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We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. ABB Inc., Advanced Power Electronics, New Berlin Wisconsin, U.S.A. Battery Energy Storage System Client Remote Interface Instructions Based On Prep. Doc. Type Javier Eduardo Mendoza 07/21/2011 Title Appr. Document Number ABB Inc. Interface Instructions BESS Systems Client Remote Interface Instructions Lang. Rev. E D Sheet No. of sh. 1 32 C:\HAYES\ENERGY STORAGE SYSTEMS\BRIEFCASES\OPERATIONS PCS DEVELOPMENT\PCS 100\PCS100 ESS\CONTROL SOFTWARE MANUALS\2011-07-21 BESS CLIENT REMOTE INTERFACE INSTRUCTIONS.DOCX LAST SAVED: 7/22/2011 8:43:00 AM Interface Instructions 1. PURPOSE .................................................................................................3 2. OVERVIEW ...............................................................................................4 2.1 OPERATION OVERVIEW OF A SINGLE LINEUP .......................4 2.2 OPERATION OF A SYSTEM WITH MULTIPLE LINEUPS ...........5 3. STANDARD INTERFACE BETWEEN ABB PLC AND CLIENT PLC ........7 3.1 COMMUNICATION SCHEMES ....................................................7 3.2 STANDARD COMMANDS TO ABB PLCS ...................................7 3.2.1 Available Client Commands............................................7 3.2.2 Control Word Definition...................................................8 3.2.3 Standard Commands for Client to ABB PLC for one Lineup or for Multiple Lineups Operated Individually.......9 3.2.4 Standard Commands for Client to ABB PLC for Multiple Lineups Operated as System.............................9 3.3 STANDARD FEEDBACKS FROM ABB PLC TO CLIENT ..........10 3.3.1 Status Word Definition ..................................................10 3.3.2 Standard Feedbacks from ABB PLC to Client PLC for one Lineup....................................................................11 4. START 4.1 4.2 4.3 4.4 5. STANDARD INTERFACE BETWEEN ABB PLC AND BATTERY MANAGEMENT SYSTEM .......................................................................18 5.1 COMMUNICATION SCHEMES ..................................................18 5.2 STANDARD BATTERY FEEDBACKS DEFINITION ...................18 5.3 STANDARD IMPLEMENTATION OF ABB PLC TO BMS COMMUNICATION ....................................................................20 6. APPENDIX A: INVERTER ACTIVE EVENT CODE .................................21 7. APPENDIX B: LINEUP FAULT REGISTERS DEFINITION .....................26 8. APPENDIX C: SYSTEM FAULT REGISTERS DEFINITION ...................29 9. REVISION HISTORY...............................................................................32 AND STOP SEQUENCES FOR A LINEUP.................................14 NORMAL STARTUP SEQUENCE..............................................14 NORMAL STOP SEQUENCE ....................................................15 FAST STOP SEQUENCE DUE ENABLE COMMAND LOST .....16 FAST STOP SEQUENCE DUE TO SYSTEM TRIP....................17 Document Number ABB Inc. Lang. Rev.. E D Sheet No. of sh.. 2 32 Interface Instructions 1. PURPOSE The ABB BESS standard application software supports commands from remote clients. This document will present: • The available client commands; • The status feedback available from the BESS software; • Standard communication implementation; • The normal startup sequence, normal shutdown sequence as well as fast stop sequence. Document Number ABB Inc. Lang. Rev.. E D Sheet No. of sh.. 3 32 Interface Instructions 2. OVERVIEW The ABB standard application software is designed to handle a Battery Energy Storage Systems (BESS) with up to four individual PCS inverter lineups. An inverter lineup is made up of several inverter modules hard paralleled to a three phase AC bus with common control. The rating of the inverter lineup is sized to the capacity of the battery attached to it. A lineup receives feedbacks from the battery to which it is coupled. The battery management system is responsible for protecting the batteries from reaching undesired voltage levels; this is done via current limits provided to the ABB PLC. A client can control the BESS lineup remotely, in some cases the battery management system and the client may be one and the same. Standard communication protocol used by ABB PLC is Modbus TCP. 2.1 OPERATION OVERVIEW OF A SINGLE LINEUP • • • • • • • • • • • • • Initially, a lineup is in shutdown state. The first step to start up a lineup is to meet all the required permissive conditions for that lineup. Once this is done, a lineup ready feedback will become true. When the lineup ready feedback is true, it is expected that the client will provide a latched enable command. When this command is received, the lineup moves to lineup enabled state and a lineup enabled feedback becomes true. If the latched enable command is given before the lineup is in ready state, then the lineup will not become enabled. The enable command must be held high at all times to allow the lineup to operate. If the enable command is lost at any time, the lineup will immediately perform a fast stop. Therefore removing the enable command acts like a fast stop. Once the lineup is in enabled state, the client is expected to provide a pulsed start command. Upon reception of this command, the lineup will go through the normal startup sequence. The normal startup sequence is automatic and requires no additional input from the client. The normal startup sequence goes through the following steps: o AC breaker is closed (if present); o DC bus is pre-charged, the inverter DC bus is pre-charged to batteries DC voltage level to prevent inrush to inverter when DC link is established. o DC breaker is closed. o Inverters are synchronized and running, this is defined as online state. A lineup will only accept KW and KVar references in online state. A pulsed stop command when the lineup is in online state will result in normal shutdown sequence which will bring the lineup back to shutdown. If a trip occurs at any point during operation, the lineup will shut down using a fast stop sequence. During a normal shutdown sequence, the inverters are stopped and then inhibited. The DC and AC breaker