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HomeMy WebLinkAboutX2019-2384 - Misc614 } 1A100•qfikol T5Lr-i Aug. 9, 2018 xzo!q-7 3sa a Hoa3 D- POWERPACK 2 SYSTEM INSTALLATION MANUAL CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Rev. 2.1 4 Warning: Read this entire document before installing or using the Powerpack System. Failure to do so or to follow any of the instructions or warnings in this document can result in electrical shock, serious injury, or death, or can damage Powerpack, potentially rendering it inoperable. PRODUCT SPECIFICATIONS All specifications and descriptions contained in this document are verified to be accurate at the time of printing. However, because continuous improvement is a goal at Tesla, we reserve the right to make product modifications at any time. The images provided in this document are for demonstration purposes only. Depending on product version and market region, details may appear slightly different. ERRORS OR OMISSIONS To communicate any inaccuracies or omissions in this manual, please send an email to: energymanualfeedbackAtesla.com. ELECTRONIC DEVICE: DO NOT THROW AWAY MEI Proper disposal of batteries is required. Refer to your local codes for disposal requirements. MADE IN THE USA ©2018 TESLA, INC. All rights reserved. All information in this document is subject to copyright and other intellectual property rights of Tesla, Inc. and its licensors. This material may not be modified, reproduced or copied, in whole or in part, without the prior written permission of Tesla, Inc. and its licensors. Additional information is available upon request. The following are trademarks or registered trademarks of Tesla, Inc. in the United States and other countries: TESLA All other trademarks contained in this document are the property of their respective owners and their use herein does not imply sponsorship or endorsement of their products or services. The unauthorized use of any trademark displayed in this document or on the product is strictly prohibited. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY TABLE OF CONTENTS 1. Installer Information 6 Tesla-Specific Tools 6 Support 7 2. Powerpack System Introduction 8 Powerpack Unit 8 Powerpack Inverter 10 Customer Connection Section 10 Safety Features 12 Tesla Site Controller 13 Energy Meters 14 3. System Description 14 System Specifications 15 Product Configurations 16 4. Transportation 16 Shipping Guidance 16 Emergency Response Guide 17 Loading and Unloading 17 Staging 18 5. Site Infrastructure 18 Conduit 18 Foundation Inspection 20 6. Site Installation 21 Site Access 21 Fencing 21 Clearances 21 Enclosure Installation 23 Positioning the Enclosures 23 Anchoring the Enclosures 24 7. Wiring 27 Wreway Installation 27 Powerpack Unit Wiring 32 Powerpack Unit DC Harness Installation 32 Communication Harness and Ground Wire Installation 33 Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 1 of 68 a F' Powerpack Inverter Wiring: Customer Connection Side 35 Disconnecting Means 35 DC Harness Installation 36 Powerpack Unit Communication Harness Installation and Testing 38 Powerpack Unit Grounding 40 Tesla Site Controller Communication Wiring 42 Powerpack Inverter Wiring: AC Conductors 42 Wireway Cover Installation 47 8. Tesla Site Controller 48 Installing the Tesla Site Controller 49 Configuring the Transformer for 440, 450, or 480 VAC 53 Configuring the Transformer for 208, 240, or 400 VAC 54 Configuring the Transformer for 120 VAC 56 Connecting a Demand Response Controller 58 Connecting a VDE 4105 Protection Relay 58 9. Energy Meters 59 Connection Requirements 60 Connecting Meters to the Tesla Site Controller 60 CT Installation in the AC Panel or Switchboard 61 Meter Configuration 64 10. Commissioning 64 Shutdown 64 Locating Enclosure Serial Numbers 65 Tesla Commissioning Responsibility 66 Revision Log 67 Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 2 of 68 IMPORTANT SAFETY INSTRUCTIONS: SAVE THESE INSTRUCTIONS This manual contains important information and safety instructions for the Tesla Powerpack 2 System and Powerpack 1.5 System that must be followed during installation and maintenance of the system. Symbols This manual and product use the following symbols to highlight important information: A DANGER: indicates a hazardous situation which, if not avoided, could result in severe injury or death. A WARNING: indicates a hazardous situation which, if not avoided, could result in injury. CAUTION: indicates a hazardous situation which, if not avoided, could result in minor injury or damage to the equipment. NOTE: indicates an important step or tip that leads to best results, but is not safety or damage related. Grounding (protective earth) terminal. Directs the user to refer to the instructions. - - - Direct current. 3N' Three-phase alternating current with neutral conductor. Caution, risk of electric shock. Energy storage timed discharge (time is indicated next to the symbol). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 3 of 68 I, Product Warnings A DANGER: Risk of electrical shock. The DC bus can be energized from either the battery side or the inverter side. Multiple energy sources terminate inside this equipment. While you should always disconnect all external power sources before servicing, opening the DC disconnect does not ensure that the DC bus is de -energized. Always check with a properly rated voltmeter that there is no voltage on the DC bus before touching. A DANGER: Lock out externally supplied AC power at the source before servicing the inverter or opening the door. A DANGER: Hazardous voltage can cause severe injury or death. A WARNING: Personal Protective Equipment (PPE) is required when working inside the Powerpack Inverter enclosures. Service personnel must wear safety glasses and gloves with a minimum voltage rating of 1500 VDC, Class 0 per ASTM D120 and IEC EN60903 standards. A WARNING: The unit has no user serviceable parts. All service must be performed by Tesla Energy Certified Installers or Tesla employees. Only trained service personnel are allowed access. A DANGER: During installation, all equipment must be de -energized. A WARNING: All electrical installations must be done in accordance with local and National Electric Code (NEC) ANSI/NFPA 70 or the Canadian Electrical Code CSA C22.1. A WARNING: All installations must conform to the laws, regulations, codes, and standards applicable in the jurisdiction of installation. A WARNING: These installation instructions are for use by qualified personnel only. To reduce the risk of electric shock, do not perform any servicing other than that specified in the operating instructions unless you are qualified to do so. A DANGER: Electric shock could occur when touching live components. A WARNING: To reduce the risk of injury, read all instructions. A WARNING: Only use this equipment as specified by Tesla. If the equipment is used in a manner that is not specified by Tesla, the protection provided by the equipment might be impaired. A DANGER: Shutting off power to the Tesla Powerpack System does not de -energize the battery, and thus a shock hazard may still be present. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 4 of 68 4 A WARNING: Batteries are not user -serviceable. Only Tesla-approved personnel must remove, replace, or dispose of batteries. A WARNING: For continued protection against risk of fire, use only replacement fuses of the same type and rating as the original fuse. Fuses must only be replaced by trained personnel. A DANGER: A Powerpack Unit, even in a normally discharged condition, is likely to contain substantial electrical charge and can cause injury or death if mishandled. A DANGER: The battery used in this device may present a risk of fire or chemical burn if mistreated. Do not disassemble, operate above 50°C (122°F), or incinerate. CAUTION: Inverter input and output circuits are isolated from the enclosure. System grounding, when required by the National Electric Code, ANSI/NFPA 70, is the responsibility of the installer. CAUTION: Do not paint any part of the Powerpack System, including any internal or external components such as exterior cabinets or grilles. CAUTION: Do not use cleaning solvents to clean the Powerpack System, or expose the system to flammable or harsh chemicals or vapors. Ahla CAUTION: Do not use fluids, parts, or accessories other than those specified in Tesla manuals, including use of non -genuine Tesla parts or accessories, or parts or accessories not purchased directly from Tesla or a Tesla-approved party. Refer to the Tesla Emergency Response Guide, TS-0004027, for detailed hazard information specific to the lithium -ion battery. The Guide also provides the hazard information for a single Tesla Powerpack Unit. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 5 of 68 1. Installer Information This document provides an installation contractor the necessary details to install a Tesla Powerpack System. The installation contractor is responsible for completing the mechanical and electrical installation of the Tesla Powerpack System. Tesla provides a Construction Completion Checklist that lists the criteria that must be inspected and completed onsite for Tesla to consider the site completed and ready for commissioning. The list includes items such as: • Physical installation such as proper anchoring, door swing, access, etc. of all equipment • Pad grading, drainage, and access • Electrical termination checks for polarity and torque for all equipment • Harness termination checks • Ethernet cable checks with VDV Scout Pro or Pro LT (VDV501-053 or 068) or equal • Insulation resistance "megger" testing for all wires • Inverter phase checking with a Greenlee 5702 Phase Sequence Indicator or equal • Meter wiring and CT polarity check • Recording site information (serial numbers, unit and meter locations, inspection date, etc.) and emailing a scanned copy to Tesla • Inverter and Tesla Site Controller start-up Ensure personal safety at all times per local and national regulations. The installation contractor is responsible for providing their own Personal Protective Equipment (PPE), including such items as safety glasses, hard hats, appropriate boots, and appropriate gloves (cut and electrical). Tesla-Specific Tools The custom torque tool, Powerpack Unit anchor template, and inverter anchor template are provided to installers during their first project. Additional or replacement tools are also available for purchase. Have the following tools ready before beginning work: Custom anchor torque tool (Tesla PN 1068396): A programmable mechanical pulse wrench attached to an aluminum extrusion to extend the reach to approximately 5'. The battery powered tool is supplied with two 14.4V batteries and one 120V US charger, and includes a 24mm Nut Grip socket to firmly hold non-magnetic nuts. The tool is pre-programmed for a maximum torque of 70 ft-lbs. Actual measured final torque is dependent on anchor and pad conditions. Figure 1: Anchor Torque Tool Kit Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 6 of 68 NOTE: The anchor tool comes standard with a US rated charger. Non -US sites may require a conversion adapter to power the anchor tool. Use of the tool is described in the "Error! Reference source not found." section below. Powerpack Unit anchor template (Tesla PN 1068864): The template indicates the mounting points of a single Powerpack Unit for easier anchor hole drilling. (Two templates are shown in Figure 2 in a back-to-back layout.) Inverter anchor template (Tesla PN 1106829): The template indicates the mounting points of a single inverter for easier anchor hole drilling. The word "FRONT" is etched on the flat edge of the template to show the door side of the inverter. The template includes a cut-out for AC window stub -up positioning (circled). Figure 2: Inverter Template (1) to Powerpack Unit Templates (2) Support NOTE: Get the most recent version of the Construction Completion Checklist before beginning work. The installer is responsible for obtaining the latest version of this manual and the Checklist to complete all site work. All partner documents are on the Partner Portal website at: https://partners.teslamotors.com For Powerpack System support, or to provide product feedback: • Email PowerpackSupport@tesla.com (responses can take 24-48 hours) Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 7 of 68 • Call Tesla Service at 650-681-6060 for urgent or time -sensitive requests 2. Powerpack System Introduction The Powerpack 2 System is a modular, fully integrated, AC -coupled industrial Energy Storage System (ESS). NOTE: Any deviation from what is specified in this installation manual must be submitted to Tesla in writing in advance for approval. A Powerpack System consists of three types of enclosure: • Rechargeable lithium -ion battery pack cabinets (Powerpack Unit) • Bi-directional power conversion system (Powerpack Inverter) • Tesla Site Controller (vertically mounted enclosure that controls system commands) The bi-directional inverter converts power for rechargeable lithium -ion battery packs (Tesla Powerpack Units). Powerpack Inverters have a nominal rating power between 65 and 650 kVA, depending on the installed number of modular Powerstages and the site's grid voltage. One Powerpack Inverter, and 1-20 Powerpack Units assigned to that inverter, make up an inverter block. 1 2 Figure 3: Example Inverter Block: Powerpack Inverter (1) and Powerpack Units (2) NOTE: It is also possible to configure a Powerpack System using Powerpack 1.5 Units and a Powerpack Inverter. This is called a Powerpack 1.5 System. This manual, and the Powerpack 2 System Site Design Manual, note where 1.5 is different from 2. For a comparison of energy and power ratings, see the section "Product Configurations". Powerpack Unit Cylindrical lithium -ion battery cells, the smallest non -divisible component of the Powerpack System, are assembled into a Pod (Figure 4), which is the smallest field replaceable unit. The Powerpack Unit is a standalone NEMA 3R enclosure containing 16 Pods connected in parallel with a single DC and communications output connection. Pods are pre -wired within the Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 8 of 68 Powerpack Unit and do not require any field assembly or adjustments. Pods must only be replaced by Tesla service personnel. 1 2 Figure 4: Powerpack Unit, Thermal Door (1) and Pod (2) The thermal management system is housed on the inner face of the Powerpack Unit door. The door includes a radiator and pump system that circulates about 26 L of a 50/50 ethylene glycol / water coolant mix through the battery to maintain thermal control. The thermal subsystem also includes 400 g of R134a (1,1,1,2-Tetrafluoroethane) refrigerant in a sealed system. All Powerpack Units ship with the necessary coolants and refrigerants included. The thermal door subsystem is a fully closed loop system. The Powerpack Unit door includes two latches that require a special tool to unlock, limiting access to authorized personnel only (Figure 5). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 9 of 68 1 • Figure 5: Powerpack Unit Security Latches NOTE: The Powerpack Unit includes an Enable circuit as a safety feature. Opening the door of any Powerpack Unit shuts down all Powerpack Units within an inverter block. Powerpack Inverter Each inverter block contains a Powerpack Inverter. It contains four main sections: Low Voltage, Powerstages, Thermal Management, and Customer Connection. • Low Voltage Section: The upper left part of the main inverter enclosure houses internal low voltage components. • Powerstage Section: The right side of the inverter enclosure contains up to ten rack - mounted Powerstages that can be scaled for the needs of the site. Powerstages are pre - installed in the inverter before shipment. • Thermal Management Section: The top cabinet of the inverter enclosure houses the thermal management system, a fully closed -loop system with fans and a radiator that contains a 50/50 ethylene glycol/water coolant mix. NOTE: Installation only involves the Customer Connection Section. Customer Connection Section The lower left side of the Powerpack Inverter enclosure (Figure 6, Figure 7) is the Customer Connection section. It contains: • The interface board, a circuit board serving as a communications gateway between the Powerpack Inverter and Powerpack Units, with CAN communication harness terminations for the Powerpack Units and Ethernet terminations for the CAT5e/CAT6 cable to the Tesla Site Controller • DC bus bars with fuses protecting each Powerpack Unit DC wire harness Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 10 of 68 • The AC bus bar for connecting the inverter to the site AC distribution panel Figure 6: Powerpack Inverter Overview 1. Low voltage boards 5. Thermal management 2. AC bus bars 6. Powerstages 3. DC bus bars and fuses 7. Interface board 4. Customer connection area Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 11 of 68 1 2 3 2 3 4 Figure 7: Customer Connection Area Details 1. AC bus bars 3. DC bus bars and fuses 2. Strain relief 4. Ground/earth A WARNING: The thermal management section is locked during operation. Do not open this cabinet while fans are in use, to avoid hazard from moving parts. Safety Features The inverter door has a DC disconnect switch that is accessible from the front of the unit and can be locked in the open position (Figure 8). The DC disconnect switch ties into the Enable safety circuit that also runs through all Powerpack Units. The DC disconnect switch must be open and unlocked in order to open the inverter door. Within the inverter, the AC and DC bus bars are covered by a clear plexiglass shield that must be removed for access. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 12 of 68 Figure 8: Powerpack Inverter DC Disconnect Switch Tesla Site Controller The Powerpack Inverter communicates with the overall system through the Tesla Site Controller, which controls the entire energy storage site. The Tesla Site Controller hosts the control algorithm that dictates the charge and discharge functions of the Powerpack Units. It is also the single point of interaction with external parties. One Tesla Site Controller is required per point of interconnection, and is provided pre -assembled in a NEMA 3R enclosure (Figure 9). Figure 9: Example Tesla Site Controller Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 13 of 68 The Tesla Site Controller communicates to each inverter block over a private TCP network. Each inverter communicates with the Tesla Site Controller and commands the Powerpack Units. For larger sites, multiple inverter blocks are connected via Ethernet to a network switch. Energy Meters Energy meters are not provided by Tesla. A meter is typically used in one of two roles: battery meter (measures the Powerpack System throughput) or site meter (measures the entire site). An additional "generator meter" might also be required for sites involving onsite generation (PV, wind, etc.). For a list of currently supported meters, refer to Tesla's Powerpack 2 System Site Design Manual. Meter wiring and configuration is described in a later section. 3. System Description The Powerpack 2 System consists of the following components and their Tesla part numbers: • Powerpack Unit 2, 4-hour: 1083931 • Powerpack Unit 2, 2-hour, 1.6-hour, or 1.2-hour: 1083932 • Powerpack Unit 1.5: 1089288 • Powerpack Inverter, 480 VAC: 1095371 O 1095371-1 Y*: 65 kVA O 1095371-2Y: 130 kVA O 1095371-3Y: 195 kVA O 1095371-4Y: 260 kVA O 1095371-5Y: 325 kVA O 1095371-6Y: 390 kVA O 1095371-7Y: 455 kVA O 1095371-8Y: 520 kVA O 1095371-9Y: 585 kVA O 1095371-0Y: 650 kVA *Where in the "-XY extension, X denotes the number of Powerstages and Y denotes fuse configuration. Rated output for 10 Powerstages produced before Aug 2017 was 500 kVA @400 VAC / 625 kVA @480 VAC. • Tesla Site Controller: 1137202 • HVDC cable harnesses: 1096272 • Communication cable harnesses: o Powerpack Unit to Powerpack Unit: 1068390 o Powerpack Unit to Powerpack Inverter: 1068391 o Pack Termination Harness: 1071858 • Wireway components: o Wireway: 1072786 o Top cap: 1072787 o Corner: 1072855 o Corner cap: 1072801 o Inverter interfaces and covers: 1072854, 1107828, 1107830 Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 14 of 68 o Kickplate: 1072788 o End cap: 1072853 • Powerpack Unit seismic washer: 1057229 • Inverter Accessory Kit (Ships inside the inverter AC panel cover. Specific parts and quantities might vary by site): o Cable gland, split black M50: 1105381 o M12 x 1.75 x 70 bolt: 1115561 o Flat M12 washers: 1031489 o Conical spring M12 washers: 1107664 o M12 x 1.75 nut: 2007063 o M8 1.25 hex nut with washer: 1004400 o Cable ties: 1104977 o Interface board jumpers: 1071276 • Tesla Site Controller Accessory Kit (if applicable): o Two transformer taps o Two terminal covers for transformer (P/N: 1139091-00-A) o Brackets from the enclosure o Screws from the enclosure o Two 1.5 A fuses (P/N: 1453351-00-A) o Computer antenna o Ethernet cable for computer (P/N: 1454046-00-A) o Power wires for RTAC (P/N: 1452792-00-A) o Ethernet cable for RTAC (P/N: 1453388-00-A) Substitution of components is not permitted. A WARNING: Mechanical damage to a Powerpack Unit can result in a number of hazardous conditions, including coolant leaks, refrigerant leaks, or fire. To prevent mechanical damage, store a Powerpack Unit in its original packaging when not in use or prior to being installed. For shipping and storage guidelines, refer to the Powerpack 2 System Transportation and Storage Guidelines. For guidance on how to respond if these hazards occur, refer to Tesla's Lithium-lon Battery Emergency Response Guide for details. 4-14 CAUTION: Do not open the battery Pod. The unit has no user serviceable parts inside. System Specifications E ui ment Powerpack Unit, 4-hr Powerpack Unit, 2-hr Powerpack Inverter Tesla Site Controller ,�y�WLength 1308 mm (51.5") 1308 mm (51.5") 1014 mm (39.9") 255 mm (10") 822 mm 822 mm 2235 mm (32.4")1 (88")1 Width Height #_ 2235 mm ___(88")1 1254 mm 2242 mm (49.4")1 (88.3")1 560 mm 742 mm (22") (29.2") Max. Shipped Weight [ Mount 2175 kg (4795 Ibs) 2075 kg Pad _(4575 Ibs) 1120 kg (2470 Pad lbs)2 21.4 kg (47.2 Ibs) Rack, Wall Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 15 of 68 I Dimensions include the 2" lifting flanges in product height. They do not include bottom anchor tabs, which interleave in installation and are not indicative of overall spacing.. For pallet width and depth dimensions, refer to the "Transportation and Storage Guidelines" document. 2 Maximum weight (weight changes depending on number of installed Powerstages, which are 55 kg/122 lb each) Product Configurations All Powerpack 1.5 and Powerpack 2 Systems use the Tesla Powerpack Inverter. However, they vary in power and energy ratings. Tesla configures two main variables for each Powerpack Inverter, according to system need: • 1 to 10 Powerstages • Four DC fuse variants: 5, 10, 15, or 20 pre -installed DC fuses (per phase), depending on the number of paired Powerpack Units per inverter NOTE: Inverter configurations are at Tesla's discretion. The inverter may be de -rated by changing software parameters to meet specific site restrictions and requirements. 4. Transportation Shipping Guidance The Powerpack 2 System Transportation and Storage Guidelines are available for guidance on shipping and transportation. The document provides packaged dimensions and weights, allowed storage conditions, and shipping guidance for land, sea, and air. Approximately nine (9) Powerpack Units can fit on a 45' long flatbed. Tesla recommends that Powerpack Units be covered by a tarp when being transported on a flatbed truck. NOTE: Powerpack System coolant is not a regulated substance according to the US Department of Transportation (USDOT). Refer to the specific MSDS for battery coolant. NOTE: Powerpack System refrigerant is a regulated substance according to the USDOT. Refer to the specific MSDS for R134a. CAUTION: Powerpack Units and the Powerpack Inverter must be transported and handled upright. k-! CAUTION: Powerpack Units ship with a 25% State of Charge (SoC). If units are expected to sit for longer than 12 months between the date of manufacture and installation, the site manager must contact Tesla at Powerpacksupporttesla.com to arrange for manual re- charging of any units that are approaching minimum SoC. Failure to recharge within 12 months can damage the hardware and would void the warranty, as described in the Limited Warranty. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 16 of 68 Emergency Response Guide A Tesla Lithium-lon Battery Emergency Response Guide is included with Powerpack Systems for shipping and transportation. The Guide provides an overview of the product materials, handling and use precautions, hazards, emergency response procedures, installation instructions, and storage and transportation instructions. The document serves as a comprehensive guide and replaces the traditional Safety Data Sheets (SDS) commonly associated with the health and safety of a chemical product. Tesla Powerpack products, as described in the Guide, meet the OSHA definition of "articles" and are therefore exempt from requiring a traditional MSDS (or the updated SDS format). Loading and Unloading The Powerpack Unit and Powerpack Inverter cabinets ship with protective covers and a temporary pallet for unloading with a forklift. -AAA CAUTION: Equipment must be strapped to the forklift while loading and unloading. Equipment can tip and fall if it is not secured. Load distribution must be adjusted to ensure the enclosure remains vertical during handling. The inverter pallet has 4-way handling access and 4xY--13" bolts securing the inverter to it. Pallet dimensions are 1118 x 1423 mm (44" x 56"). 025.4 mm 12.7 mm 025.4 mm 18 mm Figure 10: Lift Hole Dimensions, Inverter (Left) and Powerpack (Right) NOTE: The center of gravity for the Powerpack Inverter can shift depending on how many Powerstages it contains. A WARNING: When loading and unloading equipment, transporters must use suitable lifting equipment and lifting techniques for the weights specified in the Powerpack 2 System Transportation and Storage Guidelines. A WARNING: Prior to installation, inspect the unit to ensure the absence of transport or handling damage which could affect the integrity of the product. Failure to do so could result in Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 17 of 68 safety hazards. Unauthorized removal of necessary protection features, improper use, or incorrect installation or operation may lead to serious safety and shock hazards and/or equipment damage. dktoti CAUTION: Powerpack Units and inverters cannot be tilted or placed horizontally, even for a short time. Equipment cabinets contain coolant that could leak and sensitive equipment that could become damaged if not positioned upright. 414-4 CAUTION: Check all Tesla enclosures for deformation or damage and notify Tesla if any is found. Do not attempt to repair any damage. NOTE: Powerpack shipping covers are recyclable in any post-industrial plant, as recycle code #4. If a site has a large number of covers, contact your Tesla project engineer to arrange for return shipping. Staging Powerpack Units must be stored upright. Schedule Powerpack Unit delivery to minimize the storage time onsite. Batteries stored for longer than one month must be stored according to the following conditions: • Storage temperature between -20°C and 30°C • Humidity up to 95% non -condensing A WARNING: To reduce risk of fire: Do not store Powerpack Units for more than 24 hours at temperatures above 80°C (176°F). Do not expose Powerpack Units to temperatures above 150°C (302°F). Do not expose Powerpack Units to any localized heat sources or heating equipment. 5. Site Infrastructure Before the Powerpack System enclosures are anchored to the site, inspect the following work. Conduit All underground conduit must be provided and installed by the contractor. Underground conduit must be run between enclosures for power conductors and communication lines that are not enclosed in the wireways. Above -ground harness routing through wireways is covered in the section "Wireway Installation". An example underground conduit plan is shown in Figure 11. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 18 of 68 E 1 INVERTER CONTROLLER L_ 400/480V SWITCHGEAR 3 4,5,6 Figure 11: Example Underground Conduit Plan 1 One communication conduit between inverter and Tesla Site Controller (CAT5e/CAT6) 2 One DC power conduit from inverter to Tesla Site Controller (only needed for microgrid) 3 Up to four AC power conduits from inverter to site AC switchgear 4 One conduit from Tesla Site Controller to battery meter (CAT5e/CAT6) 5 One conduit from Tesla Site Controller to site meter if applicable (CAT5e/CAT6) 6 One conduit from Tesla Site Controller to customer communication interface (CAT5e/CAT6) 7 One Tesla Site Controller AC power conduit from switchgear 400/480 VAC, 2-pole, 10 A circuit NOTE: Always consult local regulations and engineering plans of record for final sizing. Figure 12 shows dimensions to correctly align the Powerpack Inverter conduit entry window with the required underground conduit running to it. NOTE: All conduit stub -ups for the inverter must land inside the AC window. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 19 of 68 3'' [0.07m] 1' 8 [O.52cm] -- AC WINDOW 3" !,[0 07mi i 6' [0.16n)] } TOP VIEW Figure 12: Powerpack Inverter AC Conduit Window ifkaA CAUTION: Do not modify the outer enclosures of any Powerpack System component. Modification of any sort voids the warranty, as well as the certification and UL listing provided with the product. If underground AC conduit cannot be run to the inverter as shown, refer to the document "Powerpack Application Note: Non -Standard Installation Requirements" and contact Tesla to discuss alternatives. Tesla must approve the non-standard installation before work begins. Foundation Inspection Check the following pad (or skid) properties before beginning to anchor enclosures: • The top of the pad is above adjacent grade, 152mm (6 in) maximum, with the edge of the concrete a maximum of 305 mm (12 in) from the front of the Powerpack System. If the site does not allow this pad height, then the pad must extend a full 4 feet in front of all Powerpack Units and include a ramp to allow service cart access. • Six feetmust be left clear in front of all Powerpack Units for unobstructed airflow. • The pad slopes a minimum of 1 %and a maximum of 2% (0.6-1.15 degrees) to allow positive drainage from the pad/base or towards a drain. • The pad must be sloped in one plane. • Concrete finish has a smooth, even surface of uniform texture and appearance, free from bulges, depressions, and other imperfections that would impact equipment anchorage or foundation/base drainage. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 20 of 68 • Any walls installed around the pad are designed to prevent standing water (drain, weep holes, etc.) with sufficient clearance between the equipment and any walls or obstructions to allow for proper drainage. NOTE: If the completed pad has areas of unevenness that prevent proper clearances, door opening, etc., grout can be used to even the surface. Always have a structural engineer approve the modification before implementing. If any aspect of the foundation inspection does not pass, contact Tesla before proceeding. 