ServiceManual - FB10-20-30 SM01 - 80-000007 - V01.01 - RIS - 2013-12-20

SERVICE MANUAL
Vanadium Redox Flow Battery
CellCube FB 10/20/30
V01.01
COPYRIGHT CELLSTROM 2013

Content
1. Introduction ___________________________________________ 7
2. Scope _________________________________________________ 7
3. Hazards _______________________________________________ 7
3.1. Symbols _________________________________________________ 7
3.2. Protective clothing _______________________________________ 9
3.3. Safety instruction ________________________________________ 9
3.3.1. Electrolyte __________________________________________________ 9
3.3.2. Hydrogen __________________________________________________ 11
3.3.3. Electrical __________________________________________________ 11
3.3.4. Mechanical ________________________________________________ 12
4. Installation preparations _______________________________ 13

4.1. Steps to be prepared by the customer_____________________ 13
4.2. Preparing an emergency plan ____________________________ 13
5. Installation ___________________________________________ 15
5.1. Preparative work ________________________________________ 15
5.1.1. Unloading _________________________________________________ 15
5.1.2. Check of delivery ___________________________________________ 15
5.1.3. Placing the battery __________________________________________ 15
5.1.4. Further equipment required __________________________________ 16
5.2. External connections ____________________________________ 17
5.2.1. Earthing connections________________________________________ 18
5.2.2. Electrical connections _______________________________________ 20
5.3. Filling the tanks with electrolyte __________________________ 20
5.4. Flow battery controller (FBC) start up _____________________ 24
5.4.1. Degassing the fluid circuits __________________________________ 25
5.4.2. First start of the FBC and test mode __________________________ 27
5.5. Forming and first charging of the electrolyte ______________ 31
5.6. Configuring and testing communication___________________ 32
5.6.1. Command & Communication interfaces _______________________ 33
5.6.2. TeamViewer _______________________________________________ 33
5.6.3. Operational test ____________________________________________ 34
5.7. Final checks and acceptance _____________________________ 34
6. Operating the FB 10/20/30 _____________________________ 35
6.1. Starting the system ______________________________________ 35
6.2. Manual stop _____________________________________________ 35
6.3. Manual start_____________________________________________ 35
6.4. EMERGENCY STOP mode ________________________________ 36
6.5. Monitoring software _____________________________________ 36
SM_Servicemanual FB10-20-30 SM01_80-000007_V01.01_RIS_2013-12-20 Page 2 / 72

7. Troubleshooting ______________________________________ 41
7.1. General procedures _____________________________________ 41
7.1.1. Opening the gas barrier _____________________________________ 41
7.1.2. Opening the fluid system ____________________________________ 42
7.1.3. Reconnecting hoses ________________________________________ 43
7.2. Leakages _______________________________________________ 43
7.3. Stack exchange _________________________________________ 44
7.4. Exchange the OCV cell___________________________________ 47
7.5. Pump exchange _________________________________________ 48
7.6. Exchange valves ________________________________________ 52
7.6.1. Exchange balance valve (motor) _____________________________ 52
7.6.2. Exchange balance valve (fluid part) ___________________________ 52
7.6.3. Exchanging a hand valve ____________________________________ 53
7.7. Exchange sensors _______________________________________ 54
7.7.1. Pressure sensors ___________________________________________ 54
7.7.2. Level sensors ______________________________________________ 54
7.7.3. Hydrogen sensor tank _______________________________________ 56
7.7.4. Hydrogen sensor fluid compartment __________________________ 56
7.7.5. Smoke detector ____________________________________________ 56
7.7.6. Temperature sensor ________________________________________ 56
7.7.7. Door position switch ________________________________________ 57
7.7.8. Leakage sensor ____________________________________________ 57
7.8. Exchange an inverter ____________________________________ 57
7.9. Exchange relays on the FBC _____________________________ 59
7.10. Exchange the FBC unit __________________________________ 59
7.11. Exchange the Tiny Tiger processor _______________________ 60
7.12. Exchange a fuse_________________________________________ 61
7.13. Exchange a pump driver _________________________________ 61
7.14. Exchange a ventilation fan _______________________________ 61
7.15. Exchange a circuit breaker _______________________________ 61
7.16. Exchange the aerial______________________________________ 62
7.17. Exchange the communications device ____________________ 62
7.18. Exchange the backup battery_____________________________ 62
8. Information about the FBC operation ___________________ 62
8.1. Low temperatures _______________________________________ 62
8.2. High temperatures _______________________________________ 62
8.3. List of error messages ___________________________________ 63
9. Yearly maintenance ___________________________________ 67
9.1. Stack testing (homogeneity and symmetry)________________ 68
9.2. Leakage sensor test _____________________________________ 68
9.3. Smoke detector test _____________________________________ 68

9.4. Hydrogen sensor test (fluid compartment)_________________ 69
10. Decommissioning _____________________________________ 70
11. Cellstrom Service Center ______________________________ 70
12. Terminology __________________________________________ 71

List of figures
Figure 3.1 – Electrolyte colours at different charge states ...................................................... 9
Figure 5.1 – Attachment swivel and plastic cover ................................................................. 16
Figure 5.2 - External switching cabinet, inside view .............................................................. 17
Figure 5.3 – Earthing connections ........................................................................................ 18
Figure 5.4 – Foundation plan with grounding points – version with standard ext.
switch cabinet ................................................................................................ 19
Figure 5.5 – Placing the IBCs with electrolyte in front of the battery ................................... 21
Figure 5.6 – Filling nozzle with end cap ................................................................................ 22
Figure 5.7 – Hose connected for filling the tank .................................................................... 22
Figure 5.8 – Drum pump in IBC, with splash protection ........................................................ 22
Figure 5.9 – Valve in the open position, gas barrier is bypassed .......................................... 23
Figure 5.10 – Partly open tank lid, positive tank.................................................................... 23
Figure 5.11 – Pump chamber, hand valve in open position .................................................. 23
Figure 5.12 – Gas barrier, normal operating position ............................................................ 24
Figure 5.13 – Pumps filled with electrolyte............................................................................ 25
Figure 5.14 – Hydraulically isolated stack with secured return hoses ................................... 26
Figure 5.15 – Correctly attached hose on the stack .............................................................. 26
Figure 5.16 – Charger connected to the DC rail ................................................................... 28
Figure 5.17 – FBC Controller ................................................................................................ 28
Figure 5.18 – Balance position of the motor valve ................................................................ 29
Figure 5.19 – Normal position of the motor valve.................................................................. 29
Figure 5.20 – DC-rail without bridge ..................................................................................... 30
Figure 5.21 – Circuit breakers F50 and F51 ......................................................................... 32
Figure 5.22 – Data communication ....................................................................................... 33
Figure 6.1 - Start button S1 .................................................................................................. 35
Figure 6.2 - FBC control buttons........................................................................................... 35
Figure 6.3 - Monitoring - Voltage and Current....................................................................... 36
Figure 6.4 - Monitoring - Battery Values ............................................................................... 37
Figure 6.5 - Monitoring - SMA A ........................................................................................... 37
Figure 6.6 - Monitoring - SMA B ........................................................................................... 38
Figure 6.7 - Monitoring - Additional ....................................................................................... 38
Figure 6.8 - Monitoring - Statistics ........................................................................................ 39
Figure 6.9 - Monitoring - Error list ......................................................................................... 39
Figure 6.10 - Monitoring - Control ......................................................................................... 40
Figure 6.11 - Monitoring - Check System ............................................................................. 40
Figure 7.1 – Valve in the open position, gas barrier is bypassed .......................................... 41
Figure 7.2 – Valve in the closed position, gas barrier is active .............................................. 42
Figure 7.3 – Stack with opened OUT connections ............................................................... 42
Figure 7.4 – Hand valve in the open position ....................................................................... 43
Figure 7.5 – Correctly attached hose on the stack ................................................................ 43
Figure 7.6 – Hydraulic shortcut on OUT nozzles................................................................... 45
Figure 7.7 – Correctly closed stack....................................................................................... 45
Figure 7.8 – Stack slide for upper row .................................................................................. 46
Figure 7.9 - Tubing on OCV cell before disconnection ........................................................ 47
Figure 7.10 – Draining the manifold before exchanging a pump ........................................... 49
Figure 7.11 – Connecting the air pump................................................................................. 49
Figure 7.12 – Hand valve in the partly closed position ......................................................... 50
Figure 7.13 – Unscrew pump clamps .................................................................................. 50
Figure 7.14 – Open screw fitting .......................................................................................... 50
Figure 7.15 – Pump head filled ............................................................................................ 51
Figure 7.16 – Position of balance valve ............................................................................... 52
Figure 7.17 – Exchanging the balance valve ....................................................................... 53

Figure 7.18 – Level sensors ................................................................................................ 55
Figure 7.19 – Temperature sensor ...................................................................................... 57
Figure 7.20 – Inverter exchange .......................................................................................... 58
Figure 7.21 – SMA piggyback communication board ........................................................... 59
Figure 7.22 – FBC board exchange ..................................................................................... 59
Figure 7.23 – Tiny Tiger exchange ...................................................................................... 60
Figure 9.1 – Stack positions ................................................................................................. 68
Figure 9.2 – Readjusting the hydrogen sensor ..................................................................... 69

1. Introduction
The information, designs and illustrations including materials, methods,
techniques or equipment that are described here, are and remain the exclusive
property of Cellstrom GmbH.
It is not permitted to transmit Information or illustrations to third parties without the
explicit written permission of Cellstrom GmbH.
The content of this handbook is only for information purpose and may be
changed at any time without prior notice. Cellstrom GmbH retains the right to
make alterations to the product design without informing the user.
2. Scope
The descriptions, instructions and recommendations contained within this
document concern only the FB 10/20/30 energy storage system. Various
peripheral devices are not covered, such as photovoltaic installations, generators
and external appliances.
This document is intended as an aid for persons that have been trained and
certified by Cellstrom to conduct installation and maintenance work on the FB
10/20/30 energy storage system. A basic knowledge of the Vanadium Redox
Flow Battery technology is assumed.
3. Hazards
3.1. Symbols
The following hazard symbols or their equivalent in the country of installation
must be prominently displayed on the FB 10/20/30.
Symbol Location Meaning

On fluid and Harmful, toxic (T) – refers to the
electrical side - charged positive electrolyte,
inside especially the V(V) component
On fluid side - Warning of explosive atmosphere –

inside refers to an explosive, hydrogen
containing gas atmosphere in the tank
and the gas exhaust pipe

On both sides - Corrosive (C) – refers to the
inside electrolyte, especially the sulphuric
acid component
On both sides - Danger from batteries

outside
On both sides and Voltage hazard – primarily refers to

external switching the 230 V AC on the electrical side but
cabinet - outside also the DC battery voltage (high
discharge currents)
On fluid side - Gloves must be worn, refers to the

inside electrolyte
On both sides - Read manual or handbook, refers to

inside all service and maintenance work
On fluid side – Eye protection must be worn, refers to

inside and outside the electrolyte
On both sides - No naked flames, refers to hydrogen

inside flammability and activating smoke
detectors.
On fluid side – No eating or drinking, refers to

inside electrolyte
On both sides - Do not enter, entry only for qualified

outside personnel
The warning symbols should be clean, legible and complete. If they are damaged
or illegible they should be replaced.