are then opened sequentially. During a fast stop sequence, the following three actions occur simultaneously: the AC breaker is opened, the DC breaker is opened and the inverters are inhibited. Document Number ABB Inc. Lang. Rev.. E D Sheet No. of sh.. 4 32 Interface Instructions 2.2 OPERATION OF A SYSTEM WITH MULTIPLE LINEUPS There are a few different architectures that may be encountered when designing a battery energy storage system. These are general descriptions and specific architectures can easily be implemented depending on system requirements. Also keep in mind that there is always only one ABB PLC managing the individual lineups. • ARCHITECTURE 1: The simplest architecture is when a system is made up of only one inverter lineup coupled to a battery container and when the battery management system is also the client. The client is defined as the source of control to the lineup. If the battery management system PLC is also the client, then the ABB PLC only communicates with this BMS/client PLC. BMS/client PLC provides commands to ABB PLC as well as battery operating parameters. ABB PLC provides feedback for lineups status and actual values. BMS/Client PLC • ABB PLC ARCHITECTURE 2: It is possible to have multiple lineups using architecture 1 in one standard container. As stated earlier, a standard system can have up to 4 inverter lineups. Although each inverter lineup can operate separately, they are all controlled by the same ABB PLC. In this architecture the ABB PLC communicates with multiple BMS/Client PLCs, normally there is one BMS/Client PLC for each battery container. As in architecture 1, individual commands and power references are provided to each inverter lineup and each inverter lineup will provide individual status and actual feedbacks, the only difference being that the communication for additional lineups will be shifted in modbus registry table. Therefore communication for lineup 1 may be defined between modbus register 40000 to 41000, communication for lineup 2 may be defined between modbus registers 41001 to 42000, and so on. BMS/Client PLC 1 BMS/Client PLC 2 ABB PLC BMS/Client PLC 3 BMS/Client PLC 4 Document Number ABB Inc. Lang. Rev.. E D Sheet No. of sh.. 5 32 Interface Instructions • • ARCHITECTURE 3: In this architecture, there is only one lineup but the client and battery management systems are separate. Therefore the ABB PLC only receives battery operational parameters from BMS and receives all commands and reference from the client. The ABB PLC also reports all lineup inverter status and actual values feedback to the client and not to the BMS. The client will often want to have detailed battery information from the BMS which is not required by the ABB PLC for normal operation. In this case, the ABB PLC can either: gather this additional information from the BMS and pass it over to the client, or an additional communication link can be established directly between BMS and client. Client PLC • ABB PLC BMS PLC ARCHITECTURE 4: Similar to previous architecture, in this case there are multiple lineups therefore multiple battery containers and multiple battery management systems but still only one client. The individual BMS’s will communicate battery specific information for each battery container to the ABB PLC. The client in this case can either control the lineup individually or together as a system. If the lineups are operated individually, then they all must be started separately and all must be given individual power references. If the lineups are operated as a system, then there is an “All Start” command available which will start all enabled lineups in sequence and an “All Stop” command which will stop all online lineups. Also, it is possible to give one system power reference that will be divided by the ABB PLC to all available lineups depending on power availability. BMS PLC 1 BMS PLC 2 Client PLC ABB PLC BMS PLC 3 BMS PLC 4 Document Number ABB Inc. Lang. Rev.. E D Sheet No. of sh.. 6 32 Interface Instructions 3. STANDARD INTERFACE BETWEEN ABB PLC AND CLIENT PLC 3.1 COMMUNICATION SCHEMES The standard communication protocol is Modbus TCP. The ABB PLC can be defined to be either master or slave to the client. In both cases, the standard communication registers definition will be the same. If ABB PLC is master then it will write these values to the client PLC’s modbus registers whereas if the ABB PLC is slave then these values will be polled by the client from the ABB PLC’s registers. 3.2 STANDARD COMMANDS TO ABB PLCS 3.2.1 Available Client Commands Enable • • • Individual Start • • Individual Stop • • All Start All Stop Reset KW Reference • • • • • • • • • • KVar Reference • • • Heartbeat • • • This command must always be high to allow the lineup to run. A separate enable command is required for each lineup. If at any point the enable to a lineup command goes low, the lineup will execute a fast stop sequence. This can be used by client as a fast stop command. When a lineup is in enabled state, a start pulse will commence the execution of the normal startup sequence. Pulse should be 2 seconds long. When a lineup is in online state, a stop pulse will commence the execution of the normal shutdown sequence. Pulse should be 2 seconds long. Only valid when using operation multiple lineups as one system. All enabled lineups will sequentially be brought online. Only valid when using operation multiple lineups as one system. All online lineups will sequentially be shutdown. If a lineup has experienced a fault, either a trip or an alarm, the reset command is used to acknowledge and reset the trip or alarm condition. Pulse should be 2 seconds long. Real power reference. A lineup will only accept a reference when in online state. Depending on system architecture there will either be individual KW reference for each lineup or one system KW reference which will be shared among online lineup depending on power availability. Reactive power reference. A lineup will only accept a reference when in online state. Depending on system architecture there will either be individual KVar reference for each lineup or one system KVar reference which will be shared among online