6. Site Installation Site Access For Tesla personnel to perform later maintenance, Tesla must have the ability to remove any locks on Tesla equipment and access to the Tesla equipment. o For combination locks, the customer must provide the combination to PowerpackSupport@tesla.com and the Project Engineer to ensure maintenance access. Contact Tesla for a recommended combination when using the provided combination lock on all Tesla Inverters. o For keyed locks, a double hasp is required to allow Tesla access by unlocking Tesla's lock. Fencing A perimeter wall, screen, or fence may be used to enclose the installation to screen equipment from view, or to deter access by persons who are not qualified. When deterring access, fences no shorter than 2.1 m (7 ft) in height are suggested. The distance from any fence to the equipment shall match the clearance requirements in Table 1, or as noted per the exceptions below. Fencing shall be locked and posted with a placard stating "Authorized Users Only", or similar. If applicable, see 2018 IFC 1206.2.8.7.3. Exceptions: • If the installation is located within a property that already contains perimeter fencing to prevent unauthorized public access, additional fencing might not be required. • Permanent chain link fence without fill or slats can be installed as close as 1.5 m (5 ft) to the front of the equipment. • Removable chain link fencing (e.g. with a swing gate, or similar) without fill or slats may be installed as close as 15 cm (6 in) in front of the equipment. When removed, the fence and its support structure must allow unobstructed equipment maintenance access and clearance for equipment door swing. Clearances Ensure that all enclosures are installed according to the clearance requirements defined in Table 1. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 21 of 68 T Equipment Powerpack Unit Table 1: Equipment Clearances Front Sides Back Top 1830 mm 105 mm 30 mm 1524 mm (60") for combustible materials, (72") (4.1") (1.25" ),2 915 mm (36") for service clearance Powerpack 1830 mm 105 mm" 100 mm r 915 mm (36") Inverter (72" )1 (4.1") (4") 1The clearance stated above is a minimum and should be increased to meet NEC 110.26 or local electrical building codes as necessary. 2 The back to back spacing of the Powerpack Units should be measured from the body of the enclosure. If the Powerpack Unit anchor template is not used, use a spacer to ensure that Powerpack Unit and Inverter enclosure walls are spaced at a minimum 90 mm (3.5") and maximum 150 mm (6") apart. NOTE: The vertical clearance for Powerpack System enclosures must extend the entire area of the service clearance. Some service equipment extends beyond the roof of the enclosure. NOTE: The required tolerance for the spacing between Powerpack Unit sides is +/- 6.4 mm (%"). NOTE: Using the Tesla-provided anchor templates during installation ensures that side and back enclosure spacing requirements are met. Sites must be laid out to allow full door swing for all Powerpack Units and inverters. The site layout must ensure that no wall or other structure interferes with any door opening fully. Trim landscaping to stay outside the clearance listed in Table 1. Maintain five feet of clearance above the unit that is clear of tree limbs and any other combustible obstructions, including but not limited to canopies and building overhangs. Combustible objects, such as wood fences, must also maintain a minimum 2' clearance from all sides of the Powerpack Unit. For any site that has signed a Capacity Maintenance Agreement (CMA), the site layout must provide adequate space to allow the addition of Powerpack Units for the duration of the contract. This includes room for an overhead lift to access the site, and clearance above the pad to place the additional Powerpack Units. Enclosure Installation NOTE: Modification of anchor tabs in any way is not permitted. Positioning the Enclosures 1. Place the inverter template (Tesla PN 1106829) on the pad with the AC window cut-out over the conduit stub -ups in the pad. 2. Mark and drill the inverter anchor holes according to the inverter template. 3. With the inverter template still in place, align the Powerpack Unit template (Tesla PN 1068864) to mark and drill Powerpack Unit anchor holes for rows C and D to the right of the inverter as viewed from the front (Figure 2, Figure 13). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 22 of 68 NOTE: The templates do not mate with an installed Powerpack Unit. Use two Powerpack Unit anchor templates to position back-to-back rows. B5 B4 A5 A4 B3 B2 B1 A3 A2 Al Dl D2 D3 D4 D5 ---yam y Cl C2 C3 C4 C5 Figure 13: Powerpack Unit Rows Relative to the Inverter 4. The inverter template does not mate directly with the Powerpack Unit template on its left side. Instead, align the inverter template holes (Figure 14, A) over the drilled inverter holes, then mark the inverter template slots (B). Remove the inverter template, then align the Powerpack Unit template holes (C) with the markings. Figure 14: Matching Powerpack Unit Template Holes to Inverter Holes 5. Complete marking and drilling the holes for Powerpack Unit rows A and B, to the left of the inverter. Anchoring the Enclosures Anchors are required for all enclosures. Stainless steel is required for outdoor installations. Note that anchors can differ by site and therefore are not provided by Tesla. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 23 of 68 NOTE: The rest of this procedure assumes use of Hilti KB-TZ 5/8" SS wedge anchors or similar. If the engineer of record recommends a different anchor, modify the procedure accordingly. 1. Cut the AC power and communication conduit stub -ups to a height no greater than 13 cm (5") above grade. This height ensures that the conduit does not stick up higher than the internal AC conduit window. 2. Open the Powerpack Inverter door and remove the AC floor panel at the front (Figure 15), to prevent damage when lifting the cabinet on top of the conduit stub -ups. Figure 15: AC Floor Panel 3. Remove the inverter accessory kit that is shipped inside the AC floor panel. Secure the door again before removing the cabinet from the pallet for anchoring. NOTE: Be sure to remove the metal templates from the pad before installing the enclosures. The templates are reusable tools for the installer. Mounting enclosures on top of the templates leaves an unacceptable gap underneath the unit. 4. For sites within 1 km of a shoreline or with a corrosion risk: Use a polyether based sealant such as Chem Link DuraLink 35 or similar. a. Before installation, apply additional sealant over the welds of the anchor bolt flanges at each corner of the Powerpack Unit and Powerpack Inverter enclosures. b. Lay two continuous beads within the edge of the base footprint of each enclosure after placing templates and drilling anchor holes, but before setting the enclosures on the pad. Set the tip of the applicator to lay each bead 6 mm (1/4") wide. Lay the first bead as close to the edge of the enclosure as possible, and the second about 26 mm (1") inside. 5. Use a lifting rig and crane, Gradall, or forklift that can lift equipment from the eyelets at the top of each enclosure. 6. Align the inverter enclosure over the pre -drilled anchor holes and anchor it in place. (Inverters do not require seismic washers, only Powerpack Units as described in the next step.) 7. Moving outward from each side of the inverter, set and anchor the Powerpack Units in each row (Al , then A2, etc.). Install a 0.375" thick seismic washer (provided by Tesla, PN 1057229) between each Powerpack Unit anchor tab and its anchor bolt head, one washer per anchor tab (Figure 16). Orient the washer so that it does not overhang the edges of the Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 24 of 68 Unit's anchor tab. Do NOT place the washer between the Powerpack Unit anchor tab and the ground. Figure 16: Seismic Washer 8. Install and torque the remaining anchors. For back-to-back configurations, use the custom anchor tool to torque the rear anchor bolts from the front of the enclosures: a. Draw lines on the socket as a visual indicator. b. Use the simple pulley/rope system to torque the rear interior bolts from the front of the Powerpack Units at the correct spacing. Fully engage the trigger and hold until completion. 9. Repeat until all Powerpack Units for that inverter block have been set. 10. Once all anchor bolts have been installed, verify the torque. 11. Use the four mounting holes, with an inner diameter of/4", in the back plate of the Tesla Site Controller enclosure to mount the unit vertically to a strut H-frame or rack (Figure 17). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 25 of 68 538 mm (21.18 in) 1--462 mm (18.18 in)-1 331 mm (13.03 in) 662 mm (26.06 in) 7. Wiring 05 mm (0.20 in) Figure 17: Tesla Site Controller Mounting Holes Wireway Installation Tesla provides a wireway to manage the cables that run between Powerpack Units, and from the Powerpack Units to the Powerpack Inverter. The wireway mechanically protects the cable harnesses and creates a continuous path that runs from the inverter to the last Powerpack Unit in each string (Figure 18). The kickplates that cover the face of each Powerpack Unit can only be accessed by opening the Powerpack Unit door. Because the door is interlocked with the Enable circuit of the inverter block, cable harness installation and maintenance can only be performed on a de -energized system. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 26 of 68 ‚Ii Figure 18: Cable Management Wireway Each row of Powerpack Units (A, B, C, and D) runs all power, ground/earth, and communication wires through its own wireway to a separate access plate in the base of the inverter. Figure 19: Inverter Block Diagram The inverter has access plates in front and in back, to accommodate Powerpack Unit cables from all four directions (Figure 20). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 27 of 68 Figure 20: Inverter Cable Access Plates, Front (Left) and Back (Right) A WARNING: Wreways must provide an effective ground -fault path. The wireway cover screws listed in the steps below are required to complete the ground path for the wireways. If you must commission or operate the system without the wireway covers installed, bond the wireway as needed to ensure an effective ground -fault current path. 1. Measure the length of wireway needed for each Powerpack Unit row, to reach that row's closest inverter access plate. 2. Cut the wireway (Tesla PN 1072786) to length. At the last Powerpack Unit in a row, cut the wireway to be even with the end of the last Powerpack Unit flap (Figure 21). File any rough edges. Figure 21: Wireway 3. Set the wireway in place. At corner locations, position wireway bottom trays with a gap of 0- 2" (Figure 22). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 28 of 68 Figure 22: Wireway Installation Gap 4. Use contractor -provided concrete screws (Tapcon screws or similar) to anchor each wireway section to the concrete pad in at least two locations. NOTE: For ease of installation, pre -drill concrete screw pilot holes in the wireway with a drill bit no larger than 3.4 mm (#29). 5. Use an 8mm (5/16") hex driver to remove the access plate(s) on the inverter base. Keep the bolts for re -use in the next step. 6. Use both re -used and additional shipped M5 0,8 x 16 mm bolts (Tesla PN 1002768-00) to install the right inverter interface (Tesla PN 1107828-00) and left inverter interface (Tesla PN 1107828-01) as needed onto the front inverter access plate openings. The left front interface window is for A -string Powerpack Units as shown in Figure 19; the right front interface is for C-string Powerpack Units. Figure 23: Powerpack Inverter Interfaces, Left and Right 7. Use both re -used and additional shipped M5 0,8 x 16 mm bolts (Tesla PN 1002768-00) to install the universal inverter interface (Tesla PN 1072854) as needed for Powerpack Unit rows B and D onto the rear inverter access plate openings (Figure 24). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 29 of 68 Figure 24: Powerpack Inverter Interface, Rear 8. Install inner wireway corners (Tesla PN 1072855) to connect the wireways for the Powerpack Unit rear rows to the wireways extending from the back of the inverter (Figure 25). Figure 25: Wireway Corners 9. Fasten each inverter interface (front and rear) and the wireway corners to the wireways with two Tesla-provided grounding screws (Figure 26). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 30 of 68 Figure 26: Wireway Grounding Screws Powerpack Unit Wiring Powerpack Unit DC Harness Installation The terminals for the DC cable harnesses, communication cable harnesses, and equipment grounding (protective earth) are recessed within the bottom section of the Powerpack Unit (Figure 27). Figure 27: Terminals Behind the Front Access Panel: Comm, Ground, DC DC harness lengths are pre-cut based on Powerpack Unit location relative to the Powerpack Inverter. Locations are assigned a Pack ID based on the naming convention shown in Figure 13 (e.g, Al, A2, B1, B2, etc). 1. For each Powerpack Unit, use a T30 Torx bit to remove the screws that attach the temporary cap over the DC terminals. Discard the cap and reinstall the screws for later reuse. 2. Lay out the Tesla-provided DC harness from each Powerpack Unit to the Powerpack Inverter. The positive (red) and negative (black) DC connectors have 3 prongs and 4 prongs respectively (Figure 28), which makes it impossible to connect to the wrong DC terminal at the Powerpack Unit. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 31 of 68 Figure 28: DC Cable Harness Connectors at the Powerpack Unit 3. Inspect the end of each DC harness to ensure the metal contact ring around the connector is correctly seated and flush with the plastic. 4. Fully seat the DC harness connectors on the Unit terminals. When fully inserted, the flanges of the connectors are just beneath flush with the surface of the Unit. 44 CAUTION: Fully seat the connectors before fastening the screws. Do not use powered tools for this connection. Using the screws to pull the connector closed can damage the terminals. 5. Use a T30 Torx bit to secure the DC harness to each Powerpack Unit DC terminal using the cap screws. Torque to 3.4 +/- 0.2 Nm (30 +/- 2 in-Ibs). If replacement screws are required, use 6 mm thread x 16 mm long hex cap head screws. Communication Harness and Ground Wire Installation 1. Install the Powerpack Unit side of the Powerpack-to-inverter communication harness (PN 1068391, Figure 29) in the Powerpack Unit communication terminal closest to the Powerpack Inverter. Leave the inverter side loose for now. Each row has a different Powerpack-to-inverter communication harness. Callout Comm Harness Connection Harness Part Number A Powerpack Unit Al to Inverter 1068391-06 B Powerpack Unit B1 to Inverter 1068391-07 C Powerpack Unit Cl to Inverter 1068391-03 D Powerpack Unit D1 to Inverter 1068391-05 Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 32 of 68 Figure 29: Communication Harness Connector 2. Connect a Tesla-provided communication cable harness (Tesla PN 1068390, Figure 29) between each Powerpack Unit in series, from the one closest to the Powerpack Inverter to the end of that row. 3. Install the communication termination harness at the last Powerpack Unit in the row (Tesla PN 1071858, Figure 30). Figure 30: Communication Termination Harness 4. Repeat the above steps for each row of Powerpack Units. 