3.2. Protective clothing
The FB 10/20/30 is divided into two sections: the fluid section and the electrical
section. When working on the fluid section protective clothing must be worn to
prevent from getting in contact with the electrolyte. Eye protection and disposable
gloves of the appropriate types must be worn. Protection for clothing (body suit)
is strongly advised and must be worn during the initial filling operation. The
electrolyte will affect most clothing materials as well as skin.
Disposable gloves have a limited stability period after contact with electrolyte and
therefore should be changed periodically. They should also be replaced if
punctured or torn. All contaminated protective equipment should be disposed
after use in PE or PP sacks, before arranging for suitable chemical waste
disposal.
When working only on the electrical side no special clothing is required. However,
when working with heavy objects (stacks, inverters, chargers, etc.) steel-capped
footwear must be worn.
Additional protective equipment may be used as deemed appropriate. In
particular rubber boots should be worn for electrolyte filling and treatment of
leakages.
3.3. Safety instruction

3.3.1. Electrolyte
The electrolyte is a solution of vanadium salts in sulphuric acid. The vanadium
gives the electrolyte its colour and as the battery is charged the colour of the
electrolytes (positive and negative) changes. From the colour it is possible to
identify whether the electrolyte is from the positive or negative tank and how high
it is charged. Using a laboratory spectrometer this state-of-charge (SOC) can be
accurately measured, but it is possible to make a very rough visual judgement.
Figure 3.1 – Electrolyte colours at different charge states
The figure above shows charged negative electrolyte (violet), discharged

negative (green), discharged positive (blue) and fully charged positive (yellow or
orange). In practice a 100% charged electrolyte will never be reached. Therefore
the colour deviates from the pictures shown above. A partly charged negative
electrolyte has a lighter green, a partly charged positive is very dark (often almost
black). The original electrolyte is a mixture of discharged positive and negative
electrolyte and has a dark green-blue colour.
Before approaching the electrolyte the safety data sheets should be read
carefully and fully understood. The electrolyte in all conditions is corrosive due to
the sulphuric acid so eye, hand and clothing protection must be worn. With the

presence of charged (even partly charged) positive electrolyte fully oxidised
vanadium is formed. This form of vanadium is toxic and should be handled with
extra care.
In general the electrolyte is most dangerous if inhaled as dry powder or ingested.
Therefore dry, crusty deposits of electrolyte should be dissolved in water and
then be absorbed onto cleaning paper and disposed. Dry deposits of electrolyte
should not be scraped away or abraded, to avoid raising hazardous dust - see
also the section on cleaning.
If any electrolyte gets in contact with eyes or skin it should be washed off
immediately with plenty of water. Eye wash bottles must be always close at hand
when working near the electrolyte, and provide the simplest method of flushing
the eyes. Similarly water in suitable containers (ca. 0.25 - 2 l) should be on hand
for cleaning electrolyte off the skin. It is essential that these measures are taken
before commencing work, because any delay in treatment is likely to worsen the
condition. Medical assistance should be sought immediately if feeling unwell
while working on the FB 10/20/30.
The electrolyte has a very long lifetime. However, the lifetime will be considerably
shortened if it becomes contaminated. Therefore, no materials that have not been
approved in writing by Cellstrom GmbH may be used in the fluid lines (this
includes pipes, pumps, pressure sensors, stacks, valves and tanks). This refers
not just to the solid components, but also to any greases, powders, fats or oils
that may be considered. Use of inappropriate materials can lead to irreparable
damage to the FB 10/20/30 and hazardous conditions to the user.
Special care must be taken when working with open tanks. Make sure that no
tools, components, other objects, dirt or liquids fall into the electrolyte!
If an electrolyte leakage happens the following actions must be taken depending
on the leakage type.
Leakages can be classified into three types, according to the severity:
Type I – minor leakage: contained on tank. Electrolyte may be dehydrated. Do
not abrade. Dry electrolyte should be dissolved with deionised water from the
spray bottle. Liquid electrolyte should be cleaned with the cleaning paper. All
surfaces should be completely cleaned from electrolyte. Contaminated waste
should be contained in plastic waste sacks for disposal. If the leakage rate is very
low (few drops per day) the battery can be kept operational and further action
should be discussed with Cellstrom. If the leakage rate is more significant the
leaking component should be replaced.
Type II – major (contained) leakage: leakage of electrolyte into secondary
container. The further action should be discussed with Cellstrom.
Type III – major (uncontained) leakage: leakage outside of the secondary
container into the surrounding environment. If possible, prevent the spillage from
spreading using physical barrier means (absorbent earth, sand bags, acid-spill
containment pillows). Arrange for pumping of the remaining electrolyte into IBCs
for reconditioning. Contact Cellstrom. If the electrolyte has entered the
surrounding soil this must be immediately collected, contained, labelled and
disposed by a local chemical treatment company. If the electrolyte or oil has
entered the sewage or water supply relevant authorities must be informed
immediately. In no case the attempt should be made to neutralise the electrolyte
– it can become very hot. All local, relevant laws must be adhered to. Follow the
pre-arranged emergency plan.

3.3.2. Hydrogen
Like every battery with a water-based electrolyte (vanadium redox, lead-acid,
nickel-cadmium, nickel-metal hydride, etc.) the battery will evolve hydrogen gas.
The amount is rather small in comparison to lead-acid batteries (especially the
flooded types) and is collected and vented from the tanks via a gas vent pipe.
The tank room is separated from the outside air by a gas barrier. The gas
atmosphere in the tank may overcome the gas barrier only when reaching a
certain overpressure. Therefore the hydrogen concentration in the tank is higher.
Hydrogen gas is flammable and explosive if concentrated enough. In air at
standard temperature and pressure this is about 4%. To prevent ignition
(accidental or deliberate) of the hydrogen in the tank head-space (the gas above
the oil layer) a flame arrestor is mounted at the end of the vent pipe.
A hydrogen sensor is built into the container to warn of any accumulation of gas.
If the level rises above a first set point (well below the explosive limit) the
ventilation fans will start automatically to blow the gas out of the container.
However, if the level continues to rise, a second warning level will be reached.
This will lead to a shutdown of the battery.
ATTENTION:
Extreme care must be taken in approaching an FB 10/20/30 which is
reporting an hydrogen alarm at level 2. The current hydrogen concentration
inside the fluid compartment is not known, since the battery was switched off
automatically. Therefore, all naked flames and sparks are forbidden when
opening the service flap on the fluid side of the FB 10/20/30 (including strict
smoking prohibition in the immediate surrounding area).
The hydrogen detector must be checked regularly and, if necessary, recalibrated
using a calibration gas (1 - 3% hydrogen in synthetic air). For further details see
chapter 9.4.
ATTENTION:
If opening the tank covers it may be assumed that the head space
contains a high level of hydrogen. This procedure should be done with extreme
care. The gas in the head-space will rapidly become diluted when the covers are
removed, but may initially be at an explosive concentration. Therefore, all naked
flames and sparks are forbidden when working on the FB 10/20/30 (including
strict smoking prohibition in the immediate vicinity). Take care of adequate air
exchange inside the battery room in case of indoor installations.
3.3.3. Electrical
The stacks should be treated as high power batteries. Even when disconnected
from the fluid and electrical circuits they will still contain some electrolyte and may
be able to give high discharge currents. Therefore, the terminals should be
covered with insulating material (e.g. electrician’s tape) if a stack is removed.
All tools should be insulated to prevent accidental short-circuits. A single stack
can deliver over 700A short-circuit current. This will cause an electric arc,
overheating of the tool and danger for the technician. For the same reason all
metallic jewellery must be removed before working on the battery, especially
necklaces and bracelets.
The inverter provides AC at a household mains level (typically 230 V or 3x 400V).
These voltages can be lethal! This should be treated with appropriate caution

Potential lethal voltages for humans are:
Over 50 V alternating current (AC)
Over 120 V direct current (DC)
Following an electric shock medical help must be sought. Dangerous
disturbances to heart rhythms can appear hours later!
The emergency stop button will stop the battery. However, voltages will still be
present (stack contacts, voltages from external sources, etc).
Before working on the battery all of the high current fuses (F1.1 – F1.10) must be
disconnected and the circuit breaker(s) FAC2 (grid/generator) need(s) to be
switched off.
If there is a need for working on the battery in operation use safety equipment
(protection goggles, safety gloves,G)
If work has to be done while it is raining or snowing it is necessary to cover the
open battery with a canvas.
Replacement of fuses and all other components is only allowed with original
parts.
All local and national electrical safety procedures must be adhered to.
3.3.4. Mechanical
There are no automated moving parts inside the FB 10/20/30 except for the fans,
motorised valves and pumps. These are relatively low power, protected and
unlikely to cause injury.
However, care should be taken when removing or replacing heavier items, like
chargers, inverters and stacks. In particular a new stack is several kilograms
lighter than one that was in service, due to the retained electrolyte weight. These
items should be carried by two people if it is required to move them any
significant distance.
When closing the service flaps take care not to squash your fingers.
The procedures outlined in this handbook for removal and exchange of
components must be followed.
The working area should be cordoned off with warning cones to prevent
accidental harm of third parties, especially when working in urban environments.
This is most necessary during the filling operations (electrolyte and oil) and
dealing with electrolyte leakages.