lineup depending on power availability. Used to supervise communication health. The client toggles this bit at a frequency of 1Hz. If bit is not toggle for a set amount of time, fault will be declared. Document Number ABB Inc. Lang. Rev.. E D Sheet No. of sh.. 7 32 Interface Instructions 3.2.2 Bit 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Control Word Definition Name Enable L1 Start L1 Stop L1 Enable L2 Start L2 Stop L2 Enable L3 Start L3 Stop L3 Enable L4 Start L4 Stop L4 Start All Stop All Reset Heartbeat • • Description • Latched high enable command to lineup 1 • 2 second pulsed start command to lineup 1 • 2 second pulsed stop command to lineup 1 • Latched high enable command to lineup 2 • 2 second pulsed start command to lineup 2 • 2 second pulsed stop command to lineup 2 • Latched high enable command to lineup 3 • 2 second pulsed start command to lineup 3 • 2 second pulsed stop command to lineup 3 • Latched high enable command to lineup 4 • 2 second pulsed start command to lineup 4 • 2 second pulsed stop command to lineup 4 • Sequential start command to all enabled lineups • Sequential stop command to all running lineups • 2 second pulsed trip and alarm reset and acknowledge command • Periodic toggling heartbeat bit used for communication supervision. • Bit should toggle once per second. • The client is responsible for toggling this bit. For operation architecture 1, 2 and 3, there will be one control word provided for each lineup. Only the first 3 bits and last 2 bits of each word are used in this case. Therefore: o b0: Enable L1 o b1: Start L1 o b2: Stop L1 o b14: Reset o b15 Heartbeat For operation architecture 4, there can be only one instance of the control word provided to the client and bits are utilized depending on number of lineups present. Document Number ABB Inc. Lang. Rev.. E D Sheet No. of sh.. 8 32 Interface Instructions 3.2.3 Standard Commands for Client to ABB PLC for one Lineup or for Multiple Lineups Operated Individually The PLC addresses specified below can be shifted depending on specific project requirements. The scheme shown below could be used in a system where the client is controlling only one lineup or multiple lineups individually, for multiple lineups these registers must be repeated. Source Variable Name Client Commands Command Word Type INT kW Set Point INT kVar Set Point INT PLC Description Address Commands to Lineup from Client TBD b0: Enable L1 b1: Start L1 b2:Stop L1 b14: Reset b15: Heartbeat TBD Real power set point to the lineup kW < 0: power drawn from the grid kW > 0: power into the grid TBD Reactive power set point to the lineup kVAr < 0: Inductive Power kVAr > 0: Capacitive Power Units Bit field kW kVAr 3.2.4 Standard Commands for Client to ABB PLC for Multiple Lineups Operated as System The PLC addresses specified below can be shifted depending on specific project requirements. The scheme shown below could be used in a system where client is controlling multiple lineups as one system. Source Variable Name INT Client Commands Command Word Type kW Set Point INT kVar Set Point INT PLC Description Address Commands to Lineup from Client TBD b0: Enable L1 b1: Start L1 b2:Stop L1 b3: Enable L2 b4: Start L2 b5:Stop L2 b6: Enable L3 b7: Start L3 b8:Stop L3 b9: Enable L4 b10: Start L4 b11:Stop L4 b12: Start All b13:Stop All b14: Reset b15: Heartbeat TBD Real power set point to the lineup kW < 0: power drawn from the grid (charging) kW > 0: power into the grid (discharging) TBD Reactive power set point to the lineup kVAr < 0: Inductive Power kVAr > 0: Capacitive Power Document Number ABB Inc. Units Bit field kW kVAr Lang. Rev.. E D Sheet No. of sh.. 9 32 Interface Instructions 3.3 STANDARD FEEDBACKS FROM ABB PLC TO CLIENT 3.3.1 Status Word Definition This is the main lineup status word provided to the client. Bit Name Description 0 Shutdown • Lineup shutdown if bit = 1. • Inverters are inhibited and stopped. • AC and DC breakers are both opened. 1 Ready • Lineup is ready if bit = 1. • The following conditions have to be met for ready status to be true: o Disconnect switch is closed. (Option) o Ground switch is open. (Option) o Breakers are in appropriate position for startup. o Inverters are in correct initial state: stopped and inhibited. o Battery voltage feedback is within acceptable range. • Lineup is ready to receive enable command. 2 Enabled • Lineup is enabled if bit = 1. • This state is achieved when system ready state is true and the latched enable command is provided by the client. • The startup sequence can be initiated when pulsed start command is given by the client. 3 AC Breaker • AC breaker status, 1 = closed 4 DC Breaker • DC breaker status, 1 = closed 5 Online, Grid • Lineup Online and Grid Connected, if bit = 1. Connect • Startup sequence was successful and lineup is ready to receive a power reference. • A pulsed stop command at this point will execute the normal shutdown sequence. 6 Standby • Lineup in standby if bit = 1. • Lineup automatically goes into this state if the power references are below defined standby limits for defined time. • In this state, AC and DC breakers are closed but inverters are stopped. • If power demand goes above standby limits, the inverters automatically return to online state. • A pulsed stop command at this point will execute the normal shutdown sequence. 7 Maintenance • Lineup in maintenance mode if bit = 1. • Lineup is in maintenance mode if local commissioning is enabled, this mode is accessed via control builder software and is usually only done by an ABB employee. • During commissioning mode, all client control is disabled. 8 Alarm • Lineup has an active alarm if bit = 1, see fault registers for more info. 9 Trip • Lineup has an active trip if bit = 1, see fault registers for more info. 10 Heartbeat • Heartbeat from ABB PLC to client. • Signal toggles periodically, used to determine communication health. 