5. Ground each Powerpack Unit by attaching the contractor -provided #6 AWG copper conductor wire to the Powerpack Unit ground lugs. A single continuous equipment grounding conductor may be used to ground multiple Powerpack Units in a single string (e.g. Powerpack Units mounted side by side, with a maximum of five Powerpack Units in a string). The lug is copper with an electroplated tin finish, and is rated for use with bare copper grounding wire. NOTE: a grounding electrode conductor (direct connection to ground) is not required for the Powerpack Unit. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 33 of 68 Figure 31: Grounding the Powerpack Unit 6. Using a contractor -provided lug, attach the grounding conductor to the wireway itself at the end of each row farthest from the inverter Figure 32). Figure 32: Grounding the Wireway Powerpack Inverter Wiring: Customer Connection Side A DANGER: Refer to the Product Warnings section at the beginning of this document for full information on safety warnings and PPE recommendations before beginning any work in the inverter. Disconnecting Means The Powerpack Inverter includes a DC disconnect handle on the front door of the unit that can be locked in the open position (Figure 8). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 34 of 68 DC Harness Installation All harnesses entering or exiting the Customer Connection side of the Powerpack Inverter are routed through the opening in the bottom of the enclosure above grade. Unlike previous models of Powerpack System that required a DC Combiner Panel in a separate enclosure, the Powerpack Inverter aggregates the DC power from its assigned Powerpack Units in its Customer Connection section. Each inverter can be assigned between 1 and 20 Powerpack Units. The inverter has four DC bus bars, two positive and two negative, located on each side of the Customer Connection sections The DC cables are provided by Tesla, rated to 1000 V and rated for their protective 200 A fuses. The negative bus bar is located above the positive one, and DC cable lengths are offset to match those heights. Fuses are pre -installed in 5, 10, 15, or 20 sets of paired fuses, even if the inverter has fewer Powerpack Units attached. For example, an inverter assigned to 13 Powerpack Units may have 15 or 20 pairs of fuses installed. Strain relief plates are provided with cable ties for both the AC and DC cables. Cable ties are preinstalled for DC cables. Cable ties are provided for the AC cables and must be installed. 1. On the Powerpack Inverter, turn the DC disconnect switch to the "off' position. 2. Open the inverter door and lock out the DC disconnect switch. 3. Remove the high voltage shield. 4. Check with a properly rated voltmeter that there is no voltage on the DC bus before proceeding. Measure bus bar to bus bar, and each bus bar to ground. 5. Check that the customer connection section has the correct number of pre -installed fuses on the DC bus bars to match the number of Powerpack Units for that inverter block. If the inverter does not have enough fuses, contact Tesla. 6. Remove both strain relief brackets that run across the front of the busbar assemblies (Figure 33, 1). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 35 of 68 3 1 3 2 re 33: Inverter Floor View 1. Strain relief v 3. DC bus bars and fuses 2. DC cable floor panels 7. Remove the applicable modular DC cable floor panels (Figure 33, 2). 8. Lay all Powerpack Unit -terminated harnesses and ground wires in the wireways. Pull each Powerpack Unit row's bundle through its nearest Powerpack Inverter interface and up through the DC floor panels. 9. Remove the applicable caps in the floor panels where all DC cables and Powerpack Unit communication harnesses will run. Leave the other plugs in place to prevent dirt and pest ingress. 10. Identify the M50 cable glands that ship with the system in the accessory kit. If they arrive assembled, unscrew the gland halves and remove the rubber inserts. Set aside the correct number of glands for the total number of that inverter block's DC connections and comm/ground connections. The kit might have more glands than are required. (Glands for comm and ground wiring have inserts with smaller -diameter holes pre -drilled.) Figure 34: DC Cable Gland and Inserts Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 36 of 68 11. Assemble the outer halves of the cable gland, top and bottom. Fasten each gland into a hole in the DC floor panel from the top face of the panel as pictured in Figure 33. NOTE: DC harnesses do not have assigned locations on the DC bus bars. However, for ease of maintenance, align the DC floor panel glands so that each Powerpack Unit row's connections are grouped together. NOTE: For ease of routing, reserve the front row of glands closest to the AC window for communication and grounding wiring in a later step. 12. Route each positive/negative DC harness pair through the inverter interface, under the inverter floor, and through an installed gland in a DC floor panel. 13. Terminate each DC harness to the DC bus bar pins (Figure 33, 3). The negative bus bar is on top, and the positive bus bar is below. Negative and positive terminations are pre - assembled at the appropriate heights. NOTE: Check that DC harnesses are securely terminated by ensuring the top tab clicks into place (Figure 35). Perform a push/pull test to ensure proper seating. Figure 35: Tabbed DC Harness Connector at the Inverter (red +, black -) 14. When all pairs of cables are routed, perform a 1000V insulation test from the HV DC+ bus bar to ground and from the HV DC- bus bar to ground with the DC disconnect open. Document the results in the Construction Checklist. 15. Fasten the strain relief zip tie below each terminal around its DC cable. 16. Leave the DC floor panels loose until the Powerpack Unit communication harnesses are installed in the next procedure. Powerpack Unit Communication Harness Installation and Testing This test verifies that all communication harnesses for each row of Powerpack Units are continuous, and all doors close and lock properly to engage the Enable circuit. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 37 of 68 1. Route the communication harnesses from the Powerpack Unit wireways (PN 1068391, one per row of Powerpack Units) through the inverter interfaces, inverter base, and DC floor panels (with cable glands already installed on the floor panels as described for the DC cables, above). 2. Close and lock all Powerpack Unit doors during the following continuity check. 3. Using a multimeter, perform a continuity check between pins 2 and 5 (the two middle pins) of each Powerpack-to-inverter communication harness connector (Figure 36). If a continuity check cannot be performed, substitute a resistance test where resistance must be less than 10 Ohms to pass. 4624 CAUTION: Be careful not to deform the communication harness contact sleeves by using large multimeter probes. Verify that the connection points on each communication harness are undamaged before terminating them in the board in the next step. Figure 36: Communication Harness Connector at the Interface Board 4. Identify the CAN termination points for the communication harnesses at the interface board (Figure 37). Figure 37: Interface Board Terminations Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 38 of 68 5. Terminate all required communication harnesses at the CAN inputs on the board (J14-J17). Populate the harnesses left to right in order, A B C D. 6. Install a jumper (Testa PN 1071276) from the accessory kit onto any unused terminations. 7. If the site will be configured as a microgrid: a. Run a Tesla Site Controller DC backup cable from the interface board through the 1" DC conduit to the Tesla Site Controller. For cable lengths of 75 m (246 ft) or less, use 4 mm2 (12 AWG) cable. For longer lengths, check site plans or consult with Tesla. b. At the inverter interface board, connect the - wire in J6 as ground, and the + wire in pin 1 of J10 for 24V power (fused at 7 A). 8. If the Tesla Site Controller will be configured with hardwired jumpstart ability: a. Run a 12 V jumpstart cable from the interface board through the same 1" DC power conduit as the 24 V backup power to the Tesla Site Controller. For cable lengths of 25 m (82 ft) or less, use 4 mm2 (12 AWG) cable. For longer lengths, check site plans or consult with Tesla. b. At the inverter, insert the + wire for 12 V power and the — wire as ground into a TE connector (TE 2P RCPT VAL-U-LOK, 794954-2 or similar). Insert the TE connector into the J3 terminal on the interface board. Figure 38: TE Connector Polarity See "Installing the Tesla Site Controller" to land the other ends of these wires in the Tesla Site Controller. + CAUTION: Do not connect any non-Tesla equipment to the inverter interface board terminals other than the microgrid or jumpstart lines as described. Non-Tesla equipment can damage the Powerpack System. NOTE: A fire -safe enclosure is required for equipment or parts of equipment that are connected to the 12 V and 24 V power customer terminals on the interface board. If such equipment is not installed inside the Powerpack Inverter enclosure itself, it requires a separate fire -safe enclosure. Powerpack Unit Grounding The Powerpack Unit equipment grounding conductors terminate at the ground lugs located in the bottom section of the Customer Connection area (Figure 39). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 39 of 68 The grounding (protective earth) lugs are identified with the following symbol: 0 1. Ground the DC grounding connections of each Powerpack Unit row onto the four M6 studs with the Tesla-provided mechanical lugs. The lugs accept #14 to #4 AWG copper ground. Lugs are torqued to the bus bar at 5.6 Nm. Secure the wire in the lug and torque according to the wire size: • 14-10 AWG: 4 Nm (35 in-Ibf) • 8 AWG: 4.5 Nm (40 in-lbf) • 6-4 AWG: 5 Nm (45 in-lbf) Figure 39: Customer Connection Ground Connections: AC Studs (1) and DC (2) 2. Replace and refasten the DC floor panel(s). 3. Unscrew the two halves of each cable gland and install the two halves of the rubber insert inside, around the cables, to prevent ingress. Fasten the cable gland outer halves together. Perform this step for both DC power cable glands and communication/ground cable glands. Figure 40: Completing Gland Installation Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 40 of 68 Tesla Site Controller Communication Wiring In addition to the communication harness, the interface board must also communicate with the Tesla Site Controller via a shielded CAT5e or CAT6 cable, provided and installed by the contractor and terminated at port EthO (Figure 37). 1. Install the field crimped Ethernet cable between the Tesla Site Controller and interface board using an EZ-RJ45 Crimp Tool or equal (Figure 41). Use a metal connector for the end that plugs into the Tesla Site Controller, and a plastic connector for the end that installs into the interface board. 2. Test field crimps using a VDV Scout Pro or Pro LT (VDV501-053 or 068) or equal. 3. Leave a paint pen mark on the cable as it passes. 568B Figure 41: Ethernet Wire Configuration Powerpack Inverter Wiring: AC Conductors A DANGER: Refer to the Product Warnings section at the beginning of this document for full information on safety warnings and PPE recommendations before beginning any work in the inverter. Each Powerpack Inverter requires a 4-wire, wye-grounded circuit (3 phases, neutral, and ground). Conductors enter the Powerpack Inverter via a bottom conduit window and terminate on the AC bus bars in the Customer Connection area. CAUTION: If not already clearly defined in the site plans, refer to the Powerpack 2 System Site Design Manual for neutral sizing requirements. The inverter is provided with four AC bus bars to connect three phases and the neutral. AC bus bars are made of tin-plated aluminum and drilled to allow the connection of up to four (4) 2-hole lugs (Figure 42). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 41 of 68 O O 0 O O O r 321.3 ( 12.65' 109.1 [ 4.3" 213.2 8.39' 44 5 [ 1.75" 7 Q,`' 13.5 ( 0 53" I 1 0 0 [ 3.94' 1 as-5 [ 1.75' 0 44.5 [ 1.75" [ 0 Figure 42: Inverter Bus Bar Dimensions (in mm/in) The lug connections allow two Tugs on each side of the bus bar with a maximum of: • Four (4) sets of 600 MCM (300 mm2) conductors per bus bar, or • Three (3) sets of 750 MCM (400mm2) conductors per bus bar, or • Two (2) sets of 1,000 MCM (500 mm2) conductors per bus bar The conductor connections are supplied by the customer and must comply with all local codes and regulations. Testa requires that the bus bar not be modified in any way and that the Testa supplied hardware be used as shown in Figure 43. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 42 of 68 Figure 43: AC Bus Bar Auxiliary power is not required for the inverter or the Powerpack Unit. The Powerpack Unit pulls auxiliary power for the control power and thermal management from the DC bus, and therefore requires no field work. 1. Keep the inverter cabinet power disconnected and locked out per the previous procedure. 2. Pull circuit conductors into the inverter via the AC bottom conduit window (Figure 33). 3. Conduct insulation testing at 500 V on the AC conductors for insulation resistance after running the conductors through the conduit, but before terminating the AC conductors on the inverter AC bus bars. Testing after termination results in the test failing. Document the results in the Construction Checklist. 4. Connect all AC conductors to the inverter bus bars using an approved connection method. Each Powerpack Inverter accessory kit includes the M12 bolts, washers, and nuts for attaching the AC lugs to the AC bus. Install the fasteners in this order: Bolt, flat washer, connector, bus bar, connector, flat washer, conical washer, nut (Figure 44). Torque to 36 Nm (26.6 ft-lbs). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 43 of 68 Figure 44: Inverter Bus Bar Fasteners NOTE: The minimum electrical clearance between one bus bar and the next bus bar, including fasteners, is 3 mm (0.12 in). 5. Apply anti -oxide coating to each HV, field -torqued lug in the inverter and switchgear if required by the AHJ. 6. Replace both AC strain relief brackets that run across the front of the customer connection section of the inverter. 7. Use the provided ties to fasten the conductors to the strain relief bar. NOTE: Where possible, arrange and fasten the AC conductors toward the center to leave clear space open on both sides. This creates better maintenance access to the DC bus bar fuses and the Interface board. 8. Install the equipment ground conductor (EGC) on the inverter grounding bus bar using approved, contractor -provided lugs. The ground studs have the following dimensions: • Six M8 studs • NEMA 1.75 pitch between vertical sets Each Powerpack Inverter includes the M8 captive washer nuts for attaching the inverter ground lugs to the ground connections. Torque to 9.0 Nm (6.6 ft-lbs). Where metal conduits are used, conduits must have insulated ground bushings connected to equipment grounding conductors. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 44 of 68 Figure 45: AC Ground Lug Example a 41 CAUTION: The inverter output AC voltage is phase -rotation sensitive. The inverter will not start without proper phase rotation. 