System Maintenance
List of Required Tools and Consumables
Tool and Equipment Requirements
| No. | Item Name | Model/Specification (Accuracy) | Unit | Qty. | Remarks |
|---|---|---|---|---|---|
| 1 | Slotted screwdriver | 2、4、6、8＂ | pcs | 1 | |
| 2 | Phillips screwdriver | 2、4、6、8＂ | pcs | 1 | |
| 3 | Wrench | pcs | 1 | ||
| 4 | Multimeter | pcs | 1 | ||
| 5 | Clamp meter | pcs | 1 | ||
| 6 | Insulation tester | pcs | 1 | ||
| 7 | Ethernet cable | CAT5E | pcs | 1 | |
| 8 | USB‑485 cable | pcs | 1 | ||
| 9 | Digital storage oscilloscope | (Not required) | pcs | 1 | |
| 10 | Power quality analyzer | (Not required) | pcs | 1 |
Consumables List
| No. | Item Name | Model/Specification | Unit | Qty | Remarks |
|---|---|---|---|---|---|
| 1 | Electrical tape | …… | pcs | 1 | …… |
| 2 | Plastic cable ties | pcs | 1 |
Inspection and Maintenance
Routine Inspection
Power-on Inspection
Perform routine inspection on the system, observe the status of equipment indicators and software monitoring information.
| Item | Inspection Content | Interval | Remarks |
|---|---|---|---|
| 1. LED Screen | |||
| LED Screen | Check whether the LED screen lights up normally during system operation. | Once every 6 months | |
| 2、Battery | |||
| Battery Indicator | Check whether all indicators on batteries and high-voltage box are lit normally. | Once every 6 months | |
| Abnormal Noise | Check for any abnormal noise during system operation. | Once every 6 months | |
| 3、Inverter | |||
| Display | Check that all voltage, power and current data on the display are normal. | Once every 6 months | |
| Energy Storage Inverter Communication | Check that communication is normal. | Once every 6 months | |
| Energy Storage Inverter Operating Status | Check history for fault records. | Once every 6 months | |
| Energy Storage Inverter Fault Log | Read error messages and warnings, and export fault records. | Once every 6 months | |
| Circuit Breaker | Check all circuit breakers via fault logs. | Once every 6 months | |
| Fan | Check for fan faults via fault logs. | Once every 6 months | |
| Functional Test | Check functions such as start/stop of inverter and on/off of circuit breakers. | Once every 2 years |
Power-off Inspection
After the equipment has been in operation for a period of time, a power-off inspection shall be carried out.
| Item | Inspection Content | Interval | Remarks |
|---|---|---|---|
| Battery | |||
| Appearance | Check for damage or rust on all batteries and high‑voltage box. | Once every 6 months | |
| Battery Fixing | Check that all battery fixing bolts are tightened. | Once every 6 months | |
| Battery Grounding | Check that the battery is properly grounded. Ensure good electrical connection between the rear surface of the battery box front cover, the battery rack surface and the grounding point (continuity is verified with a multimeter). | Once every 6 months | |
| High‑voltage Box Fixing | Check that the high‑voltage box is securely fixed; the front panel is tightly attached to the battery rack and all screws are locked. | Once every 6 months | |
| High‑voltage Box Molded Case Circuit Breaker | Check that the molded case circuit breaker of the high‑voltage box is in the normally closed position. | Once every 6 months | |
| Battery Connection | Check that the cables between batteries are securely locked;Check whether the connection terminals of the battery power cables are damaged, deformed or show signs of overheating;Check whether the battery terminals are provided with insulation protection. | Once every 6 months | |
| Connection Between Battery and High‑voltage Box | Check whether the connection terminals of the high‑voltage box power cables are damaged or deformed. | Once every 6 months | |
| Cable Fixing | Check that the connecting cables are securely fastened. | Once every 6 months | |
| Cable Aging | Check whether the cables are aged or damaged. | Once every 6 months | |
| 2.Inverter | |||
| Energy Storage Inverter Grounding | Check that the grounding cable of the energy storage inverter is securely connected. | Once every 6 months | |
| Energy Storage Inverter Fixing | Check that all bolts at the mounting points of the energy storage inverter are tightened. | Once every 6 months | |
| Energy Storage Inverter Cables | Check whether the terminals of the energy storage inverter cables are aged or damaged. | Once every 6 months |
Routine Maintenance
Power-on Maintenance
| Maintenance Item | Maintenance Content | Interval |
|---|---|---|
| 1.Battery | ||
| Battery Capacity Calibration | Complete charge and discharge cycles | Once every 3 months |
| Battery Data Analysis | Analyze BMS data (to be completed by AlphaESS engineers) | Once every 6 months |
| Check the switching function of the high‑voltage box circuit breaker | Inspected locally with the assistance of AlphaESS engineers | Once every 6 months |
