battery system circuit breaker

Installation location: Out of sun and weather, in New Zealand. Enclosure floor mounted on existing concrete floor. Good natural lighting for working. Screen LED for user operation.

(continued)

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Battery system installation: Single package BESS (OEM)

Arc flash considerations: Enclosure multiplying factor of 3

Fuses built into individual battery modules. All terminals shrouded and plug connectors used for connections


Circuit breaker response time 0.01 seconds (max). Fuse response time 0.1 seconds (max). Time coefficients provided by BESS manufacturer

There is no possibility for inter-string protection as modules are sealed


System located near switchboard, away from windows, egress areas, gas bottles and other wood stock area.

Due to location in New Zealand and design of enclosure (tall and narrow), additional structurally engineered braces have been designed to fix the unit to the wall as well as the floor


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TABLE N11

EXAMPLE 3: SEALED LITHIUM BASED BESS ARC FAULT SCENARIOS

Work activity (see

Figure N4)

Detail of possible worst case fault

contribution


Maximum power

method (doan)

Risk rating

DC arc voltage

Bolted fault current at point

of activity kA

Arcing time

second

Multi-plying factor



cm

Arc flash PPE

required?

Controls to implement

Fault 1—Work internal to enclosure and fault between circuit breaker and PCE—d.c. bus fault

Fault contribution from all three batteries with circuit breaker reducing arc fault incident energy


14.23 No System shutdown required before opening enclosure for servicing. Upon opening enclosure follow manufacturer’s instructions. Service-able components are limited and these should only be removed upon appropriate isolation. Due to potential worst case faults, PPE 2 is required

Fault 2—Work internal to enclosure and fault between circuit breaker and fuses on battery systems

Fault contributiion from all three batteries with individual fuses reducing arc fault energy


45.00 No

Fault 3—Work internal to enclosure and fault within module

Fault contribution from one battery module as a result of internal failure

60 9.00 2 3 7.76 Moderate Rare Low 116.19 No

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Fault 3

Faul t 2

Faul t 1

PCE

Bat tery Module 1Bat tery Module 1



Ful ly assembled BESSFul ly assembled BESS


The risk assessment (Table N12) has been developed and references the particular hazards noted in this Standard, as may be applicable in the installation as specified. Additional requirements under workplace and regulatory requirements should not be substituted by this matrix. Inherent risk and residual risk measures are qualitative assessments.

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TABLE N12


Tasks


references Residual


likelihood




Installation competence general (high)

General Installation carried out by licenced persons with additional appropriate accreditation and training in the products being installed


Lifting heavy items (high) Mechanical





Installation environment general (medium)

Work practices

Fan used

Breaks taken





Electrical work (high)

Electrical and Energy



Work procedure requires 2 persons attending for any live work including d.c. connections from battery systems





General electrical practice 4.3 and 4.4

Minor Unlikely Low

(continued)

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Tasks


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likelihood




(medium)

Fire hazard

No arc producing tools used with enclosure open and connections made






(low)

Toxic gas/chemical hazard






(medium)

Mechanical/ general/ chemical hazard



4.1, 4.6 and 4.8 Insignificant Rare Very low

Maintenance and general operation



Two men lift where appropriate (e.g. for enclosure) 4.8 Minor Unlikely Low


(high) External







(continued)


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Tasks


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likelihood




(high) Electrical and Energy




Batteries are always live but system has specific shrouded cables. No substitutes accepted




Check enclosure to ensure no vermin or weather ingress


Minor Unlikely Low


(medium)

Fire hazard






Work in battery enclosure Toxic gas/chemical hazard






(medium)






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N2.4 Example 4—Commercial installation containerised BESS solution

TABLE N13


Battery system installation

Single package BESS

Battery Type: Lithium LTO batteries (fire hazard level 1), with BMS and string battery management modules. Inverter and controls also housed within the container.

Nominal system voltage:

607 V d.c.

Maximum system voltage:

723 V d.c.

Prospective short circuit current rating per battery module:

4.7 kA

PCE battery port rating: DVC-C

Electrical connection: Battery modules (x176) are installed within the enclosure on racks, 22 modules per string, 8 strings. Plug connections on module front face for power, control and communications. Each string is connected to a BMU and all the BMUs are connected to a central BMS. The battery module is fully sealed – no access to internal cells.

Earthing: Floating battery bank, metal racks and enclosure earthed. Separate earth fault detection device installed in addition to inverter earth fault detection.

Enclosure: Enclosure is a shipping container insulated and with 60 minute rated material used on walls, floor and ceiling. The shipping container will be placed on bitumen hardstand.

Enclosure is designed as weather proof.

All monitoring and control of system can be done remotely excluding d.c. shutdown. A.C shutdown can be done remote from container. Batteries mounted up to 2000 mm above floor level on both sides of shipping container.

Enclosure is ‘authorized access only’. Enclosure has appropriate lighting and appropriate ventilation to meet requirements of batteries.