4. Installation preparations
The site should be prepared in such a way that in the case of a type III leakage
no electrolyte can enter sewage or water supplies or otherwise significantly
endanger people or properties.
An emergency plan (fire, type III leakage) in collaboration with the customer
should be in place before commencing installation.
4.1. Steps to be prepared by the customer

Please refer to the document “Site Preparation Guide for CellCube FB 10/20/30”.
4.2. Preparing an emergency plan

The emergency plan together with the appropriate safety data sheets can be
found in the customer documentation. This sheet is to be filled out in
collaboration with the customer. It describes procedures to be taken in case of
serious incidents (for example in the case of fire or type 3 electrolyte leakage).
Emergency telephone numbers are to be found here.
Example of an emergency plan:

5. Installation
This chapter describes the sequence of installation and the first start-up. It
explains the necessary processes for proper installation. It is absolutely
necessary, to completely read and understand this document, before starting the
work.
5.1. Preparative work

5.1.1. Unloading
To be carried out with a suitable crane (min. 10t). For installations with special
housing constructions other unloading procedures may be required.
The electrolyte is delivered in 1000 l Intermediate Bulk Containers (IBC weight is
1,5 t). Electrolyte should be transferred as rapidly as possible to the battery and
must not be left unattended outdoors. It is important that the customer is aware of
the hazards so it is ensured that a safe storage area is provided until the battery
is filled.
Warning: Danger of crushing while unloading the truck! Wear safety
equipment to avoid injuries (protective helmet, safety shoes, glovesG).
5.1.2. Check of delivery

Any damage that happened during transport shall be noted on the delivery
papers. Document with photos and contact Cellstrom GmbH.
Check if the delivery is complete. Note any missing parts on the delivery papers
and inform Cellstrom GmbH.
5.1.3. Placing the battery

The battery has to be placed on the foundation with a crane, heavy transporter or
similar equipment. By using appropriate compensation plates the battery should
be levelled out on both axes (+/-1cm on long side, +/-0,5cm on short side,). Two
hydraulic jacks can be helpful for this procedure. The level should be measured
directly on the metal frame so the service flaps have to be opened.
Warning: Danger of crushing fingers! This work shall always be done by at
least two people!
Unmount the four attachment swivels and replace them by plastic covers
(delivered with the battery).
You need the following tools: a wrench no. 30 and an allen key no. 14.

Figure 5.1 – Attachment swivel and plastic cover
Cover the fork lift openings on the base of the metal frame with metal sheets
(delivered with the battery).
5.1.4. Further equipment required

In poor weather conditions it might be necessary to protect the battery from rain
coming in from the side. Especially the front boards on the electric side should be
protected from getting wet (e.g. with a canvas cover).
For easier access to the components a step-ladder or small stage should be
used.

5.2. External connections
All external connections are done via the external switching cabinet.
Figure 5.2 - External switching cabinet, inside view
1 Communication interfaces
XCOM9 (ModBus) – communication external control system
XCOM10 Customer’s LAN / Internet
Option: XCOM1 to 4 - SMA interface (optional MC-Box or AS-Box)
Option: XCOM5 + 6 - Interface to Webbox
Option: XCOM7 + 8 - Multicluster communication interface
Option: XCOM11 – ModBus interface for further devices in the switching cabinet
2 Option: Relay switch (generator request, load shedding)
3 2x Circuit breaker for AC connection AC1 (island grid – PV, wind, loads,G)
4 2x Circuit breaker for AC connection AC2 (grid, generator)
5 2x Circuit breaker (6A) and relay switch for ventilation
6 Main earthing terminal

Warning: Danger of electric shock! Be sure to switch off all power supplies
while working at the external switching cabinet.
5.2.1. Earthing connections

Earthing connections must be made by a licensed electrician in accordance with
local regulations.
The cabinet has earthing connections on 2 corners of the base which have to be
connected with the foundation earth electrodes (in opposite corners).
See figure Figure 5.4 – Foundation plan with grounding points
Figure 5.3 – Earthing connections
A central earthing point for the battery is located in the external switching cabinet.

Figure 5.4 – Foundation plan with grounding points – version with standard ext. switch cabinet
5.2.2. Electrical connections
The availability of electrical connections is very important for further progress of
the installation so it is very advisable to check this early enough.
1. Check availability of a 1-phase power supply 230 V, 16A for operating the
electrolyte pump
2. Check availability of a 3-phase power supply with 3 x 400 V, min. 16 A for
operating the charging unit. Especially check if you have the matching
adapter for connecting the device.
3. In case of a grid connection the right grid type needs to be checked.
SI5048: only TN-grid supported
SBU5000: TN- and TT-grid supported
Check if the PE-N bridge in the external switching cabinet is needed.
For more details please refer to the document “Site preparation guide for
CellCube FB 10/20/30”.
ATTENTION: The grid must be connected in such a way that it produces
a clockwise rotation field.
Note: The electrical connection of the battery is in the responsibility of the

local electrician. It is important that there is full appreciation about those
issues on both sides, otherwise this might lead to big delays in the
installation or in the worst case even to hardware damages.
Before continuing the installation all high current fuses shall be removed from the
DC rail. Also in the external switching cabinet the AC breakers have to be
switched off.
5.3. Filling the tanks with electrolyte

The FB 10/20/30 battery is available in different sizes of power and energy
capacity. For the different storage sizes the following amounts of electrolyte are
needed:
Capacity [kWh] Electrolyte [litres]

40 2000
70 3500
100 5000
130 6500
Material and tools:

• Required amount of electrolyte in standard IBCs (intermediate bulk
containers á 1000 l)
• Tank pump
• Hose
• Cleaning paper, waste sacks

• 230 V plug socket, extension cable
• Eye wash bottle
• Deionised/distilled water in containers (20 l)
• Water in spray bottle
• Clean bucket
• Warning devices (warning cones, warning tape)
• Personal protective equipment (see safety section)
The electrolyte is delivered in standard IBCs (intermediate bulk containers), from

which it is pumped into the battery tanks:
Park the electrolyte delivery vehicle as close as possible to the FB 10/20/30. The
working area should be cordoned off with warning cones and tape (especially in
an urban environment).
Figure 5.5 – Placing the IBCs with electrolyte in front of the battery
Use one pump for each tank side to fill both tanks in parallel. Attach a hose to a
filling nozzle on each tank after removing the end cap and checking the O-ring.
The hose should be secured with at least 2 hose clamps.
Both tanks are filled in parallel. Each tank must be filled with exactly the same
amount of electrolyte. Before starting check the fill levels of all IBC containers.
Clean the IBCs around the screw caps before opening. Put each pump into a
separate IBC and loosely seal the opening with a splash protection sheet (ideally
transparent):

Figure 5.6 – Filling nozzle with end cap
Figure 5.7 – Hose connected for filling the tank
Figure 5.8 – Drum pump in IBC, with splash protection

Important:
Open the valve of the gas barrier and the left tank lid (partly) to let the initial gas
filling (nitrogen) escape from the tank while filling in the electrolyte. The tank lid
should lie loosely on the hole, so overpressure in the tank can easily escape.
Figure 5.9 – Valve in the open position, gas barrier is bypassed
Figure 5.10 – Partly open tank lid, positive tank
Both hand valves in the pump chamber should be open:
Figure 5.11 – Pump chamber, hand valve in open position

Start the drum pumps and straight away check the tightness of the filling system,
along the entire hoses, especially around the hose clamps. This requires two
people, one at the pumps and one at the tank. With the open hand valves all
pumps will be filled so carefully watch for tight connections around the pumps.
Pump out from the IBC until a little electrolyte remains in the bottom. Then lift the
IBC on one end to pump out the residual electrolyte (2-person operation). When
the pump revs up, the hand valve on the hose should be closed, the pump
switched off and transferred to the next IBC. Repeat until all the electrolyte has
been pumped from the IBCs to the tanks.
Finally a container with 10 l of deionised water should be pumped through each
hose and pump. Depending on the length of the hose less water might be
sufficient. Check if the complete hose is now filled with water. Now you can
disconnect the hose from the pump. At this point the hose must be above the
tank fill level – otherwise water/electrolyte will flow back. The hose is then raised
to empty the contents gradually into the tank.
Remove the hose from the filling nozzle and replace the end cap. Do not forget
the O-ring. Seal the openings of hose and pump tightly.
ATTENTION:
The valve of the gas barrier must be closed before starting the system.
Figure 5.12 – Gas barrier, normal operating position
5.4. Flow battery controller (FBC) start up

As soon as there is voltage on the DC bus the FBC (flow battery controller) can
be started. In normal operation the backup batteries are charged from the DC rail.
They can deliver enough energy to pump electrolyte through the stacks and
hence start the energy supply. However, for the first start an external charging
device is required to initially start the inverters for charging the electrolyte.
The FBC communicates with the miniPC, via which the status of the battery can
be monitored using the Monitoring SW (for details see chapter 6.5). All
parameters are displayed simultaneously.
Before starting the next steps it is essential that the power supply (grid or
generator) is prepared by the on-site electrician. Alternatively a PV-system
connected to AC1 can be used as a power supply for charging the battery.