11 Online, • Lineup Online and Islanding, if bit = 1. Islanding • There is an option to enable a lineup to operate in islanding mode if Mode the AC mains are lost during grid connected online operation. Document Number ABB Inc. Lang. Rev.. E D Sheet 10 No. of sh.. 32 Interface Instructions 3.3.2 Standard Feedbacks from ABB PLC to Client PLC for one Lineup The PLC addresses specified beneath can be shifted depending on specific project requirements. Source Variable Name Nameplate Info Nameplate Real Power Capacity Nameplate Reactive Power Capacity Inverter Identifier SN Inverter Firmware Rev PLC Description Address Lineup Feedback Status Registers to Client UINT %MW000 Lineup nameplate real power rating. Units kW UINT %MW001 Lineup nameplate reactive power rating. UINT %MW002 UINT %MW003 Lineup serial number, this is a five digit number, ex: SN: 14061 Firmware revision number Revision are made up of 3 components, the following revision identification R2E13 breaks up as follows: Major Versions: 2, MMMM XXXX XXXX XXXX Minor Versions: E, XXXX mmmm mmXX XXXX Revisions: 13, XXXX XXXX XXRR RRRR UINT %MW004 Main Status Word Status Word Type The binary value for R2E13 would therefore be: 0010 000101 001101 =2 =5 or E = 13 b0: Shutdown b1: Ready b2: Enabled b3: AC Breaker b4: DC Breaker b5: Online, Grid Connected b6: Standby b7: Maintenance (commissioning mode) b8: Alarm b9: Trip b10: Heartbeat (1 sec) b11: Online, Islanding Document Number ABB Inc. kVAr ENUM ENUM Bit field Lang. Rev.. E D Sheet 11 No. of sh.. 32 Interface Instructions Alarm Registers Lineup Demand Available Capacity Source Variable Name Type Instantaneous Discharge Capacity UINT PLC Address %MW005 Description Instantaneous Charge Capacity UINT %MW006 Instantaneous Capacitive Reactive Power Capacity Instantaneous Inductive Reactive Power Capacity Lineup KW Demand UINT %MW007 UINT %MW008 INT %MW009 Lineup KVAR Demand INT %MW010 Limited Lineup KW Demand INT %MW011 Limited Lineup KVAR Demand INT %MW012 Inverter Active Event Code Lineup Fault Register 1 Lineup Fault Register 2 Lineup Fault Register 3 Spares System Fault Register 1 System Fault Register 2 System Fault Register 3 Spares Spares UINT %MW013 UINT %MW014 Net instantaneous real power available to inject into the grid, all lineup limits are accounted for in this value. Net instantaneous real power available to draw from the grid, all lineup limits are accounted for in this value. Net instantaneous capacitive power that can be used to raise line voltage or affect power factor, all lineup limits are accounted for in this value. Net instantaneous inductive power that can be used to lower line voltage or affect power factor, all lineup limits are accounted for in this value. Raw set point provided to the lineup, this set point can be limited if it is beyond available power. kW < 0: power drawn from the grid (charging) kW > 0: power into the grid (discharging) Raw set point provided to the lineup, this set point can be limited if it is beyond available power. kVAr < 0: Inductive Power kVAr > 0: Capacitive Power Actual limited set point provided to the inverters. kW < 0: power drawn from the grid (charging) kW > 0: power into the grid (discharging) Actual Limited set point provided to the inverters. kVAr < 0: Inductive Power kVAr > 0: Capacitive Power Number indicating inverters error status, see active event code definition. Fault registers for lineup level events. UINT %MW015 Fault registers for lineup level events. Bit field UINT %MW016 Fault registers for lineup level events. Bit field UINT UINT %MW017 %MW018 Fault registers for system level events. Bit field UINT %MW019 Fault registers for system level events. Bit field UINT %MW020 Fault registers for system level events. Bit field UINT UINT %MW021 %MW022 Document Number ABB Inc. Units Lang. Rev.. E D 0.1kW 0.1kW 0.1kVAr 0.1 kW 0.1 kVAr 0.1 kW 0.1 kVAr ENUM Bit field Sheet 12 No. of sh.. 32 Interface Instructions AC Measurements DC Measurement s Source Variable Name Type PLC Description Address Lineup Feedback Actual Values Registers to Client DC Current INT %MW023 The calculated current on the DC bus by the inverters. I < 0: Charge I > 0: Discharge DC Voltage Inverter INT %MW024 The measured voltage on the DC bus by the inverters. Inverter Output Vavg INT %MW025 Output average voltage (rms) Inverter Output Vab INT %MW026 Output voltage across phase A-B (rms) Inverter Output Vbc INT %MW027 Output voltage of phase B-C (rms) Inverter Output Vca INT %MW028 Output voltage of phase C-A (rms) Inverter Output Iavg INT %MW029 Output average current (rms) Inverter Output Ia INT %MW030 Output current of phase A (rms) Inverter Output Ib INT %MW031 Output current of phase B (rms) Inverter Output Ic INT %MW032 Output current of phase C (rms) Inverter Output kW INT %MW033 The measured real power output from the inverter. kW < 0: power drawn from the grid kW > 0: power into the grid Inverter Output kVAr INT %MW034 The measured reactive power output from the inverter. kVAr < 0: Inductive Power kVAr > 0: Capacitive Power Inverter Output kVA INT %MW035 The measured apparent power output from the inverter. Inverter Output PF INT %MW036 Output power factor PF < 0: Inductive Power Factor PF > 0: Capacitive Power Factor Inverter Output Freq UINT %MW037 Output frequency Max Inv Temp INT %MW038 The maximum heat sink temperature of any inverter on the lineup. Document Number ABB Inc. Lang. Rev.. E D Units 0.1 Adc 0.1 Vdc 0.1 V 0.1 V 0.1 V 0.1 V 0.1 A 0.1 A 0.1 A 0.1 A 0.1 kW 0.1 kVAr 0.1 kVA 0.001 0.01 Hz 0.1 C˚ Sheet 13 No. of sh.. 32 Interface Instructions 4. START AND STOP SEQUENCES FOR A LINEUP 4.1 NORMAL STARTUP SEQUENCE Note: Commands come from client and statuses are feedbacks from BESS lineup. Example of a startup sequence: 1. Lineup trip status is true and therefore lineup is in shutdown state. 2. We assume that the cause of the trip has been cleared so the lineup fault is ready to be reset, therefore a reset pulse is given and the system trip status becomes false. 3. If the lineup is clear of trips and all breakers and disconnects are in correct position, then lineup ready status becomes true. 4. The latched enable command is given by the client while lineup ready status is true therefore lineup goes to enabled state. 5. Pulsed start command is given once lineup is in enabled state to execute automatic startup sequence; at this point lineup exits shutdown state and lineup ready status becomes false. 