Overall battery enclosure weight:

7000 kg

String isolation: Fuses provided on each string, isolation between each module (each module has a voltage of 32.8 V). Inter-string fusing provided in middle of string (between cells 11 and 12). , Circuit breaker provided at marshalling point of 8 parallel strings and adjacent to the PCE. For purposes of isolation, each module is able to be individually isolated using no load isolators (appropriately labelled)

(continued)

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Battery system installation

Single package BESS

Installation location: On hardstand outside factory in Sydney. Enclosure painted white to minimize solar gain. Enclosure has been installed on base plinth to ensure no pooling of water that may result in corrosion of container base.

Arc flash considerations:

Enclosure multiplying factor of 3

Battery internal short sustenance is measured at 0.6 seconds (this is used instead of 2 second rule of thumb in this instance)


Circuit breaker response time 0.01 seconds (max). Fuse response time 0.01 seconds (max). Time coefficients provided with fuse and circuit breaker data.

There is string fusing and inter-string fusing.


System located near switchboard, away from windows, egress areas, gas bottles and other wood stock area.

Due to location in New Zealand and design of enclosure, additional structurally engineered braces have been designed to fix the unit to the wall as well as the floor.


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TABLE N14

EXAMPLE 4: LARGE SCALE COMMERCIAL BESS ARC FAULT SCENARIOS

Work activity (see

Figure N5)




Maximum power

method (doan)

Risk rating

DC arc voltage


point of activity

kA

Arcing time

second

Multi-plying factor



cm

Arc flash PPE


Fault 1—Work internal to enclosure/room and fault between main d.c. circuit breaker and PCE

Fault contribution from all strings and all modules with circuit breaker protection

723 37.60 0.01 3 1.95 Minor Unlikely Low 58.29 Yes Prior to entry for work, external system shutdowns should be performed. Prior to entry PPE level 3 required. Isolation of battery circuit breaker and string fuses and interstring fuses prior to ANY work within the container. Due to relatively restricted space in container, all areas except inverter/door are within arc flash boundary zones (which are approximately 1.6 m from last battery rack) prior to appropriate isolation. Doors at either end of the system to be opened prior to commencement of work on any d.c. component to the system.

Fault 2—Work internal to enclosure/room and fault between circuit breaker and string protection

Fault contribution from all strings and all modules with fusing protection at string level

723 37.60 0.01 3 1.95 Minor Rare Very low

58.29 Yes

(continued)

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Work activity (see

Figure N5)




Maximum power

method (doan)

Risk rating

DC arc voltage


point of activity

kA

Arcing time

second

Multi-plying factor



cm

Arc flash PPE


Fault 3—Work internal to enclosure/room and fault between circuit breaker and string protection with inter-string protection also included

Fault contribution from all strings and all modules with fusing protection at inter-string level providing fast response above string level fusing

723 37.60 0.01 3 1.95 Minor Unlikely Low 58.29 Yes

Fault 4—Work internal to enclosure/room and fault on single string

Fault contribution from only one string as strings isolated—based on no interstring fusing

723 4.70 0.59 3 14.40 Major Rare Medium

158.31 Yes

(continued)


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Work activity (see

Figure N5)




Maximum power

method (doan)

Risk rating

DC arc voltage


point of activity

kA

Arcing time

second

Multi-plying factor



cm

Arc flash PPE


Fault 5—Work internal to enclosure/room and fault within string between interstring protection

Fault contribution from whole string but interstring protection in operation

723 4.70 0.01 3 0.24 Insignificant Rare Very Low

20.61 No

Fault 6—Work internal to enclosure/room and fault within string between inter-string fuse isolators

Fault contribution from half of string

361.5 4.70 0.59 3 7.20 Moderate Unlikely Medium

111.94 Yes

Fault 7—Work internal to enclosure/room and fault within string with all DVC-A isolators open—same as module fault

Fault contribution from one module

32.8 4.70 0.59 3 0.65 Insignificant Rare Very low

33.72 No


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Module1+ – + – + – + – + – + –

Module 2 Module 11 Module 12 Module 21 Module 22

Str ing 1

PCE

Container System

Module1+ – + – + – + – + – + –


Str ing 2

Module1+ – + – + – + – + – + –


Str ing 3

Module1+ – + – + – + – + – + –


Str ing 4

Module1+ – + – + – + – + – + –


Str ing 5

Module1+ – + – + – + – + – + –


Str ing 6

Module1+ – + – + – + – + – + –


Str ing 7

Module1+ – + – + – + – + – + –


Str ing 8

Faul t 7

Faul t 3

Faul t 4

Faul t 2 Faul t 1

Faul t 5

Faul t 6

NOTE: BMS and BMU devices are not shown in this diagram.

FIGURE N5 EXAMPLE 4: TYPICAL CONFIGURATION AND POSSIBLE D.C. ARC SCENARIOS

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The risk assessment (Table N15) has been developed and references the particular hazards noted in this Standard, as may be applicable in the installation as specified. Additional requirements under individual workplace and regulatory requirements should not be substituted by this matrix. Inherent risk and residual risk measures are qualitative assessments.