5.4.1. Degassing the fluid circuits
Material and tools:
• Torque wrench, 1,2Nm
• 7 mm socket
• Eye wash bottle, water in open container (250 ml – 2 l)
The working area should still be cordoned off.

The stacks and manifold are free of electrolyte at this moment. The pumps are
not self-priming and must to be filled with electrolyte before starting. Since the
hand valves were open while filling this state should be given already (optical
check, see following picture).
Figure 5.13 – Pumps filled with electrolyte
If there is still air in the pumps you need to allow air to escape from the system.
The return hoses to one stack of each pump circuit should be disconnected and
the free end attached with a cable tie above the level of the manifold (see
picture).

Figure 5.14 – Hydraulically isolated stack with secured return hoses
If the air has escaped from the pumps the return hoses should be reconnected to
the stacks and secured with hose clamps (1,2 Nm torque).
Important - the hose should be pushed completely onto the hose nozzle. The
hose clamp should be positioned 1 - 2 mm away from the end of the hose.
Figure 5.15 – Correctly attached hose on the stack

5.4.2. First start of the FBC and test mode
Material and tools:

• Charger, 60V, 5 - 15kW, short-circuit safe
• DC high current cables, ca. 90 mm2
• 3-phase socket, 3 x 400 V, min.16A from mains or a diesel generator
• 3-phase extension cable
• Bridge cable 35mm2
• NH-fuse handle
• VGA Monitor, USB-keyboard and USB-mouse for MiniPC
The charger must be connected directly to the DC rail as shown in the following
picture. Only in case you have a FB20 or FB30 connect the left and the right
positive rail with the bridge cable. This is necessary to make all pumps running
during the flushing procedure.

Figure 5.16 – Charger connected to the DC rail
Set Jumper 12 on the FBC to the right -> pumps will not be stopped when fluid
side is open.
Figure 5.17 – FBC Controller
Disconnect all string fuses (F1.1 – F1.10) from the DC rail using the NH fuse
handle.
Set the charger to 50 V and 50 A. The FBC starts, the red LED LD2 is on and the
display is active.

Test mode:
RESET the FBC with S1 and right after press and hold both pushbuttons A and B
for 5 seconds. The controller will start in the test mode. Various test steps will
now be carried out ending with flushing the fluid lines.
Test sequence:
a) Check the ventilation: Press the left pushbutton, no check of AC-ventilation
possible at this point.
b) Check the motor valve, it should move to the “balance” position.

Visual check -> if OK press the left pushbutton.
Figure 5.18 – Balance position of the motor valve
c) Check the motor valve moving to the “normal“ position.

Visual check -> if OK press the left pushbutton.
Figure 5.19 – Normal position of the motor valve

Flushing sequence:
During the flushing procedure it is important to check the tightness of all fluid
circuits several times.
d) Operating the pump circuit 1 (ON/OFF operation), pressure is increased in
steps up to the maximum.
e) Operating the pump circuit 2 (ON/OFF operation), pressure is increased in

steps up to the maximum.
After all pumps are working together and the pressure is within the given limits
the system responds: “Flushing successful”.
the controller then automatically changes to normal operation mode
The test mode can also be selected manually using the left pushbutton (jumping
over the test steps).
In case there is a problem with pump pressure check the system. If there is still
air in the fluid circuit the flushing procedure should be repeated.
After successful flushing switch off the battery. Check if there is no voltage on the
DC-rail. If used take out the bridge cable between positive DC-rail A and B.
Figure 5.20 – DC-rail without bridge

5.5. Forming and first charging of the electrolyte
Material and tools:
• Power charger 5 - 15 kW, voltage regulated, short-circuit safe
• 3-phase plug socket from public grid or diesel generator
• Extension cable for 3-phase power supply (3x 400V)
• VGA monitor, USB-keyboard, USB-mouse
Connect monitor, keyboard and mouse to the miniPC so you are able to monitor
the system.
Switch on the circuit breakers in the external switch cabinet (FAC2_A, FAC2_B)
to provide the external power supply.
Insert 2 to 3 string fuses, depending on the max. power of the charger (5 kW
charger = 2 strings, 6 kW charger = 3 strings).
The charger should be set to 60V and to maximum current. Start the battery and
check if all pumps are running (FB Modular Monitoring).
Warning: Do not charge the battery if pumps are not running! Stacks
may get damaged.
Important: For safety reasons first charging of the battery should only be done via
inverters from grid or generator.
Start the Master inverter of cluster A. Set the inverter’s charging power to 15 kW
(using the Power Control Software). Insert the missing string fuses in cluster A
and start Slave1 and Slave 2. As soon as the inverters are charging from
grid/generator you can switch off the power charger.
After charging the electrolyte with ~ 60 kWh (in case of the 100 kWh type) it will
have reached a state of charge (SOC) of 0%. The OCV-voltage (and hence the
SOC) will climb slowly but steadily.
If an SOC of 5% is reached cluster B can be added. Be sure that the DC-rails of
cluster A and B are not connected. Insert the NH fuses for all strings on cluster B.
If there is enough voltage on the right DC-rail (B) the pumps of circuit 2 will start
immediately. If this is not the case stop the system and restart it again.
As soon as there is a stable voltage >50V on the right DC-rail switch on the
inverters of cluster B starting with the Master.
Attention: Be sure that during operation of the battery the circuit breakers
F50 and F51 in the external switching cabinet are always switched on.
Only in the on position all AC ventilators are in operation.

Figure 5.21 – Circuit breakers F50 and F51
5.6. Configuring and testing communication

Connection:
• UMTS Modem with SIM card (SIM card provided by customer)
• Optional: directed antenna (use test SW GSMCHKV01 for adjustment)
• Optional: W-LAN or LAN connection with access to internet
The FB 10/20/30 needs access to the internet. In case of failure warnings and
alarm messages will be sent via e-mail to the Cellstrom Service Center.
Remote monitoring and data transfer is carried out via TeamViewer. As a
prerequisite access to the internet via http port 80 is requested.
For e-mail communication access is needed to:
pop.gmx.net (POP3 mail input server)

mail.gmx.net (SMTP mail output server)
If a modem is used, put customers SIM card into the data modem. The antenna
is mounted on top of the external switching cabinet. The position of the antenna
can be optimized for best transmission with the program GSMCHKV01.
During operation several parameters are stored in logfiles. This data is sent from
the FBC to the miniPC where it is stored. Per day you get a file with approx. 20
MB.

5.6.1. Command & Communication interfaces
Figure 5.22 – Data communication
Following functions are realised:

• Monitoring and control (local or remote connection via TeamViewer)
• Transfer of battery data on request (via TeamViewer)
• Alarm messaging via email
• Remote software update
5.6.2. TeamViewer
A few parameters need to be configured to assure correct and safe operation.
For details please see the Service Information SI_28. In case of troubles contact
the Cellstrom Service Center (see chapter 11).

5.6.3. Operational test
Material and tools:
• Notebook with mobile internet access
• TeamViewer SW
Test of communication functions via internet

• Remote access via TeamViewer
• Alarming via e-mail (trigger test e-mail in Monitoring SW)
5.7. Final checks and acceptance

• Function of door switches.
• State-of-charge
• Cleanliness
• Tightness
• Set jumper 12 back to normal operation (left position)
• Introducing the battery to the customer (following the Operating Manual)
• Acceptance by customer -> acceptance protocol signed by customer
• Handover of keys (optional)

6. Operating the FB 10/20/30
6.1. Starting the system
Press the start button S1 for 3 seconds and the FBC will be started from the 2
lead batteries. The pumps are driven by these batteries for 5 minutes. If the
voltage on the DC-rail reaches a value >30V the lead batteries will be switched
off and further power supply comes from the DC-rail only.
In case the DC-rail voltage falls below 22V the lead batteries will not be switched
on again automatically. A manual restart with start button S1 will be necessary.
Figure 6.1 - Start button S1
6.2. Manual stop

Start and Stop function in normal operation is executed with
pushbuttons A and B below the LCD display of the FBC
controller.
By pressing both pushbuttons A & B for 5 seconds the system
will shut down. All sensors, pumps and ventilators are
switched off and the SMA inverters changed to standby. The
LCD display shows the message „System Shut Down“.
Figure 6.2 - FBC control buttons
6.3. Manual start

If the DC-rail voltage is higher than 24V it is possible to start the system by
pressing pushbutton A for 5 seconds.
If the voltage is >24V the start button S1 has no function.

6.4. EMERGENCY STOP mode
Pressing the EMERGENCY-STOP button will stop the battery immediately, i.e. all
pumps are stopped and the inverters are changed to standby. However, voltages
will still be present (stack contacts, DC-rail, voltages from external sources, etc).
After clearing the emergency situation release the emergency stop switch (turn
clockwise) and bring up the system by restarting the FBC.
6.5. Monitoring software

Tools:
• VGA monitor
• Keyboard and mouse
VI - Voltage and Current:
Figure 6.3 - Monitoring - Voltage and Current

Battery Values:
Figure 6.4 - Monitoring - Battery Values
SMA status:
Figure 6.5 - Monitoring - SMA A

Figure 6.6 - Monitoring - SMA B
Additional:
Figure 6.7 - Monitoring - Additional

Statistic:
Figure 6.8 - Monitoring - Statistics
Error list:
Figure 6.9 - Monitoring - Error list

Control:
Figure 6.10 - Monitoring - Control
Check System:
Figure 6.11 - Monitoring - Check System

7. Troubleshooting
This chapter describes procedures for appropriate trouble shooting. It is important
to completely and thoroughly read this chapter before commencing work.
ATTENTION: When opening the fluid compartment the pumps will be
switched off automatically. For safety reasons it is necessary to shut
down the FBC and then push the Emergency Stop button before entering
the fluid compartment of the battery.
Working on the fluid side always requires two people!
7.1. General procedures

7.1.1. Opening the gas barrier
This procedure is necessary as preparation for the following tasks:
• Stack exchange (chapter 7.3)

• Pump exchange (chapter 7.5)
• Balance valve exchange (chapter 7.6.2)
• Hand valve exchange (chapter 7.6.3)
• Pressure sensor exchange (chapter 7.7.1)
• OCV-cell exchange (chapter 7.4)
• Level sensors exchange (chapter 7.7.2)
• Tank hydrogen sensor exchange (chapter 7.7.3)
Before opening the tank cover open the valve of the gas barrier (see figure
below) to let some overpressure escape from the tank head space.
ATTENTION:
Keep away all naked flames and sparks battery. Smoking is strictly
prohibited in the immediate vicinity.
Wait for at least 15 minutes.
Figure 7.1 – Valve in the open position, gas barrier is bypassed
Before the system is taken into operation again the valve must be set to the
closed position.