6. If the startup sequence completes successfully, the lineup goes into online state at which point it is ready to receive a power reference. Document Number ABB Inc. Lang. Rev.. E D Sheet 14 No. of sh.. 32 Interface Instructions 4.2 NORMAL STOP SEQUENCE Note: Commands come from client and statuses are feedbacks from BESS lineup. Example of a normal stop sequence: 1. The lineup is in online state; also the latched enable command is present so that fast stop is not executed. 2. A pulsed stop command is received and therefore the normal stop sequence executes. 3. If the shutdown sequence executes correctly the lineup goes into shutdown state normally. Since there are no trips and all permissives are met, the lineup ready state is true and since the latched enable command is present the lineup remains in enabled state. 4. If the latched enable command is removed at this point the lineup is no longer enabled. However, since there are no trips and all permissives are met, lineup ready status is true. 5. If a trip occurs at this point, the lineup is already in shutdown state but the lineup ready feedback becomes false. Document Number ABB Inc. Lang. Rev.. E D Sheet 15 No. of sh.. 32 Interface Instructions 4.3 FAST STOP SEQUENCE DUE ENABLE COMMAND LOST Note: Commands come from client and statuses are feedbacks from BESS lineup. Example of a fast stop shutdown due to loss of latched enable command: 1. The lineup is in online state; also the latched enable command is present so that fast stop is not executed. 2. The latched enable command is lost; therefore lineup goes immediately into shutdown state. Fast stop sequence is executed, all breakers are opened and inverter is inhibited as fast as possible. 1. Since there is no lineup trip, lineup ready status becomes true when lineup goes to shutdown state. 2. If a trip occurs, lineup ready status goes to false. Document Number ABB Inc. Lang. Rev.. E D Sheet 16 No. of sh.. 32 Interface Instructions 4.4 FAST STOP SEQUENCE DUE TO SYSTEM TRIP Note: Commands come from client and statuses are feedbacks from BESS lineup. Example of a fast stop shutdown due to lineup trip: 1. The lineup is in online state; also the latched enable command is present so that fast stop is not executed. 2. A trip occurs; therefore the lineup immediately goes into shutdown state. Fast stop sequence is executed, all breakers are opened and inverter is inhibited as fast as possible. 3. Even though latched enable command is true, lineup enabled status is false due to trip. 4. Lineup ready status cannot be true if lineup is tripped. Document Number ABB Inc. Lang. Rev.. E D Sheet 17 No. of sh.. 32 Interface Instructions 5. STANDARD INTERFACE BETWEEN ABB PLC AND BATTERY MANAGEMENT SYSTEM 5.1 COMMUNICATION SCHEMES The standard communication protocol is Modbus TCP. There are two possible communication schemes: 1. Client and Battery Management System are Separate PLC’s: in this situation ABB PLC is directly receiving commands and power references from the client. The BMS is only providing battery operational parameters to the ABB PLC. In this scheme, the battery has to provide additional feedback to ABB PLC providing status information: • Batteries ready • Batteries trip • Batteries alarm • Heartbeat reply 2. Client and Battery Management System are same PLC: in this situation ABB PLC is receiving commands and power references from the BMS. Additional status feedbacks are not necessary since BMS can fast stop inverter lineup by removing enable command. 5.2 STANDARD BATTERY FEEDBACKS DEFINITION SIGNAL DESCRIPTION Batteries Ready Batteries Trip • • • Batteries Alarm • • • Heartbeat • • • This signal indicates that the batteries are ready for operation; lineup cannot be started unless this signal is available. This signal indicates that there is a fault inside the battery system and requests a fast stop from the ABB PLC. In the event of battery alarm, operator will refer to battery specific alarm and trip information resource. This signal indicates that there is an alarm inside the battery system. ABB PLC does not take any action at this point. In the event of battery alarm, operator will refer to battery specific alarm and trip information resource. Used to supervise health of communication between ABB PLC and battery management system. The heartbeat is toggled by ABB PLC The battery management system is responsible for simply replying the same signal back to ABB PLC. Document Number ABB Inc. Lang. Rev.. E D Sheet 18 No. of sh.. 32 Interface Instructions DC Voltage • • DC Current SOC • • • Charge Current Limit • • • • Discharge Current Limit • • • • Limit Max Allowable DC Voltage • • • Limit Minimum • Allowable DC • Voltage • DC voltage feedback from BMS. DC voltage feedback is used as the reference point to the inverters during the DC pre-charge portion of the startup sequence. DC current feedback is not used in any logic. Battery State of Charge value is used in systems made up of multiple lineups for lineup balancing. Functionality is available to define allowable SOC difference between lineup and maximum power used to equalize battery lineups. This is the maximum allowable charge current limit to the batteries. The maximum current limit is multiplied with the DC voltage to obtain the maximum charge power limit. The battery management system is responsible for regulating battery charging via this signal. Charge and discharge current limits are the main signals used by battery management system to regulate charging and discharging of the batteries. This is the maximum allowable charge current limit to the batteries. The maximum current limit is multiplied with the DC voltage to obtain the maximum charge power limit. The battery management system is responsible for regulating battery charging via this signal. Charge and discharge current limits are the main signals used by battery management system to regulate charging and discharging of the batteries. This is the maximum allowable DC voltage for the batteries. This limit should not be reached because the charge current limit should prevent the batteries from becoming overly charged. If this limit is reached, the system will trip. This is the