TABLE N15


Tasks


references Residual


likelihood




Installation competence general

(high) General

Installation carried out by licenced persons with additional appropriate accreditation and training in the products being installed


Lifting heavy items

(high) Mechanical






(medium)

Work practices

Fan used

Breaks taken





(continued)

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Tasks


references Residual


likelihood



Electrical work





Batteries are always live but each battery has individual shroud fitted. Only batteries being worked on will have shroud removed at time of work. All isolation links to be pulled open.





4.3 and 4.4

Minor Unlikely Low


(medium)

Fire hazard


Smoke detector installed and linked into sites fire indication panel and alarms






(low)

Toxic gas/Chemical hazard






(medium)





(continued)


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Tasks


references Residual


likelihood



Maintenance and general operation







(high) External












Batteries are always live but each battery has individual shroud fitted. Only batteries being worked on will have shroud removed at time of work. All isolation links to be pulled open.





Minor Unlikely Low

(continued)


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Tasks


references Residual


likelihood




(medium)

Fire Hazard


Smoke detector maintained





Work in battery enclosure Toxic Gas/Chemical hazard






(medium)



Where cracks or splits, items removed and handled with appropriate PPE protection.

4.1, 4.6 and 4.8



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BIBLIOGRAPHY

The following are the informative documents referred to this Standard:

AS/NZS 3008 Electrical installations—Selection of cables 3008.1.1 Part 1.1: Cables for alternating voltages up to and including 0.6 V/1kV—

Typical Australian installation conditions

3112 Approval and test specification—Plugs and socket-outlets

SAA/SNZ HB 76 Dangerous Goods—Initial Emergency Response Guide

*** END OF DRAFT ***

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PREPARATION OF JOINT AUSTRALIAN/NEW ZEALAND STANDARDS

Joint Australian/New Zealand Standards are prepared by a consensus process involving representatives nominated by organizations in both countries drawn from all major interests associated with the subject. Australian/New Zealand Standards may be derived from existing industry Standards, from established international Standards and practices or may be developed within a Standards Australia, Standards New Zealand or joint technical committee.

During the development process, Australian/New Zealand Standards are made available in draft form at all sales offices and through affiliated overseas bodies in order that all interests concerned with the application of a proposed Standard are given the opportunity to submit views on the requirements to be included.

The following interests are represented on the committee responsible for this draft Australian/ New Zealand Standard:

Australasian Fire and Emergency Service Authorities Council Australian Energy Council Australian Energy Market Operator Australian Industry Group Australian PV Institute Australian Solar Council Clean Energy Council Clean Energy Regulator Construction, Environment and Workplace Protection, ACT Government Consumer Electronics Suppliers Association CSIRO Department of Economic Development, Jobs, Transport and Resources (VIC) Electrical Compliance Testing Association Electrical Regulatory Authorities Council Electrical Safety Organisation (New Zealand) Electricity Engineers Association (New Zealand) ElectroComms and Energy Utilities Industries Skills Council Energy Networks Australia Engineers Australia Independent Expert (EL-054) Institute of Electrical and Electronics Engineers Institute of Electrical Inspectors Joint Accreditation System of Australia and New Zealand Master Electricians Australia National Electrical and Communications Association New Zealand Electrical Institute NSW Fair Trading Office of the Technical Regulator (SA) Research Institute for Sustainable Energy Solar Energy Industries Association Standards New Zealand Sustainable Electricity Association New Zealand Sustainable Energy Association The University of New South Wales Wellington Electrical Association Worksafe New Zealand

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Standards Australia

Standards Australia is an independent company, limited by guarantee, which prepares and publishes

most of the voluntary technical and commercial standards used in Australia. These standards are

developed through an open process of consultation and consensus, in which all interested parties are

invited to participate. Through a Memorandum of Understanding with the Commonwealth

government, Standards Australia is recognized as Australia’s peak national standards body.

Standards New Zealand

The first national Standards organization was created in New Zealand in 1932. The New Zealand

Standards Executive is established under the Standards and Accreditation Act 2015 and is the

national body responsible for the production of Standards.

Australian/New Zealand Standards

Under a Memorandum of Understanding between Standards Australia and Standards New Zealand,

Australian/New Zealand Standards are prepared by committees of experts from industry,

governments, consumers and other sectors. The requirements or recommendations contained

in published Standards are a consensus of the views of representative interests and also take

account of comments received from other sources. They reflect the latest scientific and industry

experience. Australian/New Zealand Standards are kept under continuous review after publication

and are updated regularly to take account of changing technology.

International Involvement

Standards Australia and Standards New Zealand are responsible for ensuring that the Australian

and New Zealand viewpoints are considered in the formulation of international Standards and that

the latest international experience is incorporated in national and Joint Standards. This role is vital

in assisting local industry to compete in international markets. Both organizations are the national

members of ISO (the International Organization for Standardization) and IEC (the International

Electrotechnical Commission).

Visit our web sites

www.standards.org.au www.standards.govt.nz

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