| heck whether the DC‑side insulation resistance is within a reasonable range | If no insulation fault is reported by the BMS during normal system operation, the insulation resistance is within the reasonable range | Once every 6 months |
Power-off Maintenance
| Maintenance Item | Maintenance Content | Interval |
|---|---|---|
| 1.Battery System | ||
| Battery Grounding | Perform grounding test with a multimeter | Once every 3 months |
| Battery Fixing | Check whether the battery is firmly fixed on the battery rack | Once every 6 months |
| High-voltage Box Grounding | Perform grounding test with a multimeter | Once every 3 months |
| Battery Label | Check for damage; replace with the same label if damaged | Once every 3 months |
| 2.Inverter | ||
| Appearance | Check whether the inverter appearance is damaged or deformed | Once every 6 months |
| Inspection of live part screws, power cables and communication cables of energy storage inverter | Check that screws, power cables and communication cables are connected properly, without jamming or looseness, and connectors are not loose | Once every 6 months |
| Cleaning and anti-rust inspection of energy storage inverter | Clean the energy storage inverter and check whether cable connectors are rusted | Once every 6 months |
| Power circuit connection | Check and tighten power cables if loose; check whether power and control cables are damaged; pay special attention to the contact surface between cable insulation and metal; check whether insulation ties are detached from cable terminals | Once every 6 months |
| Clean ventilation baffle or air duct | After power off, remove dust with a brush or vacuum cleaner | Once every 6 months |
| Safety | Check warning labels and replace if necessary | Once every 6 months |
After all equipment has stopped operating, the following precautions shall be noted during maintenance:
· Observe relevant safety standards and regulations during operation and maintenance.
· Disconnect all electrical connections to ensure the equipment is de-energized.
· The number of maintenance personnel shall be no less than two during maintenance.
· The equipment shall be repaired by qualified professionals. Unauthorized disassembly of the equipment is strictly prohibited.
· Appropriate protective measures shall be taken during maintenance, such as insulating gloves, insulating shoes and earplugs.
· Energy storage systems are usually located away from urban areas. Relevant emergency rescue measures shall be established for implementation when necessary.
· When the entire system remains idle for a long time (i.e., the battery has not been charged for two weeks or longer), the battery SOC shall be charged to 30%~50% to prevent over-discharge.
· If any situation cannot be explained in this manual, please contact us in a timely manner.
Storage Environment
| Category | Name | Storage Environment |
|---|---|---|
| Finished Product | Battery High-voltage Box | 1. Store batteries indoors in cartons, and control indoor humidity below 65%. Close doors and windows tightly when external humidity is high to prevent moisture ingress. 2. 2. Carton stacking and environment requirements: 3. ① Place cartons on wooden shelves at least 25 cm above the ground and 10 cm away from walls. 4. ② Leave gaps between cartons for moisture ventilation. 5. ③ Install fans to improve air and moisture circulation. |
Cable | Power Cable Communication Cable | Seal with PE bags, then place in cartons and store indoors. |
Inverter | PCS | 1. Temperature: Storage temperature shall not be lower than -20℃ or higher than 40℃ for a long time; recommended around 25℃. Provide heating and cooling measures. 2. 2. Humidity: 0–95% RH, non‑condensing, no obvious moisture. For long‑term storage, keep below 85% RH. Use dehumidifiers if needed. 3. 3. Dust prevention: No heavy dust or sand. Seal equipment with stretch film. Take extra protection in dusty areas. Inspect weekly. 4. 4. Fire prevention: Equip with fire extinguishing system or fire extinguishers. No open flames. Apply fireproof clay at the bottom of equipment. 5. 5. Rodent prevention: Check for holes in advance. Install rat baffles. Keep equipment well‑packed and inspected regularly. 6. 6. Coastal area: Strict isolation and protection against salt spray and moisture. Use sealed structure, corrosion‑resistant materials, coatings, surface treatment, corrosion inhibitors. Keep dry; install and maintain unobstructed drainage pipes. |
System | System | 1. For equipment stored over 6 months: Perform power‑on charge–discharge test every 6 months after checking appearance and internal wiring. Ensure battery SOC is 30%–50% before power‑off. 2. 2. After on‑site installation: Seal the bottom cable entry with fireproof materials. |