9. Check that the phases of the inverter are connected to the corresponding utility phases by using a Greenlee 5702 Phase Sequence Indicator or equal. (Check the manual for the phase indicator tool before use.) a) Connect the tester leads to phase 1, 2 and 3 of the inverter. Refer to the labels on the bus bar. b) Check that all phases show clockwise rotation. If any phases show counterclockwise rotation, swap phases 1 and 3 and retest. 10. Once all power and communication wires are installed for the inverter, apply a sealant to the edges of the AC window where the steel from the enclosure meets the concrete (plumber's foam or similar), rated for applicable fire resistance requirements. 11. Seal the conduit stub -ups using a material identified by the manufacturer as compatible with the cables and the conduit materials (duct seal, moldable putty, or similar), rated for applicable fire resistance requirements. (Figure 46 shows both sealants.) Ensure that all bottom plates in the inverter are completely sealed from dirt and pest ingress. CAUTION: Some foaming agents such as plumbing foam can degrade insulation and PVC conduit pipes. Ensure all sealants are compatible with site materials. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 45 of 68 Figure 46: Sealing Conduit Window 12. Perform a grounding resistance test. The system should show: • < 1 Ohm between each earth bar and the main system earth bar • < 1 Ohm between the system's exposed metal and the local earth bar • Only one neutral earth bond per system 13. Vacuum the interior of the inverter. Include the LV shelf and the customer connection area. Wireway Cover Installation Once all inverter and Powerpack Unit harnesses are installed and tested as needed, complete the installation of all covers and kickplates to protect wiring. 1. If not already done, use the door key (ships attached to the Powerpack Unit door) to open all Powerpack Unit doors. 2. Install the Powerpack Unit kickplates (Tesla PN 1072788, Figure 47) using 3 screws and an integrated lock washer for each (Tesla PN 1072856). See the grounding warning at the beginning of the Wireway Installation section. Make sure that: • The kickplate is centered between the Powerpack Unit's vertical flaps • The flanges on either end of the kickplate are fitted over the top of the Powerpack Unit horizontal flaps Figure 47: Powerpack Unit Kickplate Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 46 of 68 3. Install the inverter interface covers (Tesla PN 1107830-00, right and 1107830-01, left) (Figure 48). Figure 48: Wireway Covers: Inverter Interfaces (1), Top Caps (2), End Cap (3) 4. Cut the top cap (Tesla PN 1072787) to fit between Powerpack Units, and between the Units and the inverter, over the straight wireway segments. File any rough edges. Set the top cap over the wireway. NOTE: Do not cut the top cap with too tight a tolerance. A top cap that is too long can damage Powerpack Units during removal and installation, and makes servicing more difficult. 5. Screw the cap to the wireway using sheet metal screws (Tesla PN 1072829). See the grounding warning at the beginning of the Wireway Installation section. At least 2 screws are required between Powerpack Units. For segments greater than 6" in length, at least one screw is required on each end. 6. Slide on the corner cap (Tesla PN 1072801) and attach it using 4 sheet metal screws (Tesla PN 1072829). At least 2 of the 4 screws must be fastened. 7. At the end of each Powerpack Unit string, press the wireway end cap (Tesla PN 1072853) over the top edge of the kickplate. Optional: The end cap can be screwed to the tray using Tesla PN 1072829. 8. Tesla Site Controller The Tesla Site Controller can be powered from a 400 VAC or 480 VAC, 2-pole, 10 A circuit. The engineer of record must design the means and methods of pulling this circuit. In a multiple Powerpack Inverter scenario, this circuit can be provided from the AC switchboard. For AC and ground conductors, use a minimum of 2.5 mm2 (14 AWG) copper rated to 90 °C. Refer to the "Site Infrastructure" section of this manual to ensure all needed conduit is in place. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 47 of 68 Installing the Tesla Site Controller Figure 49: Tesla Site Controller Interior Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 48 of 68 1 Real -Time Automation Controller (RTAC): optional (PN 1129636) 2 Terminals for computer power 3 Tesla Site Controller Computer 2 (optional, PN 1052303) 4 Tesla Site Controller Computer (primary): includes four RS-232/422/485 ports, Ethernet ports 5 RSP Network Switch: Connects both Tesla Site Controller computers to the inverter using Ethernet 6 DCDC converter and surge protector: Connector for 24 V backup power 7 Jumpstart terminals (optional): used to connect a 12 V power supply that can jumpstart a microgrid inverter if needed 8 Grounding terminals 9 Terminals for transformer wiring 10 Fuse block between AC mains and transformer: Default configuration is shipped with 0.5A KLDR Fuse (PN: 1053860-00-A) for 480 VAC, other fuses are in the accessory kit 11 Transformer, 120/240/480 V NOTE: The components and wiring locations in the image above are correct, but wiring color may differ. Check the wiring diagrams below for wire colors. 1. Mount the Tesla Site Controller enclosure on a rack or wall using appropriate fasteners capable of supporting 22 kg (48 Ibs). Mounting brackets are included. NOTE: The Tesla Site Controller is over 18 kg (40 lbs). Use proper precautions in carrying and lifting the module. 2. Pull the AC conductors (phase and phase -neutral), min. 14 AWG, through the conduit from the switchgear, and up through the bottom of the Tesla Site Controller enclosure. Land them on terminals L1 and L2 of the fuse block (Figure 49, image callout 10). Land the AC ground wire on the ground terminal on the same DIN rail (callout 8). 3. Pull the Ethernet meter wiring through the conduit from the inverter(s) and up through the bottom of the Tesla Site Controller enclosure. Connect to the network switch (callout 5). 4. If the site is configured as a microgrid, pull the DC backup cable through the conduit from the inverter(s) interface boards. Connect the two wires to the Aux in/rtn terminals on the bottom of the DCDC converter (image callout 6). 5. If the Tesla Site Controller will be configured with hardwired jumpstart ability, pull the 12 V jumpstart cable through the conduit from the inverter(s) interface boards. Connect the two wires to the jumpstart terminals (callout 7). 6. For any region other than North America, replace the region -specific SIM card in the right- hand (primary) computer: a. Insert a long flathead screwdriver in the hole of the back mounting tab. Gently pry up on the mounting tab until it lifts free of the DIN rail. Set the computer in a stable place, being careful not to pull on the wires that are still connected. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 49 of 68 Figure 50: Removing Computer from DIN Rail b. Remove the Ethernet connector from the top of the primary computer. c. Use a small flathead screwdriver to remove the connector holding the + and — wires from the top of the primary computer. d. Use a Philips head screwdriver to remove the six screws from the computer back cover. Set the cover aside. e. Remove the SIM card from its slot. Figure 51: Computer SIM Card Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 50 of 68 f. Replace the SIM card with the one that shipped with the system for this region. g. Replace the back cover. Fasten the six screws hand -tight. h. Replace the computer on the DIN rail. i. Replace the Ethernet, + and — wires. 7. If not already installed, install the internal antenna from the Tesla Site Controller accessory kit onto the connector in the top left corner of the computer. NOTE: If the internal antenna for the computer does not fit, contact Powerpack Support. 8. To install the second computer (if one was ordered for the site): a. Identify the space on the DIN rail to the left of the existing computer. b. Hook the second computer onto the DIN rail: align the two small hooks on the back of the computer under the rail first, then gently push until the top half of the mounting bracket snaps into place. c. Connect the included positive wire from the right side of the terminal block (callout 2) to the computer's + terminal. d. Connect the included negative wire from the left side of the terminal block (callout 2) to the computer's - terminal. e. If not already installed, install the antenna from the Tesla Site Controller accessory kit onto the connector in the top left corner of the computer. 9. To install the RTAC (if one was ordered for the site): a. Use a Philips head screwdriver to unfasten the two M5 screws holding the DIN rail to the top of the backplane of the enclosure. b. Snap the RTAC unit onto the DIN rail. c. Reinstall the DIN rail onto the enclosure backplane. Torque to 2.8 Nm (24.8 in -lb). d. Install the leads of 1.5 mm2 (16-14 AWG) wire that were provided with the system. Connect them to the power terminals on the top DIN rail (callout 2). e. Install the Tesla-provided Ethernet cable from the LAN1 port on the RTAC to the LAN1 port on the master computer. 10. Configure the transformer wiring according to the voltage of the incoming AC power. Choose the correct transformer procedure below for this site. Diagrams include the optional RTAC unit and optional second computer. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 51 of 68 Configuring the Transformer for 440, 450, or 480 VAC The Tesla Site Controller is already default -wired for 480 VAC sites. The transformer is wired directly into terminal blocks as shown below. NOTE: Configure 440 and 450 VAC input the same as for 480V. 5 A C RTAC Diode Redundancy Module Out In + - I - - + + 5 A C b +V -V OUt DC/DC SEtV m +V -V 24V Power Supply GND N Ll IN IN SMC2 SMC Com: ton. C 2 cant Csma tem3 Cans Cans mov Fuse Block Figure 52: Layout Diagram for 480 VAC SWITCH Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 52 of 68 Configuring the Transformer for 208, 240, or 400 VAC For 208 VAC, 240 VAC or 400 VAC line to neutral input: 1. Remove the brown and white wires altogether that run from the left side of the transformer to the top of the 1.6 A fuse block. 2. Replace the default fuses in the fuse block with the ones meant for 120 and 240 VAC configurations (1.5A ATQR Fuse, PN: 1453351-00-A). 3. Move the orange and white wires from the right side of the transformer to the top of the 1.6 A circuit breaker. The transformer should now be completely disconnected. CAUTION: 240 VAC may only be in LINE to NEUTRAL form. Wiring as split phase can cause a short in the system. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 53 of 68 5 A C b +V -V -V +V OUT OC/DC SELV n +V -V 24V Power Supply GNO N Li RTAC Figure 53: Layout Diagram for 240 VAC (L-N) Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 54 of 68 Configuring the Transformer for 120 VAC For 120 VAC: rewire the transformer to be used as a step-up and branch circuit protection at the source. 1. Ensure that all power is off to the Tesla Site Controller. 2. Disconnect the wires running to and from the transformer. 3. Replace the default fuses in the fuse block with the ones meant for 120 and 240 VAC configurations (1.5A ATQR Fuse, PN: 1453351-00-A). 4. On both the left and right sides of the transformer, use a Philips screwdriver to remove the tap connecting the two middle terminals. Install two taps that connect the middle to the outer terminals. The new taps ship in a bag inside the Tesla Site Controller enclosure. Figure 54: Transformer Taps 5. Connect the orange and white wires coming from the L1 and N terminals of the 24V power supply to the LEFT side of the transformer, the opposite side from which they were removed (shown in the image below). 6. Connect the brown and white wires coming from the top terminals of the 1.6 A circuit breaker to the RIGHT side of the transformer, the opposite side from which they were removed. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page SS of 68 5 A c b RTAC Diode Redundancy Module Out In - - + + 5 A b C DC/DC SELV +V -V -V +V 24V Power Supply IN SMC Con2 Corn: Con.! Carn3 IN SMC Corn2 Con! Coma Cu,,; Figure 55: Layout Diagram for 120 VAC SWITCH tra nsformer 1 Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 56 of 68 Connecting a Demand Response Controller Australia installations might require a Demand Response Enabling Device (DRED) to be connected to the Powerpack System, to comply with utility regulations for controlling output power. Tesla supports the FuturePoint Sunspec Demand Response Controller (DRC), FuturePoint part number 006A-SUNS, as the interface hardware to translate the DRED signals into Modbus commands. The Sunspec is provided by the site or the contractor. The DRED is controlled by the Electricity Network Operator and, in turn, sends signals to the DRC that instruct the inverter via the Sunspec Interface to take the required action. NOTE: All regions except Australia can skip this procedure. 1. Choose an installation point for the Sunspec DRC enclosure, probably close to the Tesla Site Controller enclosure. 2. Mount the DRC vertically on a wall or similar structure with the conduit entry on the bottom, as described in the FuturePoint Sunspec DRC User Guide. 3. Provide a single phase, 230 VAC, minimum 10A circuit from the existing premise electrical system and connect it to the Sunspec DRC 230 VAC power supply terminals. The circuit shall be designed per installation code by the design engineer for the project. 4. Use an Ethernet cable to connect the Sunspec Ethernet port to the LAN1 port inside the Tesla Site Controller. The LAN1 port on the Tesla Site Controller functions as a DHCP client, and the TCP port on the Sunspec DRC has an inbuilt DHCP server. No other hardware is required for direct connection or control to the Powerpack Inverter(s). 5. Connect the AS4755 DRED input port on the Sunspec DRC to a site- or contractor -supplied AS4755 compliant Demand Response Enabling Device (DRED). For full installation details, refer to the FuturePoint Sunspec DRC User Guide. Connecting a VDE 4105 Protection Relay For installations that must comply with VDE 4105 requirements, configure the relay as specified below. NOTE: Regions that do not require VDE 4105 compliance can skip this procedure. 1. Procure an additional, contractor -provided contactor and protection relay that is VDE 0124 certified and is correctly sized to support the entire site. The protection relay is not required to have anti-islanding functionality. 2. Install the contactor and protection relay upstream of the Powerpack System. The installation must comply with all local and regional codes. 3. Wire the contactor such that loss of power to the relay results in an immediate trip for the Powerpack Inverter. 4. Configure the protection relay such that a loss of power for less than 3 seconds does not result in the loss of the last 5 trip error messages on the relay. 5. Set the relay to match the voltage and frequency ride -through settings listed in the table below. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 57 of 68 Table 2: Protection Relay Setting Values Protective Function Protection Relay Setting Values* Voltage drop protection U< 0.8 Un < 100 ms Rise -in -voltage protection U> 1.1 Un ** < 100 ms Rise -in -voltage protection U» 1.15 Un < 100 ms Frequency decrease protection f< 47.5 Hz < 100 ms Frequency increase protection f> 51.5 Hz < 100 ms * The duration set point "<100 ms" for the protection relay setting value is based on the assumption that the maximum proper time for both NS protection and interface switch is also 100 ms. This leads to a maximum total disconnection time of 200 ms. If the proper time of a component is less than 100 ms (e.g., 50 ms), then this allows for a longer period during which to perform the measurements and evaluation of the protective function (e.g., up to 150 ms). This could then lead to a protection relay setting value higher than "<100 ms", i.e. "<150 ms". However, in that case, only the 100 ms shall be visualized as setting value at the NS protection. Still, the disconnection time of 200 ms shall not be exceeded under any circumstance. ** It shall be ensured that the voltage at the network connection point cannot fall below 1.1 Un. If compliance with this requirement is ensured by a central NS protection, then it is permissible to set the rise -in -voltage protection at the decentralized power generation unit or system to a value of up to 1.15 Un. In that case, the system erector should consider any possible effects on the customer installation. Combination of central NS protection (U>: 1.1 Un) and integrated NS protection (U>: 1.1 to 1.15 Un) is advisable, if the voltage drop in the house installation cannot be neglected. This is typically the case with longer connection lines. 9. Energy Meters Every site requires a "battery meter" that measures the AC energy output of the battery system (Figure 56). A "site meter" (that measures the net load of the site with the battery system included) is optional, but required for some control functions. An additional "solar meter" (or "generator meter") might also be required for sites involving PV installations. See the Powerpack 2 System Site Design Manual for further meter details. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 58 of 68 Tesla Powerpack System Powerpack Controller 4 4 { Pp units § \ U On -site Generation III 111111111 I PV Array ar Panel H' Board Battery Meter Electrical Infrastructure Powerpack Point of Connection (PoC) kwh Generation Meter Mawr Site Distribution Board kWh Existing Grid Infrastructure Site Existing Meter Metering Figure 56: Metering Overview Site Loads (multiple circuits) Connection Requirements All meters are connected to the Tesla Site Controller using Ethernet cable. NOTE: RS485 connections are no longer supported. CAUTION: Pay particular attention to meters during installation. The Powerpack System cannot operate correctly without the correct meter wiring and meter installation. Ethernet connection requirements: • Shielded CAT5e or CAT6 • Field -crimped Ethernet cables must be tested with a LAN tester, at minimum Connecting Meters to the Tesla Site Controller Connect a direct line between the meter and the Tesla Site Controller, from the meter(s) into an available port (ports 2-5) of the Ethernet switch. Use a metal connector for the end that plugs into the Tesla Site Controller, and a plastic connector for the end that installs into the meter. Ensure the Ethernet switch is also connected to LAN2. If the Tesla Site Controller is communicating over an external, third party network, connect the external third party network to LAN1. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 59 of 68 NOTE: If the site is using multiple external communication devices that use LAN1 (such as a customer interface, utility monitoring device, or external -network meter), a second Ethernet switch is required. Contact Tesla for details. CT Installation in the AC Panel or Switchboard 1. Check meter -specific requirements to determine whether to use core CTs or Rogowski coils. Figure 57: CT Types, Core (Left) and Rogowski (Right) 2. Verify that the CTs used match the chosen meter's specifications. NOTE: Tesla is not responsible for the correct installation of the meter on the AC side. The Powerpack System will not operate correctly with incorrect CT installation or wiring to the meters. This is a common point of installation failure, and requires careful installer attention. 3. Read the label on each CT to verify the CT ratio and the arrow that indicates the direction of flow. Record each meter's make, model, serial number, and CT ratio on the Construction Checklist. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 60 of 68 CURRENT TRANSFORMER accuRRcrasvO 11L / 30° lean." BIL5S C. ORE!-ININIIINt ON M Nr Figure 58: CT Ratio and Arrow 4. All meters are phase -sensitive. For each meter, use color -coded wires to help identify phases on voltage references and CT leads. NOTE: Each phase's voltage wiring must correspond to the same phase of current wiring, and the positive and negative polarity of each phase must be installed correctly to match the sign convention in Figure 59. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 61 of 68 Generation 4=1 Utility (Site Meter) Battery 122* 4=2 Loads Figure 59: Metering Sign Convention NOTE: Be sure to install shorting blocks for core CTs. Shorting blocks are not required for Rogowski coils. NOTE: Do not field -extend the leads on a Rogowski coil. Doing so can degrade signal accuracy. If longer leads are required, reach out to the appropriate manufacturer for a project specific order. 5. Install the battery meter wiring on the battery AC panel so that only the Powerpack System output is measured. 6. If using a site meter, install wiring so that all customer loads including the Powerpack System output are captured. Site meter wiring is typically installed adjacent to the utility meter or at the site's point of common coupling (PCC). 7. If using a generation meter, install wiring so that all solar generation is measured. Some sites might require more than one solar meter; refer to site drawings. 8. If using a consumption (facility load) meter, install wiring to measure the facility load only (excluding all Powerpack System activity and generation sources). 9. For each meter, perform a resistance check between the positive and negative terminals from each CT: • Core CTs: Ensure resistance between each CT pair is -0 Ohms. • Rogowski coils: Ensure resistance between each CT pair is 20-60 Ohms, and resistance from one pair to another pair is open (-100 kOhms or more). 10. On the meter UI, set the CT ratio per the installed CTs and document in the Construction Checklist. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 62 of 68 . Meter Configuration Once AC -side and Tesla Site Controller wiring is complete, turn on the meter(s) and set the following parameters as described in the meter manual: For Ethernet Using LAN1: Contact Tesla for IP address settings. For Ethernet Using LAN2: • Assign the meters to static IP addresses Meters are assigned addresses in batches by meter type: • Battery = 192.168.90.201 to 192.168.90.209 (first battery meter starting at 201, next at 202, etc.) • Site = 192.168.90.210 to 219 (first site meter starting at 210, next at 211, etc.) • PV = 192.168.90.220 to 229 (first PV meter starting at 220, next at 221 , etc.) • Busway = 192.168.90.230 to 239 (first busway at 230, next at 231, etc.) • Set the Subnet Mask to 255.255.255.0. • Set the Default Gateway to 192.168.90.1. NOTE: If the installation is using SolarCity SEL735 meters, also refer to the SEL735 Meter Guide on the Grid portal for complete configuration instructions. NOTE: To save the IP address settings, the meter must be turned off, then turned back on. 10. Commissioning Shutdown For an emergency or unknown behavior: 1. Open the upstream AC breaker (if one is present). 2. Open the DC Disconnect switch on each affected inverter to isolate the Powerpack Units from the inverter (Figure 6). 3. Open the AC disconnect device connected to the AC output of each affected inverter, to isolate the inverter from the grid or other energy sources. ++ CAUTION: Wait a minimum of 5 minutes before closing the DC disconnect any time the DC disconnect has been opened. Equipment can be damaged if the DC disconnect is closed too fast. For a planned shutdown: The procedure varies depending on site configuration. Refer to the Powerpack 2 System Operation and Maintenance Manual for details. A WARNING: Any work inside enclosures not explicitly mentioned in the Powerpack 2 System Installation Manual should only be performed by Tesla or Tesla approved service Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 63 of 68 technicians who are qualified and have lockout/tagout equipment. Qualified personnel can find further safety and verification directions in the Powerpack System Service Manual. Locating Enclosure Serial Numbers The serial number locations of each type of enclosure are shown in the images below. These images are examples; the exact appearance of a site's enclosures might vary. Figure 60: Serial Numbers on Powerpack Unit (left) and Inverter (right) Figure 61: Tesla Site Controller VIN Location Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 64 of 68 Tesla Commissioning Responsibility After the installation contractor completes the entire installation and the Construction Checklist, Tesla is responsible for commissioning the Tesla Site Controller communication with the Powerpack Inverter and initial start-up of the Powerpack System. This includes: 1. Tesla Site Controller communication with the Tesla Server 2. Tesla Site Controller communication with the Powerpack Inverter 3. Powerpack Inverter communication with Powerpack Units and basic functionality 4. Inverter block and system level performance testing 5. System start-up sequence checklist NOTE: Owner and site manager responsibilities are detailed in the Powerpack 2 System Operation and Maintenance Manual. Aug. 9, 2018. CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 65 of 68 Revision Log Revision # Date Description 1.00 02-03-2017 Initial Release 1.01 02-07-2017 • Fixed rounding error on inverter weight • Added specs for Powerpack Unit 2, 2-hour 1.02 04-06-2017 • Added megger testing for AC conductors before termination • Added DRC section for Australia installations • Listed all Powerpack Inverter part numbers according to number of Powerstages • Added a pointer to the Site Design Manual to check transformer configuration if one is present • Added diagrams of Powerpack Inverter's center of gravity points with minimum and maximum Powerstages installed • Updated pad construction pre -checks • Updated wiring spec and diagram for RS-485 meter wiring • Added note about applying anti -oxide coating to each HV, field -torqued lug in the inverter and switchgear in the "Inverter Wiring: AC Connectors" section • Added DC insulation test at the inverter bus bar, clarified details of AC conductor insulation test 1.03 05-12-2017 • Added section to "Wiring" to describe VDE 4105 relay installation where applicable • Defined in "Site Construction" that the site requires a lockable AC breaker upstream of each inverter • Expanded CT Installation instructions • Updated clearances above units • Removed appendix of vocabulary terms as not relevant to installers, and simplified product overview • Added shutdown procedure details 1.04 07-28-2017 • Added cautions to not use paint, solvents, or non- Tesla-approved parts • Fixed image error showing DC bus bars • Added comparison of system variants for 1.5 and 2 in "Product Configurations" 1.05 10-30-2017 • Added AC conductor specs in case of only using 2 wires per phase • Updated inverter and 2-hr Powerpack weights to be more precise in "System Specifications" • Changed megger tests from pass/fail to recording results on the Construction Checklist • Removed need for special top cap for inverter interface covers; inverter covers are now longer. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 66 of 68 Revision # Date Description • Added details about inverter bus bar fasteners and dimensions. • Updated nameplate rating from 62.5 kVA per Powerstage to current rating of 65 kVA each. • Added details to Controller and jumpstart wiring on the inverter interface board. • Specified that CAT5e or CAT6 must be shielded. • Updated top clearances in "Clearances". • Added reminder in "Anchoring the Enclosures" to remove anchor templates before landing the enclosures on the pad. 2.0 03-06-2018 • Updated back to back spacing figures in "Clearances". • Added caution not to use the DC harness screws to seat the connectors on the Unit. • Updated enclosure shipped weights. • Fixed typos in DC ground lug torques. • Moved details about wiring choice and site design to the Site Design Manual. • Added information about the Controller throughout. • Added minimum electrical clearances between AC bus bars. 2.1 08-09-2018 • Added mounting hole dimensions for Controller • Added bolt PNs and a note about bolt re -use for the inverter interfaces in "Wireway Installation" • Added wire routing guidance in "Powerpack Inverter Wiring: AC Conductors" • Changed DC cable megger test from 500 V to 1000 V in `Powerpack Inverter Wiring: Customer Connection Side" • Clarified that only the new Controller and Ethernet (not RS485), are now supported • Removed snow -specific site spacing • Added site access information to "Site Installation" • Added corrosion prevention steps to "Anchoring the Enclosures" • Renamed Controller to Tesla Site Controller for clarity • Added sealing and vacuuming steps to "Powerpack Inverter Wiring: AC Conductors" 2.2 10-08-2018 • Modified all mentions of "Site Controller" and "Controller" to "Tesla Site Controller" Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 67 of 68 CITY OF NEWPORT BEACH COMMUNITY DEVELOPMENT DEPARTMENT BUILDING DIVISION 100 Civic Center Drive I P.O. Box 1768 I Newport Beach, CA 92658-8915 www.newportbeachca.gov I (949) 644-3200 OVER—THE—COUNTER PLAN REVIEW COMMENT SHEET Project Description: TESLA BATTERY STORAGE Project Address: 1 HOAG Plan Check No.: 1720-2019 Permit App. Date: 7/31/2019 Valuation: Plan Reviewer: Soon Cho Phone: 949-644-3281 The project plans were reviewed for compliance with the following codes and standards: 2016 CBC; 2016 CRC; 2016 CPC; 2016 CEC; 2016 CMC; 2016 California Energy Code; 2016 California Green Building Standards Code (CALGreen); and Chapter 15 of the Newport Beach Municipal Code (NBMC). 1. Obtain plan review approval from the following: a. Building Division b. EMP c. FIRE 2. PROVIDE FOUNDATION PLAN STAMPED AND SIGNED BY LICENSED ENGINEER OR ARCHITECT. 3. PROVIDE ENGINEERING DESIGN FOR NEW SLAB AND ANCHORAGE FOR NEW BATTERY STORAGE SYSTEM. 4. PROVIDE ENLARGED FLOOR PLAN OF THE AREA. SHOW EXISTING DOORS a. CALCULATE OCCUPANT LOADS AND SPECIFY TYPE OF OCCUPANCY OF THE ROOM. b. DOOR SHALL SWING OUTWARD. 1010.1.10. 5. PROVIDE PANIC HARDWARE IN THE EXIT DOOR. CBC 1010.1.10. 6. Return the checked set of plans at the time of recheck. Additional comments may following pending further review. CORE STATES M.211111111CM GROUP July 31, 2019 Building Plan Check -Permit no. 1720-2019 RE: Hoag Hospital Tesla Battery 1 Hoag Dr. Newport Beach, CA 92663 Per Building comments dated 7/31/19 (attached), please see below responses and revised drawings incorporating said changes. BUILDING COMMENTS (Soon Cho): 1. Obtain plan review approval from the following: a) Building Division b) EMP c) Fire Response: Responses have been included with this submittal, all parties above will review/approve the plan set. 2. Provide Foundation Plan Stamped and signed by licensed engineer or Architect. Response: Foundation plan S-1 has been added and included with this submittal. 3. Provide Engineering Design for new slab and anchorage for new battery storage system. Response: New slab and anchorage has been designed, refer to sheet S-1 for related information. 4. Provide enlarged floor plan of the area. Show existing doors. a) Calculate occupant loads and specify type of occupancy of the room. b) Door shall swing outward. 