minimum allowable DC voltage for the batteries. This limit should not be reached because the discharge current limit should prevent the batteries from becoming overly discharged. If this limit is reached, the system will trip. Document Number ABB Inc. Lang. Rev.. E D Sheet 19 No. of sh.. 32 Interface Instructions 5.3 STANDARD IMPLEMENTATION OF ABB PLC TO BMS COMMUNICATION The PLC addresses specified beneath can be shifted depending on specific project requirements. Actual Values Protection Parameters Status Type Variable Name Type PLC Description Address Standard Feedbacks from Battery Management System to ABB PLC Units %MW000 b0: Ready, if bit = 1 b1: Tripped status, if bit = 1 b2: Alarm status, if bit = 1 b3: Heartbeat reply Discharge Current Limit UINT %MW001 The maximum current that can be drawn from the battery system. The BMS must reduce this limit to prevent batteries from becoming overly discharged. Charge Current Limit UINT %MW002 The maximum current that can be supplied to the battery system. The BMS must reduce this limit to prevent batteries from becoming overly charged. Min DC Voltage UINT %MW003 The minimum allowable DC bus voltage. If the DC bus voltage drops to this level, the lineup will be tripped since it is assumed regulation has failed. Max DC Voltage UINT %MW004 The maximum allowable DC bus voltage. If the DC bus voltage reaches this level, the inverters will trip since it is assumed that regulation has failed. DC Voltage Battery INT %MW005 The measured voltage of the DC bus. DC Current Battery INT %MW006 The measured current on the DC bus. SOC UINT %MW007 Actual battery SOC value Standard Writes from ABB PLC to Battery Management System Status Word Heartbeat Query UINT UINT TBD b0: Heartbeat Query toggles every second. If there are additional commands needed by BMS the heartbeat query can be bundle inside a project specific command word. Document Number ABB Inc. Lang. Rev.. E D Bit field 0.1 A 0.1 A 0.1V 0.1V 0.1 Vdc 0.1 Adc 0.1 Bit field Sheet 20 No. of sh.. 32 Interface Instructions 6. APPENDIX A: INVERTER ACTIVE EVENT CODE Code 1 GDM and Event log Description Module Start Failure 2 3 IGBT Desat Desat Cooling Time 4 5 LVDC PSU Voltage Low Internal Fault 6 7 8 Internal Fault Internal Fault DC Bus Overvoltage 9 10 11 DC Bus Voltage High DC Bus Voltage Low DC Bus Undervoltage 12 13 14 Internal Fault Internal Fault Internal Fault 15 Internal Fault 16 17 18 Parameter Error Parameter Check Error Internal Warning 19 20 21 Internal Error Internal Internal Fault 22 Internal Fault 23 24 25 26 27 Internal Fault Internal Fault Internal Internal Input Voltage Low 28 29 30 Internal Internal Fault Internal Fault 31 Internal Error Inverter Active Event Code Full description & Action Module start failure due to NVRAM (1), FPGA (2) or Configuration ID (3) errors. Remove power and restart ESS. Inverter or Rectifier IGBT fault. Remove power and restart ESS. Inverter or Rectifier Desat Cooling Time before Reset Allowed. Wait for 15min before attempting a reset. Control low voltage power supply failure. Check AC supply voltage is correct. Rectifier or Inverter interlock error, when 2 transistors of the same bridge are activated. SPI watchdog error. Check all communication cables. Generic FPGA fault. Check all communication cables. DC Bus overvoltage, limit set by hardware. Reset or remove power and restart ESS. DC Bus voltage high. Possibly the AC mains is high. DC Bus voltage is low. Possibly the AC mains is low. DC Bus undervoltage, requiring softcharge to recover. This is common when the rectifier module is stopped. Zero sequence current 1ms exceeds threshold. Zero sequence current 100ms abs average exceeds threshold Rectifier or Inverter lost synchronisation with master. Check all communication cables. Rectifier or Inverter cannot synchronise to master within timeout. Check all communication cables. Error setting parameter. Reset or remove power and restart ESS Low speed parameter read back limit check detects error. Reset or remove power and restart ESS. Control Loop processing result late. Reset or remove power and restart ESS. Internal Code Error. Reset or remove power and restart ESS. DSP stack has reached 75% threshold level. Timeout between activating softcharge contactor and back contact activated. Timeout between de-activating softcharge contactor and back contact release. Precharge relay & softcharge resistor is enabled for too long. Errors indicated by the softcharge manager. The softcharge sequence takes too long, causing restart sequence. DC Bus ripple voltage high. Check all three phases are present. Phase lock loop not locked to input signal. This is common when the supply to the ESS is switched off. Model control loop parameters out of range. Second contactor activation before recharge delay has timed out. Softcharge error if the DCV < 0.15 PU after 200 ms, bus not charging. Short circuit on the DC bus. FPGA has been reset or is not initialised. Reset or remove power and Document Number ABB Inc. Lang. Rev.. E D Sheet 21 No. of sh.. 32 Interface Instructions restart ESS. Document Number ABB Inc. Lang. Rev.. E D Sheet 22 No. of sh.. 32 Interface Instructions 40 Internal Error 41 Internal Error 42 Initialisation Failure 43 Fault Reset Timeout 44 Internal Fault 46 Inverter Unbalanced 47 DC Bus Unequal 48 Internal 49 50 51 55 HW Current High HW Overcurrent Current Limit Sin Filter Over Temp 56 Heatsink Hot 57 Heatsink Over Temp 58 Enclosure Hot 59 Enclosure Over Temp 60 Transistor Case Hot 61 Transistor Case Overtemp 62 63 Transistor Junction Hot Copper Hot 64 Copper Over Temp 66 Transformer Hot 67 68 69 VCAN Warning VCAN Error Rectifier Lost 70 Inverter Lost Streaming Data Interface error count too high. Check all communication cables are not run next to power cables. Streaming Data Interface and Mode Manager mode mismatch. Check all communication cables are not run next to power cables. Error during initialisation of master, rectifier or inverter. Check all communication cables. Remove power and restart ESS. Error in master resetting faults in rectifier or inverter. Check all communication cables. Remove power and restart ESS. Error in master setting parameters in