Figure 7.2 – Valve in the closed position, gas barrier is active
7.1.2. Opening the fluid system

Letting air into the fluid system increases the drainage speed.
This procedure is necessary as preparation for the following tasks:
• Stack exchange (chapter 7.3)

• Pump exchange (chapter 7.5)
• Balance valve exchange (chapter 7.6.2)
• Hand valve exchange (chapter 7.6.3)
• OCV-cell exchange (chapter 7.4)
Remove the return hoses (OUT) of one stack in each pump circuit. Prepare
cleaning paper to catch any electrolyte dripping out.
Figure 7.3 – Stack with opened OUT connections
Wait for at least 5 minutes for remaining electrolyte to drain back into the tanks.
The hand valve in the pump chamber must be in the open position (see figure
below).

Figure 7.4 – Hand valve in the open position
7.1.3. Reconnecting hoses

The Stack- and OCV-hoses should be pushed completely onto the hose nozzle.
The hose clamp shall be only 1 - 2 mm away from the end of the hose.
Figure 7.5 – Correctly attached hose on the stack
The right torque for tightening the hose clamp is 1,2 Nm.
7.2. Leakages
Material and tools:
• Eye wash bottle
• Water in open container (250 ml – 2 l)

The working area should be cordoned off with warning cones and tape
(especially if in an urban environment).
For classification of leakage please refer to chapter 3.3.1
7.3. Stack exchange

Material and tools:
• Torque wrench (adjustable)
• Eye wash bottle, spray bottle
• Water in containers (250 ml – 2 l)
• 7 & 13 mm sockets
• 13 mm spanner
• Electrician’s tape
• Plastic drip tray (PE, PP or PVC-U)
• Pliers (to cut cable ties)
• 2 short hoses (~40cm) and 4 hose clips
• Plastic beakers (various sizes) as collecting vessels
• Personal safety equipment (see safety section)
• Stack slide
Park the vehicle with the replacement stack as close to the FB 10/20/30 as
possible. Cordon off the working area using warning cones and tape.
Discharge the battery as far as possible.
Switch off the battery by pressing and holding both pushbuttons (A and B) on the
FBC-board for 5 seconds. Switch off all inverters (DC-switch at the front) and
remove all string fuses from the DC-rail. Afterwards press the emergency stop
button (= safe state).
Open the valve of the gas barrier for at least 15 minutes -> refer to chapter 7.1.1.
Open the hydraulic system to drain the fluid circuits -> refer to chapter 7.1.2.
Shortcut the open nozzles OUT+ and OUT- with the short hose and tighten the
hose clips.

Figure 7.6 – Hydraulic shortcut on OUT nozzles
Now disconnect the inlet hoses as well. The stack is now completely
disconnected from the fluid system.
In case there are any electrolyte residues on the stack they have to be diluted
with water before wiping them away with cleaning paper. You shouldn’t inhale
any electrolyte dust so refrain from scratching it away in dry condition.
Now connect also IN+ with IN-. Write the last SOC onto the stack. The higher the
SOC was the more gas might be produced inside the stack during transport
(overpressure inside the stack).
Figure 7.7 – Correctly closed stack
Disconnect the electrical cables from the stack terminals. Insulate the stack
connectors thoroughly with electrician’s tape (there may still be a significant
voltage across the terminals).
ATTENTION: Work carefully - danger of short cut of the stack terminals!
The stack is heavy (ca. 40 kg), 2 people are required to carry it!
Remove the stack with the help of the stack slide. Secure the slide on 4 points as
shown on the following picture before you use it.

Figure 7.8 – Stack slide for upper row
Transfer the stack to a plastic drip tray. The stack has to be packed into a tight
plastic bag for transport and sent back to Cellstrom declared as dangerous good.
ATTENTION: If it is not possible to send the stack back to Cellstrom then it
has to be destroyed irrecoverably by a certified disposal company. Don’t
disassemble the stack, this is very dangerous!
Insert the new stack and reconnect in the reverse order of disconnection. Tighten
the screws at the electrical stack terminals with a torque of 6 Nm. If they are not
tightened enough the connections can get very hot -> danger of burning hands.
Finally the stacks must be reconnected to the hoses and the hose clamps
tightened with a torque of 1,2 Nm -> please refer to chapter 7.1.3.
Important:
Be sure to close the valve of the gas barrier again before you restart the system
-> see chapter 7.1.1.
Restart:
• Release Emergency Stop button
• Insert string fuses and start battery
• Start flushing sequence in FBC test mode (reset with S1 and press both
pushbuttons A & B)
• Check tightness during degassing process
• After successful degassing FBC switches automatically into normal
operation mode
• Switch on the inverters starting with the slaves

7.4. Exchange the OCV cell
Material and tools:
• 7 mm sockets
• Allen screwdriver
• Cable ties
• Plastic drip tray (PE, PP or PVC-U)
Secure the working area with warning cones and tape. Switch off the battery by
pressing and holding both pushbuttons (A and B) at the FBC-board until the
battery switches off. Switch off all inverters (DC-switch at the front). Afterwards
press the emergency stop button (= safe state).
Note the positions of the OCV connections (stickers available?). Unscrew the
OCV cell and lift it high to drain it as much as possible. Mark the position of hoses
(IN / OUT +/-). Remove all hoses starting with top connections and secure them
with cable ties so no electrolyte can drip out. Watch carefully not to rotate the
open OCV cell too much. Always keep the open nozzles on top. Empty the rest of
electrolyte into a bucket and clean the OCV cell. Seal the open nozzles with short
hose pieces shortcutting Out+ with Out- and In+ with In-. Install new OCV Cell
and reconnect hoses in the reverse sequence.
Figure 7.9 - Tubing on OCV cell before disconnection

Finally the OCV cell must be reconnected to the hoses and the hose clamps
Important:
Restart:

• Start battery
pushbuttons A & B)
operation mode
• Check for correct reading of SOC
7.5. Pump exchange

Material and tools:
• Air pump
• Pressure adapter (article no. 3167)
• Water and spray bottle
• Allen key No. 5
• 7 mm socket
• Replacement pump
• Set of keys for pump screw fitting (article no. 2616, 3 different sizes)
This task must be done by 2 people.
Secure working area. Switch off the battery by pressing and holding both
pushbuttons (A and B) at the FBC-board until the battery switches off. Switch off
all inverters (DC-switch at the front). Afterwards press the emergency stop button
(= safe state).
Lift up the corresponding manifold pipe on one end to empty it completely.

Figure 7.10 – Draining the manifold before exchanging a pump
Open the pipe coming from the faulty pump at the screw fitting and connect the
adapter for the air pump as shown in the following pictures. Close the open end
of the pipe with the end cap. Prepare enough paper and a beaker to collect any
dripping electrolyte.
Figure 7.11 – Connecting the air pump
By using the air pump the electrolyte level can be reduced to below the hand
valve. Therefore the faulty pump will be almost free of electrolyte. Firmly pump air
into the tank until you hear air entering the tanks (bubbling sound). One person
continues pumping while the other one closes the hand valve. Be sure to move
the valve to the correct position so the pump to be exchanged remains free of
electrolyte (see figure below). At each possible position the valve snaps in place.

Figure 7.12 – Hand valve in the partly closed position
The faulty pump can now be removed and exchanged without significant spillage
of electrolyte. First disconnect the electrical connections.
Unscrew the two clamps (use allen key no.5).
Figure 7.13 – Unscrew pump clamps
Open the screw fitting with a special spanner wrench (article no. 2616). Prepare
paper to collect any remaining electrolyte.
Figure 7.14 – Open screw fitting

Exchange the pump and reconnect in the reverse order.
Now the hand valve can be changed to the open position to fill the pumps with
electrolyte. The pumps are not self-priming therefore at least at one stack the
OUT-hose must remain open at that point. The pump head will now fill up with
electrolyte -> visual check, it must turn dark.
Figure 7.15 – Pump head filled
Finally the hoses must be reconnected to the stacks and the hose clamps
Important:
Restart:

• Start battery
• Start flushing sequence in FBC test mode (reset FBC with S1 and press
both pushbuttons A & B)
operation mode

7.6. Exchange valves
7.6.1. Exchange balance valve (motor)
The balance valve is positioned in the electronic compartment next to the Front
Board Left (FBL).
Figure 7.16 – Position of balance valve
If the motor valve does not operate the motor can be exchanged separately from
the rest of the valve without having to switch off the FB 10/20/30.
Disconnect the plug from the FBC socket X11 before you exchange the motor.
7.6.2. Exchange balance valve (fluid part)

Material and tools:
• Strap-type oil filter wrench (that can be opened)
• Stoppers/ sealing materials for stacks and hoses
Secure the working area warning cones and tape. Switch off the battery by
The balance valve should now be largely free of electrolyte and can be removed,
after electrical disconnection, using the strap oil filter wrench.

Figure 7.17 – Exchanging the balance valve
A new valve should be inserted, tightened (hand-tight – over-tightening can

damage the valve) and reconnected electrically. The fluid line should then be
reconnected in the reverse order of disconnection.
Important:
Restart:
• Reset the emergency stop button

• Start battery
pushbuttons A & B). The motor valve is tested during the procedure.
• Check tightness during degassing process.
operation mode.
7.6.3. Exchanging a hand valve

If a hand valve in the pump chamber has to be exchanged the tank on that
specific side needs to be emptied first down to a level which is below the hand
valve.
If the pump chamber is also filled with electrolyte it must also must be emptied
and cleaned. In order to do this the pumps may have to be removed. If electrolyte
has entered the air vents of the pumps the pumps should be replaced.
For this procedure it is necessary to contact the Cellstrom Service Center first for
detailed clarification of the failure situation.

7.7. Exchange sensors
7.7.1. Pressure sensors
Material and tools:
• Vaseline (pure)
Disconnect electric plug on pressure sensor. Unscrew sensor, replace by new

one. Connect electric plug and secure with screw.
Important:
Restart:

• Start battery
pushbuttons A & B)
operation mode
• Check for correct reading of pressure
7.7.2. Level sensors

Material and tools:
• Allen key, no. 4

Before opening the tank:

Open the valve at the gas barrier for at least 15 minutes -> refer to chapter 7.1.1.
ATTENTION:
Nothing is permitted to fall into the tank, all tools and screws must be
removed from the top of the tank before opening the tank cover.
When opening the tank observe the following safety precautions (see also
Service Information SI21).
• Open the screws of the level sensor unit by hand (don’t use any electric
tools). Put the screws away from the opening so they can’t fall into the
tank accidently.
• Smoking and handling with open flames is forbidden within a range of 10
meters
• Avoid flying sparks (attention on construction sites)
• Avoid electrostatic charging (use an earthing strap, no synthetic clothes)
Figure 7.18 – Level sensors

Open screws of level sensor unit and replace by new one. Fix plate with screws.
Switch on system and check function of level sensors.
Important:

Restart:

• Start battery
pushbuttons A & B)
operation mode
• Check for correct reading of levels
7.7.3. Hydrogen sensor tank

Cordon off the working area and switch off battery.
Open the valve at the gas barrier for at least 15 minutes -> refer to chapter 7.1.1.
ATTENTION:
Nothing is permitted to fall into the tank. All tools and screws must be
removed from the top of the tank before opening it.
When opening the tank observe the following safety precautions (see also
Service Information SI21).
• Smoking and handling with open flames is forbidden within a range of 10
meters
• Avoid flying sparks (attention on construction sites)
• Avoid electrostatic charging (use an earthing strap, no synthetic clothes)
Disconnect X.52 on FBC sensor is without power. Disconnect the plug at the
sensor (next to the OCV-cell). Screw out the faulty sensor and exchange it
against the new one. Be sure to screw the sensor on tight. Then reconnect X52.
Restart battery and check for correct indication of the hydrogen value.
7.7.4. Hydrogen sensor fluid compartment

Disconnect X27 on FBC sensor is without power. Exchange sensor, reconnect
X27. Eventually check signal current (4mA in normal operation, no H2).
7.7.5. Smoke detector

Disconnect X27 on FBC sensor is without power. Exchange sensor, reconnect
X27. Check function with test gas.
7.7.6. Temperature sensor

If the in-tank temperature sensor has to be exchanged unplug it electrically at the
sensor (see picture). Screw off the sensor and pull it out. Insert new sensor and
tighten the screw. Reconnect electrically and check function.

Figure 7.19 – Temperature sensor
For all other temperature sensors disconnect the appropriate sensor cable at the
FBC board (X24 – X26). Exchange sensor and check function.
7.7.7. Door position switch

Open switch housing, disconnect cables. Exchange switch and adjust new switch
position. Connect cables and check proper function.
7.7.8. Leakage sensor

Check and clean sensors. A sensor that has been contaminated with electrolyte
must be exchanged. Disconnect plug and replace sensor (an alarm will be
generated: broken sensor). Check function and reset alarm.
7.8. Exchange an inverter

Material and tools:
• Socket wrench
• Allen socket
• Screw drivers
• Toolset for exchanging inverters (article no. 2425)
This task must be done by 2 people.
Secure working area. Switch off the battery by pressing and holding both
pushbuttons (A and B) at the FBC-board until the battery switches off. Afterwards
Switch off all inverters using the DC circuit breakers at the front. Similarly the
circuit breaker on the AC side must be switched off. Now the inverter can be
opened and all cables disconnected.
Mount the rails and take out the inverter as shown in the following pictures.

Figure 7.20 – Inverter exchange
Before taking the inverter off the rails prepare an adequate supporting base so
you don’t squash your fingers and also don’t damage the front cover.
ATTENTION: Due to the very heavy weight (64 kg) it is necessary to do
this job with at least 2 people.
Insert a new inverter by reversing the order of these operations. Watch out for the
fastening torque on the cable shoes.
Note: Install SMA piggyback communication board and SD card (if MASTER-
inverter was exchanged).

Figure 7.21 – SMA piggyback communication board
7.9. Exchange relays on the FBC

Switch off battery. The relay retaining clip is pushed out of position to remove and
replace the relay. The retaining clip is put back in place. Switch on battery, check
function.
7.10. Exchange the FBC unit

Switch off battery. Unplug all cables and open 4 screws at the backplane to
exchange the FBC board. Mark all plugs so they can be reconnected in the right
way later on.
Figure 7.22 – FBC board exchange

Set jumpers as on the original board. If the right FBC-SW is already loaded onto
the processor the FBC can be restarted again.
Check if the correct calibration parameter set is loaded: use a multi meter
to check correct reading of DC voltage.
If the FBC-SW is not on the processor eventually replace with the original Tiny-
Tiger processor. In this case please contact the Cellstrom Service Center.
7.11. Exchange the Tiny Tiger processor

Material and tools:
• Allen key No. 2,5
• Slotted screw driver
• ESD-wrist band
• ESD protective clothing (antistatic shoes, only cotton clothes,G)
Switch off battery. Unplug X1, X2 and X6 to disconnect any supply voltage.
Unscrew the display unit which is mounted in front of the Tiny Tiger processor.
Take out the processor very carefully, maybe supporting a little with a slotted
screwdriver.
Figure 7.23 – Tiny Tiger exchange

After exchanging the Tiny Tiger processor reconnect everything in the reverse
order.
The processor has to be flashed with the latest FBC-FW. A description of how to
do this task can be found in the Service Information No. 27.
More further clarification please contact the Cellstrom Service Center (see
chapter 11)
7.12. Exchange a fuse

NH-fuses: disconnect fuse, put electrical joint compound onto the contacts of the
new fuse. Reconnect fuse with a fast movement. Always replace fuses with same
rating.
Low power fuses: shut down battery. Remove protective cover of fuse and
replace defective fuse with same rating. Replace protective cover and start
system.
7.13. Exchange a pump driver

Material and tools:
• PZ3 screwdriver
• Screwdriver fine
• Heat sink paste
• Scraper (to apply paste)
Switch off battery and take out the corresponding Neozed fuses for the defect
DC/DC converter (see following table).
DC/DC converter Pump Fuse

T2 PU1 FP1.3 + FP1.5
T3 PU2 FP1.4 + FP1.6
T4 PU3 FP2.3 + FP2.5
T5 PU4 FP2.4 + FP2.6
Dismount defective DC/DC converter. Eventually mark cables. Apply heat sink
paste to new DC/DC converter, connect cables and mount unit. Insert fuses, start
battery and check functionality.
7.14. Exchange a ventilation fan

All fans are fitted with a plug and can therefore be exchanged without interrupting
the battery. After disconnecting the plug the fan should be taken out and a new
one connected in place. After plugging in the new fan the operation of the fan can
be checked.
7.15. Exchange a circuit breaker

Switch off battery, shut off inverters and all circuit breakers in the external
switching cabinet.
Circuit breaker FAC1:

Disconnect the faulty FAC1 circuit breaker and secure system. Exchange circuit
breaker.
Circuit breaker FAC2:
The grid/generator power supply has to be switched off at the customer and
secured against resetting. When there is no voltage anymore on the line a FAC2
circuit breaker can be exchanged.
7.16. Exchange the antenna

Remove cable. Check plug (corrosion, mechanical defects). Connect new
antenna, adjust and check communication.
7.17. Exchange the communications device

UMTS modem/router: After exchanging the device put the SIM card into the new
modem, restart and configure the router, check function.
miniPC: System must be setup individually. Change USB data storage stick to
new PC. Set communication parameters in the Monitoring SW correctly. Check
function and communication.
7.18. Exchange the backup battery

Disconnect X2 on FBC. Disconnect wiring on old batteries and remove them.
Insert new backup batteries, reconnect cables and connector X2.
Check charge current and voltage (full = approx. 27.2V, current approx. 0.2 -
0.4A).
8. Information about the FBC operation

8.1. Low temperatures
During normal use the inside of the battery will adjust itself to an operating
temperature which allows normal working conditions for all aggregates. In case of
failure the battery might cool down. If the temperature falls below 10°C extra care
has to be taken when restarting the system. Leakages might appear in the fluid
system. Please observe stacks and hose connections.
8.2. High temperatures

High temperatures (>40°C) are dangerous for the highly charged positive
electrolyte, since Vanadium might precipitate. This process is irreversible. During
normal operation the battery will control itself and take appropriate measures to
avoid dangerous situations for the electrolyte (forced cooling, lowering of SOC,..).
Don’t switch off the system even if the temperature rises above 40°C for a short
period of time.
If a failure restricts these measures immediate service intervention will be
necessary to protect the system.

8.3. List of error messages
1 Charging stopped
2 Battery switched off, only communication on
3 Charging stopped, ventilation on
4 System switched off, only manual restart possible
5 System switched off – Emergency Stop, failure is reset after FBC restart
6 Pumps in circuit 1 stopped
7 Pumps in circuit 2 stopped
8 Charging disabled in circuit 1
9 Charging disabled in circuit 2
10 Pump pressure in circuit 1 = 800mbar
11 Pump pressure in circuit 2 = 800mbar
Alarm 1 Broken pressure sensor: pump 1(+).