rectifier or inverter. Check all communication cables. Remove power and restart ESS. Variation in current level between inverter modules above threshold. Check all inverters are operating. Difference in DC Bus voltages between rectifier and inverter is above threshold. DC Bus undervoltage - lower than URMS*sqrt(2)*correction - the control loop does not have enough headroom to control inductor voltages. Check the incoming AC voltage is not too high Short duration transistor overcurrent, limit set by hardware. Long duration transistor overcurrent, limit set by hardware. Current Limit. PTC in module sine filter indicates overtemperature. Check all module fans are operating properly and ambient temperature is not too high. Rectifier or Inverter Heatsink hot (heatsink mounted sensor). Check all module fans are operating properly and ambient temperature is not too high. Rectifier or Inverter Heatsink overtemperature (heatsink mounted sensor). Check all module fans are operating properly and ambient temperature is not too high. Rectifier or Inverter Enclosure internal hot. Check all module fans are o are operating properly and ambient temperature is not too high. Rectifier or Inverter Enclosure internal over temperature. Check all module fans are operating properly and ambient temperature is not too high. Rectifier or Inverter Transistor Case model hot. Check all module fans are operating properly and ambient temperature is not too high. Rectifier or Inverter Transistor Case model overtemperature. Check all module fans are operating properly and ambient temperature is not too high. Rectifier or Inverter Transistor Junction model hot. Check all module fans are operating properly and ambient temperature is not too high. Copper model hot due to high average current. Reduce the load on the ESS. Copper model overtemperature due to high average current. Reduce the load on the ESS. Embedded transformer sensor or transformer enclosure sensor indicates warning temperature (180 deg). VCAN warning that is recoverable. Check all communication cables. VCAN error that cannot be recovered. Check all communication cables. Master lost communications with Rectifier module. Check all communication cables. Master lost communications with Inverter module. Check all communication cables. Document Number ABB Inc. Lang. Rev.. E D Sheet 23 No. of sh.. 32 Interface Instructions 71 Master Lost 72 Module Coms Warning Module Coms Fault 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 90 91 104 105 106 107 108 151 152 153 154 155 156 158 159 160 IOM Lost PC Comms Lost GDM/UIM Lost Module Number Changed Module Number Mismatch Module Display Warning Module Display Error Utility Voltage Low Utility Open Source IOM Testmode Negative Phase Rotation Output Voltage High Not Passed Tester IRQ Frequency Error Serial Number Error Heatsink Cold or Sense Flt Enclosure Cold or Sense Flt Sync Voltage Too Low Zero Seq Sync V Too High Stop Button Override Input Voltage Low Timeout RFI Lead Misconfiguration Stop Ramp Down Ramp Up Wait Sync Good, No Output Syncing Volt/Freq, No Output Syncing Phase, No Output Sync' d, No Output Sync' d, output enabled Wait Sync Good Rectifier or Inverter lost communications with Master module. Check all communication cables. Streaming Data Interface 2 subsequent frames lost. Check all communication cables. Streaming Data Interface frame loss exceeds threshold. Check all communication cables. Master lost communications with critical IOM. Master lost communications with critical TCPM (PC). Master lost communications with critical GDM/UIM. Module Number Changed. If a module has been replaced check the module ID number is set to the same as the replaced module. Number of rectifier and inverter modules unequal. Module display board warning. Module display board error. Utility voltage below threshold. Utility open source detected. Input has been switched off. IOM testmode activated. Negative phase rotation detected. Correct the phase sequence. Output over-voltage detected. Product, Module or DSPE has not passed production tests. Software task IRQ not occurring at correct frequency. The system (product) serial number in SCM and DSPE are different. Rectifier or Inverter Heatsink sensor error or too cold. Rectifier or Inverter enclosure sensor error or too cold. The voltage reference for synchronisation is too low to allow synchronisation. There is too much zero sequence voltage to allow synchronisation. The GDM stop button has been used to stop the converter. The input AC voltage as been too low and the converter timed out. The RFI configuration in the power modules does not match the Master map. Check the part numbers of the power modules are correct for this machine. The ESS is in the stop state. The ESS is ramping down the output power. The ESS is ramping up the output power. Waiting for the synchronise sense to be stable before confirming synchronising. Synchronising voltage and frequency Synchronising phase ESS is synchronised but the output off ESS is synchronised and output enabled Waiting for the synchronise sense to be stable before confirming Document Number ABB Inc. Lang. Rev.. E D Sheet 24 No. of sh.. 32 Interface Instructions 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 191 Syncing Voltage/Freq Syncing Phase Correction Synchronised Enable Generator Mode Run Sync Out Of Spec CIOB Lost CIOB Module Error CIOB Analog IP Overrange CIOB PTC Overtemp Output Freq Too Low Output Freq Too High Output Volt Too Low Output Volt Too High System SW Overcurrent System Overload 198 199 200 Reduced System Capacity CIOB RS485 Timeout Output Volt Too High Timed Standby unload Standby Redundancy Trip 201 Unbalanced DC bus 202 Transistor Junction OverTemp Zero Sequence Voltage High 195 197 203 204 205 Dcbus center ripple high Battery Full Power Limiting 206 Battery Empty Power Limiting 207 CT Zero Sequence High Reboot Current Ramp Up 209 213 synchronising. Synchronising voltage and frequency Synchronising phase ESS is synchronised Generator control mode enabled ESS is in the Run state The synchronise sense input is out of tolerance Master lost communications with Can IO board CIOB has an internal error