Alarm 2 Broken pressure sensor: pump 2(-).
Alarm 3 Broken pressure sensor: pump 3(+).
Alarm 4 Broken pressure sensor: pump 4(-).
Alarm 5 Broken temperature sensor: outdoor.
Alarm 6 Broken temperature sensor: fluid room.
Alarm 7 Broken temperature sensor: electronic room.
Alarm 8 Broken temperature sensor: electrolyte.
Alarm 9 Broken temperature sensor: FBC board.
Alarm 10 Broken backup battery sensor: voltage.
Alarm 11 Broken backup battery sensor: current.
Alarm 12 Broken backup battery sensor: supply current.
Alarm 13 Broken current pressure sensor: pump1 (+).
Alarm 14 Broken current pressure sensor: pump2 (-).
Alarm 15 Broken current pressure sensor: pump3 (+).
Alarm 16 Broken current pressure sensor: pump4 (-).
Alarm 17 Broken H2 sensor: room.
Alarm 18 Broken sensor ???
Alarm 19 Broken leakage sensor: LK1
Alarm 25 Broken leakage sensor: LK1 & LK5. Battery has switched off!
Alarm 26 Broken leakage sensor: LK2 & LK6. Battery has switched off!
Alarm 27 Broken OCV sensor.
Alarm 28 Hydrogen concentration from room H2 sensor is high. Please check system!
Alarm 29 Hydrogen concentration from room H2 sensor is too high.Battery has been switched off!
Alarm 30 Too high inlet pressure pump 1(+). Pumps in circuit 1 has been switched off.

Alarm 31 Too high inlet pressure pump 2(-). Pumps in circuit 1 has been switched off.
Alarm 32 Too high inlet pressure pump 3(+). Pumps in circuit 2 has been switched off.
Alarm 33 Too high inlet pressure pump 4(-). Pumps in circuit 2has been switched off.
Alarm 34 High inlet pressure in pump 1(+). Please check battery!
Alarm 35 High inlet pressure in pump 2(-). Please check battery!
Alarm 36 High inlet pressure in pump 3(+). Please check battery!
Alarm 37 High inlet pressure in pump 4(-). Please check battery!
Alarm 38 Too high pressure difference across membrane in pump circuit 1. Pumps in circuit 1 has been switched off!
Alarm 39 Too high pressure difference across membrane in pump circuit 2. Pumps in circuit 2 has been switched off!
Alarm 40 High pressure difference across membrane in pump circuit 1. Please check battery!
Alarm 41 High pressure difference across membrane in pump circuit 2. Please check battery!
Alarm 42 Low pressure in pump 1(+). Please check battery!
Alarm 43 Too low pressure in pump 1(+). Please check battery!
Alarm 44 Low pressure in pump 2(-). Please check battery!
Alarm 45 Too low pressure in pump 2(-). Please check battery!
Alarm 46 Low pressure in pump 3(+). Please check battery!
Alarm 47 Too low pressure in pump 3(+). Please check battery!
Alarm 48 Low pressure in pump 4(-). Please check battery!
Alarm 49 Too low pressure in pump 4(-). Please check battery!
Alarm 50 Cannot reach required pressure in pump 1(+). Charging of circuit 1 disabled!
Alarm 51 Cannot reach required pressure in pump 2(-). Charging of circuit 1 disabled!
Alarm 52 Cannot reach required pressure in pump 3(+). Charging of circuit 2 disabled!
Alarm 53 Cannot reach required pressure in pump 4(-). Charging of circuit 2 disabled!
Alarm 54 Temperatur in fluid room is too high. Battery has been switched off!
Alarm 55 Temperatur in fluid room is high. Please check system!
Alarm 56 Temperatur in electronic room is too high. Battery has been switched off!
Alarm 57 Temperatur in electronic room is high. Please check system!
Alarm 58 Temperatur of electrolyte is high. Please check battery!
Alarm 59 Temperatur of electrolyte is too high. Charging of all groups has been stopped!
Alarm 60 Temperatur of electrolyte too low. Please check battery!
Alarm 61 Temperatur of electrolyte is too low. Charging of all groups has been stopped!
Alarm 62 Temperatur on controller board is too high. Battery has been switched off!
Alarm 63 Temperatur on controller board is high. Please check system!
Alarm 64 Voltage of backup battery is too low. Please check system!
Alarm 65 Voltage of backup battery is low. Please check system!
Alarm 66 Voltage of backup battery is too high. Please check system!
Alarm 67 Voltage of backup battery is high. Please check system!
Alarm 68 Controller is powered from backup battery. Please check system.
Alarm 69 Voltage of DC-Bus A is high. Please check system!
Alarm 70 Voltage of DC-Bus A is too high. Charging of circuit 1 disabled!
Alarm 71 Voltage peaks of DC-Bus A is high. Please check system!
Alarm 72 Voltage peaks of DC-Bus A is too high. Charging of circuit 1 disabled!
Alarm 73 Voltage of DC-Bus A is low. Please check system!
Alarm 74 Voltage of DC-Bus A is too low. Discharging of circuit 1 disabled!

Alarm 75 Voltage peaks of DC-Bus A is low. Please check system!
Alarm 76 Voltage peaks of DC-Bus A is too low. Discharging of circuit 1 disabled!
Alarm 77 Water or electrolyte in sump area was detected (LK1). Battery has switched off.
Alarm 78 A lot of electrolyte in pump area was detected (LK3). Battery has been switched off!
Alarm 79 A lot of water in pump area was detected (LK3). Battery has been switched off!
Alarm 80 A lot of electrolyte in sump area was detected (LK4). Battery has been switched off!
Alarm 81 A lot of water in sump area was detected (LK4). Battery has been switched off!
Alarm 82 Electrolyte in area - tank cover left - was detected (LK1). Please check system!
Alarm 83 Water in area - tank cover left - was detected (LK1). Please check system!
Alarm 84 A lot of electrolyte in area - tank cover left - was detected (LK5). Battery has been switched off!
Alarm 85 A lot of water in area - tank cover left - was detected (LK5). Battery has been switched off!
Alarm 86 Electrolyte in area - tank cover right - was detected (LK2). Please check system!
Alarm 87 Water in area - tank cover right - was detected (LK2). Please check system!
Alarm 88 A lot of electrolyte in area - tank cover right - was detected (LK6). Battery has been switched off!
Alarm 89 A lot of water in area - tank cover right - was detected (LK6). Battery has been switched off!
Alarm 90 Electrolyte level in positive tank too high. Battery has been switched off!
Alarm 91 Electrolyte level in negative tank too high. Battery has been switched off!
Alarm 92 Electrolyte level in positive tank too low. Battery has been switched off!
Alarm 93 Electrolyte level in negative tank too low. Battery has been switched off!
Alarm 94 Total electrolyte level is low. Please check system!
Alarm 95 Total electrolyte level is high. Please check system!
Alarm 96 Undefined electrolyte level sensor value. Please check system!
Alarm 97 Cannot open level balancing valve. Please check system!
Alarm 98 Cannot close level balancing valve. Please check system!
Alarm 99 Electronic department door is open.
Alarm 100 Fluid department door is open.
Alarm 101 Smoke was detected. System has been switched off!
Alarm 102 Software emergency has been activated. System has been switched off!
Alarm 103 Cannot communicate to OCV cell. Please check system!
Alarm 104 Implausible OCV voltage value was measured. Please check system!
Alarm 105 Implausible OCV temperature value was measured. Please check system!
Alarm 106 High number of watchdog resets in OCV cell was detected. Please check system!
Alarm 107 not plausible relation of OCV, battery voltage and current.
Alarm 108 SOC is low. Please check system!
Alarm 109 SOC is too low. Discharging stopped!
Alarm 110 Battery is empty. System will sleep until tomorrow!
Alarm 111 System was manually switched off by user!
Alarm 112 battery is switched off by SMS.
Alarm 113 back-up battery disconnected. Battery stopped.
Alarm 114 SOC is too high.Charging stopped!
Alarm 115 No Modbus Communication to H2 Tank Sensor
Alarm 116 Modbus communication error ICPCon A2!

Alarm 119 Voltage of DC-Bus B is high. Please check system!
Alarm 120 Voltage of DC-Bus B is too high. Charging of circuit 2 disabled!
Alarm 121 Voltage peaks of DC-Bus B is high. Please check system!
Alarm 122 Voltage peaks of DC-Bus B is too high. Charging of circuit 2 disabled!
Alarm 123 Voltage of DC-Bus B is low. Please check system!
Alarm 124 Voltage of DC-Bus B is too low. Discharging of circuit 2 disabled!
Alarm 125 Voltage peaks of DC-Bus B is low. Please check system!
Alarm 126 Voltage peaks of DC-Bus B is too low. Discharging of circuit 2 disabled!
Alarm 127 Communication error to SMA A. Please check system!
Alarm 128 Communication error to SMA B. Please check system!
Alarm 129 SMA A switched off, due to low DC voltage. Remove fuse and discharge DC bus A!
Alarm 130 SMA B switched off, due to low DC voltage. Remove fuse and discharge DC bus B!
Alarm 131 SMA A is in error state! Error number:
Alarm 132 SMA B is in error state! Error number:
Alarm 133 SMA A is not in operation state. Please check system!
Alarm 134 SMA B is not in operation state. Please check system!
Alarm 135 Grid/generator voltage and frequency of SMA A is not in valid range. Please check system!
Alarm 136 Grid/generator voltage and frequency of SMA B is not in valid range. Please check system!

9. Yearly maintenance
The following issues need to be checked once a year:
Outside:
removal of plant covering from the battery housing
cleaning the ventilation holes and exchanging the filters
optical check-up of the flame arrestor
check-up of the battery coverage to paint damage and corrosion
check-up of the transmission antenna (if existing)
check-up of the external electric cabinet and external cabling (closing, tightness, dirt,
isolation)
Inside:
check for tightness - rainwater, condensation: remove and seal
cleaning the inside
check the fluid system for leaks
check pumps (sound, pressure), tubes and hoses
check gas barrier (tightness oil container)
check and clean ventilation and flaps
check control of the external ventilation system (if applicable)
check the cooling system with heat exchanger (if applicable)
check functionality of emergency stop
check sensors (smoke, H2, leakage, temperature, tank level, pressure)
check DC-rails, contacts
measure string-homogeneity (currents) und stack-symmetry (voltage)
check backup-batteries, exchange every 3 years
check Li-battery at FBC-board, exchange every 5 years
take electrolyte samples from each tank

9.1. Stack testing (homogeneity and symmetry)
All pumps shall be active and the power at a constant level. Using a voltmeter the
individual stack voltages should be measured (string-symmetry). The stack
voltages in each string should be as symmetrical as possible. The difference
between 2 stacks of a string shall not exceed 1V. The maximum voltage of any
stack must not exceed 32V, this is a critical value, which has to be observed
during charging. Compare the voltages only if the string currents are above 20A.
If a stack voltage is too high the stack must be replaced.
Also the pump pressure and the system tightness should be checked.
Stack positions and numbering:
String No. 10 9 8 7 6 1 2 3 4 5
Stack No. 19 17 15 13 11 1 3 5 7 9
Stack No. 20 18 16 14 12 2 4 6 8 10
Figure 9.1 – Stack positions
9.2. Leakage sensor test

No special test is required. The FBC checks for broken cables to the leak
sensors. The sensors on the tank cover have a double level sense. The ohmic
value of the leakage sensors should be roughly equal (in the Monitoring SW
~650).
9.3. Smoke detector test

Material and tools:
• Test gas bottle for smoke detectors
The smoke detector must respond straight away and trigger an alarm when
sprayed at with test gas. The FBC switches the battery off and sends an alarm
message by e-mail. After solving the alarm cause the sensor has to be reset by
screwing the sensor off and on again. The alarm condition must be reset (FBC)
and the battery restarted.

9.4. Hydrogen sensor test (fluid compartment)
In standard air atmosphere the sensor should show 0% (visible in the Monitoring
SW). If the value is >0% and does not decrease when ventilation is on or the
service flap is open on the fluid side (min. ½ hour) the sensor needs to be
readjusted.
Before adjusting the H2-sensor you have to be sure to exclude the possibility of a
higher H2-concentration as a reason for the shown value. In case of doubt please
contact the Cellstrom Service Center.
The H2-sensor can be adjusted to zero by turning the potentiometer Z (left on the
picture). As a reference use calibration gas (1 - 3% hydrogen in synthetic air).
The signal of the H2-sensor is an analogue signal (4mA – 20mA) representing the
level of H2 concentration. The signal is measured on the FBC board and there
are 2 action levels:
H2 alarm on low level (level 1):

If a low concentration of H2 is detected an alarm message is generated and the
venting system switched on.
H2 alarm on high level (level2):

If a high concentration of H2 is detected an alarm message is generated and the
battery will be switched off by the FBC controller.
4mA represents 0% concentration of H2 in air = 0% of measuring range

20mA represents the lower explosion limit of the gas mixture (4% of H2
concentration in air ) = 100% of measuring range
Alarm level 1 = 5% of measuring range
Alarm level 2 = 20% of measuring range
Figure 9.2 – Readjusting the hydrogen sensor
If readjusting is not successful the sensor needs to be exchanged by a new one.

10. Decommissioning
Before the system can be decommissioned the battery has to be discharged
completely (electrically). The remaining charge (<10%) will be equalised by
mixing the liquids of each tank while filling the IBC containers. Positive and
negative electrolytes are mixed 1:1 during this procedure. Special equipment is
needed for that task. The electrolyte can be re-used again afterwards.
Please get in contact with the Cellstrom Service Center for clarification of details.
Tanks and fluid system will contain remains of electrolyte and have to be treated
as contaminated chemical components during decommissioning. The appropriate
safety data sheets are contained in the system documentation.
The open hose sockets of the stacks shall be closed with 2 short hose pieces and
the electrical terminals isolated before the stacks are taken out of the battery.
Electrical and electronic components shall be disposed according to local rules.
The steel frame shall be recycled.
11. Cellstrom Service Center

Cellstrom Service Hotline: +43 2236 379000 – 379
Cellstrom Service Mailbox: servicesupport@cellstrom.com

12. Terminology
Term Meaning
A Ampere – unit of current
AC Alternating current – the standard form of electricity from
the mains. It is generally as a single phase (2 or 3 pins) for
most domestic appliances; however three phases (4 or 5
pins) are used for higher power devices such as cookers
and larger electric motors.
Cell The smallest unit of a battery. In the FB 10/20/30 many
cells are packaged together to form a stack.
Converter An electrical device for changing the voltage of an
electrical supply. This is used when a DC load runs at a
different voltage to the battery.
Cycle In battery terminology a cycle is the process of charging
followed by discharging (or vice versa), to bring the battery
back to the same state-of-charge (typically completely
discharged or charged). Battery life is often given as the
number of cycles to a certain depth-of-discharge.
Charge Level The charge level of the system is a measurement for the
storage capacity of the energy storage system during
normal operation. The system can always be operated
within a charge level between 0% and 100%.
DC Direct current – the standard form of electricity from a
battery. It may be used by some appliances but generally
an inverter is used to convert it to AC.
DOD Depth-of-discharge - The capacity which has been taken
out of the battery in %. Therefore, an 80% depth-of-
discharge would leave 20% charge still in the battery.
Electrolyte In the FB 10/20/30, an electrolyte is a solution of vanadium
salts in sulphuric acid. In a lead-acid battery it is just
sulphuric acid.
ESS Energy storage system – a device, such as the FB
10/20/30 that can be used to store energy (especially
electricity) until it is wanted.
FBC Flow battery control – also smart controller. An essential
component of the FB 10/20/30.
Inverter An electrical device for turning battery DC electricity into
mains AC electricity
kW Kilowatt (thousand watt) – unit of power. Mathematically it
is equal to the current multiplied by the voltage, e.g. a 1 A,
230 V computer takes 1 x 230 =230 W = 0.23 kW of power
kWh Kilowatt-hour – unit of energy. Mathematically it is equal to
the power multiplied by the usage time, e.g. a 0.23 kW
computer used for 6 hours takes 0.23 x 6 = 1.38 kWh of
energy
Load Anything that takes electricity to work. In this description it
is any appliance connected to the FB 10/20/30.
Monitoring SW The monitoring software displays the main parameters in a
graphical way. The SW runs on the miniPC and can used
also for remote diagnostics.

Oxidation state A numerical measure of how far a substance has reacted.
Vanadium in the FB 10/20/30 can have oxidation states +2
(little reacted), +3, +4 or +5 (fully reacted).
SOC State-of-charge – The capacity (in %) which still remains in
the battery
Stack A group of cells through which the electrolytes are flowed.
At both ends of the stack are electrical connectors, through
which the battery may be charged and discharged.
Stage In the FB 10/20/30 not all of the stacks must be active at
the same time, especially when the power is low. The
controller can decide to activate or deactivate groups of
stacks together, known as a stage.
String A group of batteries that are connected in series, i.e.
positive to negative terminals. In the FB 10/20/30 the
stacks are grouped in pairs, so that it has 5 strings of 2
stacks each.
Thermal mass A measure of how difficult it is to raise the temperature of
an object. The FB 10/20/30 has a higher thermal mass
than an equivalent amount of lead-acid batteries.
V Volt – unit of voltage/ potential difference
Vanadium A common metal that is widely distributed in nature. It
reacts to form brightly coloured salts that are used in
solution in the FB 10/20/30.
END OF THE DOCUMENT

ServiceManual - FB10-20-30 SM01 - 80-000007 - V01.01 - RIS - 2013-12-20

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SERVICE MANUAL

Vanadium Redox Flow Battery

COPYRIGHT CELLSTROM 2013

4. Installation preparations _______________________________ 13

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Symbol Location Meaning

On fluid side - Warning of explosive atmosphere –

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On both sides - Danger from batteries

On both sides and Voltage hazard – primarily refers to

On fluid side - Gloves must be worn, refers to the

On both sides - Read manual or handbook, refers to

On fluid side – Eye protection must be worn, refers to

On both sides - No naked flames, refers to hydrogen

On fluid side – No eating or drinking, refers to

On both sides - Do not enter, entry only for qualified

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3.3. Safety instruction

Figure 3.1 – Electrolyte colours at different charge states

The figure above shows charged negative electrolyte (violet), discharged

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4.1. Steps to be prepared by the customer

4.2. Preparing an emergency plan

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5.1. Preparative work

5.1.2. Check of delivery

5.1.3. Placing the battery

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5.1.4. Further equipment required

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Figure 5.2 - External switching cabinet, inside view

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5.2.1. Earthing connections

Figure 5.3 – Earthing connections

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Note: The electrical connection of the battery is in the responsibility of the

5.3. Filling the tanks with electrolyte

Capacity [kWh] Electrolyte [litres]

Material and tools:

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The electrolyte is delivered in standard IBCs (intermediate bulk containers), from

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Figure 5.7 – Hose connected for filling the tank

Figure 5.8 – Drum pump in IBC, with splash protection

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Figure 5.9 – Valve in the open position, gas barrier is bypassed

Figure 5.10 – Partly open tank lid, positive tank

Both hand valves in the pump chamber should be open:

Figure 5.11 – Pump chamber, hand valve in open position

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Figure 5.12 – Gas barrier, normal operating position

5.4. Flow battery controller (FBC) start up

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The working area should still be cordoned off.

Figure 5.13 – Pumps filled with electrolyte

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