preventing it from running. CIOB Analog input signal is overrange (5%) CIOB external PTC overtemperature Output Freq Too Low Output Freq Too High Output Volt Too Low Output Volt Too High Software overcurrent detection The load on the ESS is > 100%. To avoid activating the ESS thermal protection the load should be reduced. One or more power modules are not operating, possibly due to a dual supply system losing one feed CIOB RS485 Communications timeout (MODBUS) The output voltage has been too high for a specified time. The converter is unloading to enter standby state The converter is in standby state (power saving) Too many power modules have tripped and the system cannot continue to operate The DC bus voltage from mid-bus to ground is outside the threshold set by menu 68 Max unbalance. There may be a ground fault on the DC. Rectifier or Inverter Transistor Junction model hot. Check all module fans are operating properly and ambient temperature is not too high. The zero sequence voltage of the inverter output is higher than expected. Not common for ESS converters as the inverter connection is 3 wire floating. There is high frequency ripple voltage on the DC link. This is an indication of a phase to ground fault on the inverter AC side. The maximum battery voltage as defined in the DC menu 61 Over volt level has been reached. The PCS100 is now limiting the incoming power to avoid overcharging the battery. The minimum battery voltage as defined in the DC menu 66 Under volt level has been reached. The PCS100 is now limiting the outgoing power to avoid over-discharging the battery. The AC current sensors are detecting a high level of zero sequence current. This could be an indication of a ground fault within the system. The system is rebooting, perhaps after a firmware upgrade. The system is ramping up the output current to the setpoint. Document Number ABB Inc. Lang. Rev.. E D Sheet 25 No. of sh.. 32 Interface Instructions 7. APPENDIX B: LINEUP FAULT REGISTERS DEFINITION Lineup Fault Register 1 Bit Type of event Fault String LINEUP TRIP FC0000 T AC Safeties Bypass ! ! # $ LINEUP TRIP FC0001 T AC Unexpected Status & LINEUP TRIP FC0002 T AC Operation Fault ! FC0003 T AC OCP Relay Trip ! ) LINEUP TRIP FC0004 T AC Racked Out ! * LINEUP TRIP + LINEUP TRIP FC0050 A Breaker Module Simulation Active FC0100 T DC Safeties Bypass , FC0101 T DC Unexpected Status , ! / LINEUP TRIP FC0103 T DC OCP Relay Trip , ! $ LINEUP TRIP FC0104 T DC Racked Out , ! $* LINEUP TRIP FC2000 T Battery Fault " ! ! ( ! , 0 ! " ( 0 " 1 2 ( , ( ( " Document Number ABB Inc. % " FC0150 A Breaker Module Simulation Active FC0200 T Ground Fault Resistivity trip level FC0250 A Ground Fault Resistivity alarm level FC0300 A VFD Control Module Simulation Active " % , $) LINEUP ALARM ! # FC0102 T DC Operation Fault $' LINEUP ALARM ( ! LINEUP TRIP $& LINEUP TRIP ! ! . $$ LINEUP ALARM " " LINEUP TRIP LINEUP TRIP % % ' - " !" # Lang. Rev.. E D Sheet 26 No. of sh.. 32 Interface Instructions Lineup Fault Register 2 Bit Type of event Fault String LINEUP TRIP FC2001 T Battery Communication Loss $ LINEUP ALARM FC2050 A Battery Alarm & LINEUP ALARM ' LINEUP TRIP FC2051 A Battery View Module Simulation Active FC2100 T PCS Inverter Fault ) LINEUP TRIP * LINEUP ALARM # " !" # + LINEUP ALARM FC2101 T PCS Inverter Comm Loss FC2150 A PCS Inverter Warning " ( !" " ( " ( " ( !" " " FC2151 A PCS Inverter Derated ( ( ( $ 3 " ( LINEUP ALARM FC2152 A PCS Comm Module Simulation Active . LINEUP ALARM FC2250 A KW Output VS Reference Deviation / LINEUP ALARM FC2251 A KVar Output VS Reference Deviation $ LINEUP TRIP FC2300 T DC Voltage High , 41 ( # $$ LINEUP TRIP FC2301 T DC Voltage Low , ( $& LINEUP ALARM FC2350 A Lineup in Overload Cooldown $' LINEUP ALARM FC2351 A Lineup Over Temperature Derated $) LINEUP ALARM FC2352 A Power Limit Module Simulation Active $* LINEUP ALARM FC2450 A Lineup Failed To Go To Standby " ( 45 ( " " ( ( ( - 45 ( 41 ( # # ( # " ( " Document Number ABB Inc. ( # Lang. Rev.. E D Sheet 27 No. of sh.. 32 Interface Instructions Lineup Fault Register 3 Bit Type of event Fault String LINEUP ALARM FC2451 A Lineup Failed To Return From Standby FC2500 T Startup Fault $ LINEUP TRIP & LINEUP TRIP FC2501 T AC Breaker Open Unexpectedly ' LINEUP TRIP FC2502 T Inverters Inhibited Unexpectedly ) LINEUP TRIP FC2503 T Inverters Not Running Unexpectedly * LINEUP TRIP FC2504 T DC Breaker Open Unexpectedly + LINEUP TRIP - LINEUP ALARM FC2505 T Battery Vdc Too Low To Start FC2550 A State Machine Module Simulation Active " " # ! % # ( % # ( , # ! , ( # % # # ( . / $ $$ $& $' $) $* Document Number ABB Inc. Lang. Rev.. E D Sheet 28 No. of sh.. 32 Interface Instructions 8. APPENDIX C: SYSTEM FAULT REGISTERS DEFINITION System Fault Register 1 Bit 6 7 8 $ 6 7 8 & 6 7 8 ' 6 7 8 2 $ , 9 ! 2 $ $ , 2 $ & , 2 $ ' ) 6 7 8 2 $ ) ! , ! * 6 7 8 2 $ * " + 6 7 8 - 6 7 8 2 $ + , "" 2 $ - " :# 2 " . 6 7 7 ! ! ( " #, ! ( " " ( ( ( ( " " "" " / 6 7 7 2 $ * 7 2 $ *$ ! $ 6 7 7 2 $ *& 2 &2 " &" $$ 6 7 7 2 $ *' 2 '2 " '" $& 6 7 7 2 $ *) 2 )2 " )" $' 6 7 7 2 $ ** 8 7 ! $) 6 7 7 2 $ *+ $* 6 7 7 2 $ *! ! 2 $2 " $" 9 ! " :# $& 1 8 " ( ! Document Number ABB Inc. . " $& 1 9 Lang. Rev.. E D Sheet 29 No. of sh.. 32 Interface Instructions System Fault Register 2 Bit 6 7 7 2 $ *. 9 # $ 6 7 7 & 6 7 7 2 $ */ :# 2 $ + ' 6 7 7 ) 6 7 7 2 $ +$ 7 2 $ +& * 6 7 7 2 $ +' + 6 7 7 2 $ +) - 6 7 8 . 6 7 8 / 6 7 7 2 $$ 7 ;7 ;2 2 $$ $ 8 ;7 ;2 2 $$* 75 # $ 6 7 7 2 $$*$ $$ 6 7 7 $& 6 7 7 $' 6 7 7 $) 6 7 7 $* 6 7 7 2 ' 45 2 ' 45 2 ' 41 2 ' 41 2 ' 9 # # : :# # ( ( ( % 2 % ( " " . " ( ( " ( , "" < # , "" ( 45 ( # ( 45 ( , "" < # ( , "" ( 41 # ( 41 Document Number ABB Inc. 8 " " , * ( *$ ( *& ( *' ( *) ( ( "" ( "" ( "" ( "" Lang. Rev.. E D Sheet 30 No. of sh.. 32 Interface Instructions System Fault Register 3 Bit 6 7 8 2 '$ # $ 6 7 & 6 7 7 8 2 '$* 2 $ ., 8 ' ) * + . / $ $$ $& $' $) $* Document Number ABB Inc. Lang. Rev.. E D Sheet 31 No. of sh.. 32 Interface Instructions 9. REVISION HISTORY REVISIONS TABLE REV REV IND DATE DESCRIPTION BY A 06/01/2011 FIRST ISSUE JM B 06/02/2011 SECOND ISSUE JM C 06/09/2011 THIRD ISSUE JM D 07/21/2011 FOURTH ISSUE JM Document Number ABB Inc. Lang. Rev.. E D Sheet 32 No. of sh.. 32