1010.1.10. Response: a) No occupant loads to be calculated; this is an outdoor equipment area. b) No door present. There is an existing sliding gate for entrance/exit/maintenance. This area is secured for qualified personnel only. 5. Provide panic hardware in the exit door. CBC 1010.1.10. www.core-eng.com georgic . new jersey . massachusetts . texas. missouri . florida . north carolina washington arkansas . california pennsylvania CORE STATES GROUP Response: Not applicable to existing area. This is not a building, but a fenced in equipment area. 6. Return the checked set of plans at the time of recheck. Additional comments may following pending further review. Response: Noted. Feel free to contact me directly with any questions or concerns. Respectfully, Cheree Naes Project Coordinator Core States Group 4240 E. Jurupa St. Ste.402 Ontario, CA 91761 909-471-1895 www.core-eng.com georgic . new jersey massachuselts . texas. missouri . florida . north carolina . washington . arkansas . california . pennsylvania 0 1.64 LIFO t' Ew Po CITY OF NEWPORT BEACH \ � COMMUNITY DEVELOPMENT DEPARTMENT BUILDING DIVISION 100 Civic Center Drive I P.O. Box 1768 I Newport Beach, CA 92658-8915 www.newportbeachca.gov I (949) 644-3200 OVER-THE-COUNTER PLAN REVIEW COMMENT SHEET Project Description: TESLA BATTERY STORAGE Project Address: 1 HOAG Plan Check No.: 1720-2019 Permit App. Date: 7/31/2019 10/7/19 10/17/19 Valuation: Plan Reviewer: Soon Cho Phone: 949-644-3281 The project plans were reviewed for compliance with the following codes and standards: 2016 CBC; 2016 CRC; 2016 CPC; 2016 CEC; 2016 CMC; 2016 California Energy Code; 2016 California Green Building Standards Code (CALGreen); and Chapter 15 of the Newport Beach Municipal Code (NBMC). 1. Obtain plan review approval from the following: a. Building Division b. EMP c. FIRE 2. PROVIDE FOUNDATION PLAN STAMPED AND SIGNED BY LICENSED ENGINEER OR ARCHITECT. 3. PROVIDE ENGINEERING DESIGN FOR NEW SLAB AND ANCHORAGE FOR NEW BATTERY STORAGE SYSTEM. 4. PROVIDE ENLARGED FLOOR PLAN OF THE AREA. SHOW EXISTING DOORS a. CALCULATE OCCUPANT LOADS AND SPECIFY TYPE OF OCCUPANCY OF THE ROOM. b. DOOR SHALL SWING OUTWARD. 1010.1.10. c. IF HAZARDOUS ANALYSIS IS DETERMINED TO BE H-2 OCCUPANCY, THEN SHOW THE DOOR MEETS ABOVE ITEMS. d. FOR H-2 OCCUPANCY, SPECIFY THE DISTANCE FROM THE BUILDING TO STORAGE BATTERY NOT LESS THAN 30' TO COMPLY WITH TABLE 705.8. 5. PROVIDE PANIC HARDWARE IN THE EXIT DOOR. CBC 1010.1.10. a. IF HAZARDOUS ANALYSIS IS DETERMINED TO BE H-2 OCCUAPNCY 6. Return the checked set of plans at the time of recheck. Additional comments may following pending further review. 7. 10/17/2019: WAITING FOR TODD LETTERMAN TO REVIEW THE HAZARDOUS MATERIAL ANALYSIS FOR H-2 OCCUPANCY. CORE STATES .rulunim mrainumio GROUP October 21, 2019 Building Plan Check -Permit no. 1720-2019 RE: Hoag Hospital Tesla Battery 1 Hoag Dr. Newport Beach, CA 92663 Per Building comments dated 10/17/19 (attached),please see below responses and revised drawings incorporating said changes. BUILDING COMMENTS (Soon Cho): 1. Obtain plan review approval from the following: a) Building Division b) EMP c) Fire Response: Electrical Approved, Mechanical and Plumbing not required. Building comments responded to below. 4. Provide enlarged floor plan of the area. Show existing doors. a) Calculate occupant loads and specify type of occupancy of the room. b) Door shall swing outward. 1010.1.10. c) If Hazardous Analysis is determined to be H-2 Occupancy, then show the door meets above items. d) For H-2 Occupancy, specify the distance from the building to storage battery not less than 30' to comply with Table 705.8. Response: a) This is not a room, but a Methane Treatment area outside of the hospital interior, in the parking lot. There are no walls or doors, just a sliding fence gate. Only Qualified Maintenance personnel are allowed in this area. See attached photos for clarity. b) The sliding gate is only opened for maintenance, by qualified personnel, and is left open during the maintenance process. 1010.1.10 does not apply here as this is not a specific type of occupancy, but a gated area for the Methane Treatment area. c) H-2 Occupancy does not apply. www.core-eng.com georgia . new jersey . massachusetts . texas. missouri . florida . north carolina . washington . arkansas . california . pennsylvania CORE STATES 211111110,■ GROUP d) H-2 Occupancy does not apply. 5. Provide panic hardware in the exit door. CBC 1010.1.10. a) If Hazardous analysis is determined to be H-2 Occupancy Response: a) H-2 Occupancy does not apply. 6. Return the checked set of plans at the time of recheck. Additional comments may following pending further review. Response: Will Comply. 7. 10/17/2019: Waiting for Todd Letterman to review the hazardous material analysis for H-2 occupancy. Response: Noted. Feel free to contact me directly with any questions or concerns. Respectfully, Cheree Naes Project Coordinator Core States Group 4240 E. Jurupa St. Ste.402 Ontario, CA 91761 909-471-1895 www.core-eng.com georgia . new jersey . massachusetts . texas. missouri . florida . north Carolina . washington . arkansas . california . pennsylvania 1 t 1 r CITY OF NEWPORT BEACH FIRE DEPARTMENT Life Safety Services 100 Civic Center Drive I P.O. Box 1769 I Newport Beach, CA 92658-8915 www.newportbeachca.gov 949- 644-3200 PLAN REVIEW CORRECTIONS Plan Check No. 1720-2019 Project Description Energy Storage System Project Address 1 Hoag Drive Reviewed By Todd Letterman CFPS, CET, Fire Plans Examiner FNS Prevention Group tletterman@nbfd.net (951) 691-7993 Date Comments Issued 8/12/19/10/8/19 Provide written responses to all corrections. Clearly indicate any necessary changes by using Bubble and delta on plans. Per CFC Section 1.1.3.2 State regulated buildings, structures and applications. This is acute care hospitals, asate-psychiatric hospitals, skilled nursing and/or intermediate treatment centers regulated by the Office of Statewide Health Planning and Development. See Section 1.10 for additional scope provisions. 1.10.1 OSHPD 1. unless otherwise stated. 1. Provide construction documents in accordance with California Fire Code (CFC) Section 608.1.2. • 2. Provide a hazard analysis per CFC Section 608.1.3, 608.1.3.1 and 608.1 3.2 3. Indicate ratings of all separations. 4. Indicate maximum allowable quantities per CFC Section 608.3 5. Indicate the battery storage system comply with UIL 1973 and UL 9540 per CFC Section 608.4.1 6. Indicate a type of Energy management system per CFC Section 608.4.3 7. Indicate battery chargers per CFC 608.4.4 8. Indicate the listings for the inverters per CFC Section 608.4.5 9. Indicate compliance with Thermal runaway per CFC Section 608.4.7 10. Indicate that the room has adequate fire suppression system installed per CFC Section 608.5.1 11. Is smoke detection provided within the room per CFC Section 608.5.2? 12. Indicate if there is a gas detection system per CFC Section 608.5.4 13. Indicate per CFC 608.2.3 stationary battery arrays. Storage batteries, per -packaged stationary storage battery systems and pre-engineered stationary storage battery systems shall be segregated into stationary battery arrays not exceeding 50 kWh each. Each stationary battery array shall be spaced a minimum 3 feet from other stationary battery arrays and from walls in the storage room or area. The storage arrangements shall comply with Chapter 10. 14. Provide information on how class and division and location was determined. California Electrical Code (CEC) Section 500.4 15. Get approval from MEP City of Newport Beach 16. Detail and specify listed fittings, locations, and procedure for installation, at hazardous locations. CEC 500 and 501. Detail and bubble locations on riser diagrams, this include all voltages. 17. Indicate distances to property lines and buildings. CORE STATES ummins Aiinenasta GROUP August 28, 2019 Building Plan Check -Permit no. 1720-2019 RE: Hoag Hospital Tesla Battery 1 Hoag Dr. Newport Beach, CA 92663 Per Fire comments dated 8/12/19 (attached), please see below responses and revised drawings incorporating said changes. FIRE COMMENTS (Todd Letterman): 1. Per CFC Section 1.1.3.2 State regulated buildings, structures and applications. This is an OSHPOD facility and needs to be reviewed by the governing authority. General acute care hospitals, acute psychiatric hospitals, skilled nursing and/or intermediate care facilities, clinics licensed by the Department of Public Health and correctional treatment centers regulated by the Office of Statewide Health Planning and Development. See Section 1.10 for additional scope provisions. 1.10.1 OSHPD. 1. Specific scope of application of the agency responsible for enforcement, enforcement agency and the specific authority to adopt and enforce such provisions of this code, unless otherwise stated. Response: The scope of work on this project is in an outdoor equipment area and not in OSHPD jurisdiction. No OSHPD submittal is required for this project. Feel free to contact me directly with any questions or concerns. Respectfully, Cheree Naes Project Coordinator Core States Group 4240 E. Jurupa St. Ste.402 Ontario, CA 91761 909-471-1895 www.core-eng.com georgic . new jersey . massachusetts texas. missouri . florida . north carolina washington arkansas california pennsylvania k litortoi TSLri Aug. 9, 2018 POWERPACK 2 SYSTEM INSTALLATION MANUAL CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Rev. 2.1 Warning: Read this entire document before installing or using the Powerpack System. Failure to do so or to follow any of the instructions or warnings in this document can result in electrical shock, serious injury, or death, or can damage Powerpack, potentially rendering it inoperable. PRODUCT SPECIFICATIONS All specifications and descriptions contained in this document are verified to be accurate at the time of printing. However, because continuous improvement is a goal at Tesla, we reserve the right to make product modifications at any time. The images provided in this document are for demonstration purposes only. Depending on product version and market region, details may appear slightly different. ERRORS OR OMISSIONS To communicate any inaccuracies or omissions in this manual, please send an email to: energymanualfeedback@tesla.com. ELECTRONIC DEVICE: DO NOT THROW AWAY MN Proper disposal of batteries is required. Refer to your local codes for disposal requirements. MADE IN THE USA ©2018 TESLA, INC. All rights reserved. All information in this document is subject to copyright and other intellectual property rights of Tesla, Inc. and its licensors. This material may not be modified, reproduced or copied, in whole or in part, without the prior written permission of Tesla, Inc. and its licensors. Additional information is available upon request. The following are trademarks or registered trademarks of Tesla, Inc. in the United States and other countries: TESLA All other trademarks contained in this document are the property of their respective owners and their use herein does not imply sponsorship or endorsement of their products or services. The unauthorized use of any trademark displayed in this document or on the product is strictly prohibited. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY } TABLE OF CONTENTS 1. Installer Information 6 Tesla-Specific Tools 6 Support 7 2. Powerpack System Introduction 8 Powerpack Unit 8 Powerpack Inverter 10 Customer Connection Section 10 Safety Features 12 Tesla Site Controller 13 Energy Meters 14 3. System Description 14 System Specifications 15 Product Configurations 16 4. Transportation 16 Shipping Guidance 16 Emergency Response Guide 17 Loading and Unloading 17 Staging 18 5. Site Infrastructure 18 Conduit 18 Foundation Inspection 20 6. Site Installation 21 Site Access 21 Fencing 21 Clearances 21 Enclosure Installation 23 Positioning the Enclosures 23 Anchoring the Enclosures 24 7. Wiring 27 Wreway Installation 27 Powerpack Unit Wiring 32 Powerpack Unit DC Harness Installation 32 Communication Harness and Ground Wire Installation 33 Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 1 of 68 Powerpack Inverter Wiring: Customer Connection Side 35 Disconnecting Means 35 DC Harness Installation 36 Powerpack Unit Communication Harness Installation and Testing 38 Powerpack Unit Grounding 40 Tesla Site Controller Communication Wiring 42 Powerpack Inverter Wiring: AC Conductors 42 Wreway Cover Installation 47 8. Tesla Site Controller 48 Installing the Tesla Site Controller 49 Configuring the Transformer for 440, 450, or 480 VAC 53 Configuring the Transformer for 208, 240, or 400 VAC 54 Configuring the Transformer for 120 VAC 56 Connecting a Demand Response Controller 58 Connecting a VDE 4105 Protection Relay 58 9. Energy Meters 59 Connection Requirements 60 Connecting Meters to the Tesla Site Controller 60 CT Installation in the AC Panel or Switchboard 61 Meter Configuration 64 10. Commissioning 64 Shutdown 64 Locating Enclosure Serial Numbers 65 Tesla Commissioning Responsibility 66 Revision Log 67 Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 2 of 68 IMPORTANT SAFETY INSTRUCTIONS: SAVE THESE INSTRUCTIONS This manual contains important information and safety instructions for the Tesla Powerpack 2 System and Powerpack 1.5 System that must be followed during installation and maintenance of the system. Symbols This manual and product use the following symbols to highlight important information: A DANGER: indicates a hazardous situation which, if not avoided, could result in severe injury or death. A WARNING: indicates a hazardous situation which, if not avoided, could result in injury. CAUTION: indicates a hazardous situation which, if not avoided, could result in minor injury or damage to the equipment. NOTE: indicates an important step or tip that leads to best results, but is not safety or damage related. Grounding (protective earth) terminal. Directs the user to refer to the instructions. — — — Direct current. 3N- - Three-phase alternating current with neutral conductor. ". - Caution, risk of electric shock. Energy storage timed discharge (time is indicated next to the symbol). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 3 of 68 Product Warnings A DANGER: Risk of electrical shock. The DC bus can be energized from either the battery side or the inverter side. Multiple energy sources terminate inside this equipment. While you should always disconnect all external power sources before servicing, opening the DC disconnect does not ensure that the DC bus is de -energized. Always check with a properly rated voltmeter that there is no voltage on the DC bus before touching. A DANGER: Lock out externally supplied AC power at the source before servicing the inverter or opening the door. A DANGER: Hazardous voltage can cause severe injury or death. A WARNING: Personal Protective Equipment (PPE) is required when working inside the Powerpack Inverter enclosures. Service personnel must wear safety glasses and gloves with a minimum voltage rating of 1500 VDC, Class 0 per ASTM D120 and IEC EN60903 standards. A WARNING: The unit has no user serviceable parts. All service must be performed by Tesla Energy Certified Installers or Tesla employees. Only trained service personnel are allowed access. A DANGER: During installation, all equipment must be de -energized. A WARNING: All electrical installations must be done in accordance with local and National Electric Code (NEC) ANSI/NFPA 70 or the Canadian Electrical Code CSA C22.1. A WARNING: All installations must conform to the laws, regulations, codes, and standards applicable in the jurisdiction of installation. A WARNING: These installation instructions are for use by qualified personnel only. To reduce the risk of electric shock, do not perform any servicing other than that specified in the operating instructions unless you are qualified to do so. A DANGER: Electric shock could occur when touching live components. A WARNING: To reduce the risk of injury, read all instructions. A WARNING: Only use this equipment as specified by Tesla. If the equipment is used in a manner that is not specified by Tesla, the protection provided by the equipment might be impaired. A DANGER: Shutting off power to the Tesla Powerpack System does not de -energize the battery, and thus a shock hazard may still be present. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 4 of 68 A WARNING: Batteries are not user -serviceable. Only Tesla-approved personnel must remove, replace, or dispose of batteries. A WARNING: For continued protection against risk of fire, use only replacement fuses of the same type and rating as the original fuse. Fuses must only be replaced by trained personnel. A DANGER: A Powerpack Unit, even in a normally discharged condition, is likely to contain substantial electrical charge and can cause injury or death if mishandled. A DANGER: The battery used in this device may present a risk of fire or chemical burn if mistreated. Do not disassemble, operate above 50°C (122°F), or incinerate. CAUTION: Inverter input and output circuits are isolated from the enclosure. System grounding, when required by the National Electric Code, ANSI/NFPA 70, is the responsibility of the installer. asa� CAUTION: Do not paint any y part of the Powerpack System, including any internal or external components such as exterior cabinets or grilles. +44 CAUTION: Do not use cleaning solvents to clean the Powerpack System, or expose the system to flammable or harsh chemicals or vapors. CAUTION: Do not use fluids, parts, or accessories other than those specified in Tesla manuals, including use of non -genuine Tesla parts or accessories, or parts or accessories not purchased directly from Tesla or a Tesla-approved party. Refer to the Tesla Emergency Response Guide, TS-0004027, for detailed hazard information specific to the lithium -ion battery. The Guide also provides the hazard information for a single Tesla Powerpack Unit. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 5 of 68 1. Installer Information This document provides an installation contractor the necessary details to install a Tesla Powerpack System. The installation contractor is responsible for completing the mechanical and electrical installation of the Tesla Powerpack System. Tesla provides a Construction Completion Checklist that lists the criteria that must be inspected and completed onsite for Tesla to consider the site completed and ready for commissioning. The list includes items such as: • Physical installation such as proper anchoring, door swing, access, etc. of all equipment • Pad grading, drainage, and access • Electrical termination checks for polarity and torque for all equipment • Harness termination checks • Ethernet cable checks with VDV Scout Pro or Pro LT (VDV501-053 or 068) or equal • Insulation resistance "megger" testing for all wires • Inverter phase checking with a Greenlee 5702 Phase Sequence Indicator or equal • Meter wiring and CT polarity check • Recording site information (serial numbers, unit and meter locations, inspection date, etc.) and emailing a scanned copy to Tesla • Inverter and Tesla Site Controller start-up Ensure personal safety at all times per local and national regulations. The installation contractor is responsible for providing their own Personal Protective Equipment (PPE), including such items as safety glasses, hard hats, appropriate boots, and appropriate gloves (cut and electrical). Tesla-Specific Tools The custom torque tool, Powerpack Unit anchor template, and inverter anchor template are provided to installers during their first project. Additional or replacement tools are also available for purchase. Have the following tools ready before beginning work: Custom anchor torque tool (Tesla PN 1068396): A programmable mechanical pulse wrench attached to an aluminum extrusion to extend the reach to approximately 5'. The battery powered tool is supplied with two 14.4V batteries and one 120V US charger, and includes a 24mm Nut Grip socket to firmly hold non-magnetic nuts. The tool is pre-programmed for a maximum torque of 70 ft-lbs. Actual measured final torque is dependent on anchor and pad conditions. Figure 1: Anchor Torque Tool Kit Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 6 of 68 NOTE: The anchor tool comes standard with a US rated charger. Non -US sites may require a conversion adapter to power the anchor tool. Use of the tool is described in the "Error! Reference source not found." section below. Powerpack Unit anchor template (Tesla PN 1068864): The template indicates the mounting points of a single Powerpack Unit for easier anchor hole drilling. (Two templates are shown in Figure 2 in a back-to-back layout.) Inverter anchor template (Tesla PN 1106829): The template indicates the mounting points of a single inverter for easier anchor hole drilling. The word "FRONT" is etched on the flat edge of the template to show the door side of the inverter. The template includes a cut-out for AC window stub -up positioning (circled). Figure 2: Inverter Template (1) to Powerpack Unit Templates (2) Support NOTE: Get the most recent version of the Construction Completion Checklist before beginning work. The installer is responsible for obtaining the latest version of this manual and the Checklist to complete all site work. All partner documents are on the Partner Portal website at: https://partners.teslamotors.com For Powerpack System support, or to provide product feedback: • Email PowerpackSupport@tesla.com (responses can take 24-48 hours) Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 7 of 68 • Call Tesla Service at 650-681-6060 for urgent or time -sensitive requests 2. Powerpack System Introduction The Powerpack 2 System is a modular, fully integrated, AC -coupled industrial Energy Storage System (ESS). NOTE: Any deviation from what is specified in this installation manual must be submitted to Tesla in writing in advance for approval. A Powerpack System consists of three types of enclosure: • Rechargeable lithium -ion battery pack cabinets (Powerpack Unit) • Bi-directional power conversion system (Powerpack Inverter) • Tesla Site Controller (vertically mounted enclosure that controls system commands) The bi-directional inverter converts power for rechargeable lithium -ion battery packs (Tesla Powerpack Units). Powerpack Inverters have a nominal rating power between 65 and 650 kVA, depending on the installed number of modular Powerstages and the site's grid voltage. One Powerpack Inverter, and 1-20 Powerpack Units assigned to that inverter, make up an inverter block. 1 • 2 Figure 3: Example Inverter Block: Powerpack Inverter (1) and Powerpack Units (2) NOTE: It is also possible to configure a Powerpack System using Powerpack 1.5 Units and a Powerpack Inverter. This is called a Powerpack 1.5 System. This manual, and the Powerpack 2 System Site Design Manual, note where 1.5 is different from 2. For a comparison of energy and power ratings, see the section "Product Configurations". Powerpack Unit Cylindrical lithium -ion battery cells, the smallest non -divisible component of the Powerpack System, are assembled into a Pod (Figure 4), which is the smallest field replaceable unit. The Powerpack Unit is a standalone NEMA 3R enclosure containing 16 Pods connected in parallel with a single DC and communications output connection. Pods are pre -wired within the Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 8 of 68 Powerpack Unit and do not require any field assembly or adjustments. Pods must only be replaced by Tesla service personnel. 1 2 Figure 4: Powerpack Unit, Thermal Door (1) and Pod (2) The thermal management system is housed on the inner face of the Powerpack Unit door. The door includes a radiator and pump system that circulates about 26 L of a 50/50 ethylene glycol / water coolant mix through the battery to maintain thermal control. The thermal subsystem also includes 400 g of R134a (1,1,1,2-Tetrafluoroethane) refrigerant in a sealed system. All Powerpack Units ship with the necessary coolants and refrigerants included. The thermal door subsystem is a fully closed loop system. The Powerpack Unit door includes two latches that require a special tool to unlock, limiting access to authorized personnel only (Figure 5). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 9 of 68 Figure 5: Powerpack Unit Security Latches NOTE: The Powerpack Unit includes an Enable circuit as a safety feature. Opening the door of any Powerpack Unit shuts down all Powerpack Units within an inverter block. Powerpack Inverter Each inverter block contains a Powerpack Inverter. It contains four main sections: Low Voltage, Powerstages, Thermal Management, and Customer Connection. • Low Voltage Section: The upper left part of the main inverter enclosure houses internal low voltage components. • Powerstage Section: The right side of the inverter enclosure contains up to ten rack - mounted Powerstages that can be scaled for the needs of the site. Powerstages are pre - installed in the inverter before shipment. • Thermal Management Section: The top cabinet of the inverter enclosure houses the thermal management system, a fully closed -loop system with fans and a radiator that contains a 50/50 ethylene glycol/water coolant mix. NOTE: Installation only involves the Customer Connection Section. Customer Connection Section The lower left side of the Powerpack Inverter enclosure (Figure 6, Figure 7) is the Customer Connection section. It contains: • The interface board, a circuit board serving as a communications gateway between the Powerpack Inverter and Powerpack Units, with CAN communication harness terminations for the Powerpack Units and Ethernet terminations for the CAT5e/CAT6 cable to the Tesla Site Controller • DC bus bars with fuses protecting each Powerpack Unit DC wire harness Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 10 of 68 • The AC bus bar for connecting the inverter to the site AC distribution panel Figure 6: Powerpack Inverter Overview 1. Low voltage boards 5. Thermal management 2. AC bus bars 6. Powerstages 3. DC bus bars and fuses 7. Interface board 4. Customer connection area Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 11 of 68 1 Figure 7: Customer Connection Area Details 1. AC bus bars 3. DC bus bars and fuses 2. Strain relief 4. Ground/earth A WARNING: The thermal management section is locked during operation. Do not open this cabinet while fans are in use, to avoid hazard from moving parts. Safety Features The inverter door has a DC disconnect switch that is accessible from the front of the unit and can be locked in the open position (Figure 8). The DC disconnect switch ties into the Enable safety circuit that also runs through all Powerpack Units. The DC disconnect switch must be open and unlocked in order to open the inverter door. Within the inverter, the AC and DC bus bars are covered by a clear plexiglass shield that must be removed for access. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 12 of 68 Figure 8: Powerpack Inverter DC Disconnect Switch Tesla Site Controller The Powerpack Inverter communicates with the overall system through the Tesla Site Controller, which controls the entire energy storage site. The Tesla Site Controller hosts the control algorithm that dictates the charge and discharge functions of the Powerpack Units. It is also the single point of interaction with external parties. One Tesla Site Controller is required per point of interconnection, and is provided pre -assembled in a NEMA 3R enclosure (Figure 9). Figure 9: Example Tesla Site Controller Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 13 of 68 The Tesla Site Controller communicates to each inverter block over a private TCP network. Each inverter communicates with the Tesla Site Controller and commands the Powerpack Units. For larger sites, multiple inverter blocks are connected via Ethernet to a network switch. Energy Meters Energy meters are not provided by Tesla. A meter is typically used in one of two roles: battery meter (measures the Powerpack System throughput) or site meter (measures the entire site). An additional "generator meter" might also be required for sites involving onsite generation (PV, wind, etc.). For a list of currently supported meters, refer to Tesla's Powerpack 2 System Site Design Manual. Meter wiring and configuration is described in a later section. 3. System Description The Powerpack 2 System consists of the following components and their Tesla part numbers: • Powerpack Unit 2, 4-hour: 1083931 • Powerpack Unit 2, 2-hour, 1.6-hour, or 1.2-hour: 1083932 • Powerpack Unit 1.5: 1089288 • Powerpack Inverter, 480 VAC: 1095371 O 1095371-1 Y*: 65 kVA O 1095371-2Y: 130 kVA O 1095371-3Y: 195 kVA O 1095371-4Y: 260 kVA O 1095371-5Y: 325 kVA O 1095371-6Y: 390 kVA O 1095371-7Y: 455 kVA O 1095371-8Y: 520 kVA O 1095371-9Y: 585 kVA O 1095371-0Y: 650 kVA *Where in the "-XY extension, X denotes the number of Powerstages and Y denotes fuse configuration. Rated output for 10 Powerstages produced before Aug 2017 was 500 kVA @400 VAC / 625 kVA @480 VAC. • Tesla Site Controller: 1137202 • HVDC cable harnesses: 1096272 • Communication cable harnesses: o Powerpack Unit to Powerpack Unit: 1068390 o Powerpack Unit to Powerpack Inverter: 1068391 o Pack Termination Harness: 1071858 • Wireway components: o Wireway: 1072786 o Top cap: 1072787 o Corner: 1072855 o Corner cap: 1072801 o Inverter interfaces and covers: 1072854, 1107828, 1107830 Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 14 of 68 Powerpack Unit, 4-hr Powerpack Unit, 2-hr Powerpack Inverter o Kickplate: 1072788 o End cap: 1072853 • Powerpack Unit seismic washer: 1057229 • Inverter Accessory Kit (Ships inside the inverter AC panel cover. Specific parts and quantities might vary by site): o Cable gland, split black M50: 1105381 o M12 x 1.75 x 70 bolt: 1115561 o Flat M12 washers: 1031489 o Conical spring M12 washers: 1107664 o M12 x 1.75 nut: 2007063 o M8 1.25 hex nut with washer: 1004400 o Cable ties: 1104977 o Interface board jumpers: 1071276 • Tesla Site Controller Accessory Kit (if applicable): o Two transformer taps o Two terminal covers for transformer (P/N: 1139091-00-A) o Brackets from the enclosure o Screws from the enclosure o Two 1.5 A fuses (P/N: 1453351-00-A) o Computer antenna o Ethernet cable for computer (P/N: 1454046-00-A) o Power wires for RTAC (P/N: 1452792-00-A) o Ethernet cable for RTAC (P/N: 1453388-00-A) Substitution of components is not permitted. ® WARNING: Mechanical damage to a Powerpack Unit can result in a number of hazardous conditions, including coolant leaks, refrigerant leaks, or fire. To prevent mechanical damage, store a Powerpack Unit in its original packaging when not in use or prior to being installed. For shipping and storage guidelines, refer to the Powerpack 2 System Transportation and Storage Guidelines. For guidance on how to respond if these hazards occur, refer to Tesla's Lithium-lon Battery Emergency Response Guide for details. 4,4 CAUTION: Do not open the battery Pod. The unit has no user serviceable parts inside. System Specifications E uipment i Length Width 1308 mm 822 mm (51.5") S32.4" )1 1308 mm 822 mm (51.5") (32.4" )l 1014 mm 1 1254 mm (39.9") (49.4" )1 Tesla Site Controller 255 mm j 560 mm (10") (22") Max. Shipped Heightr Wei ht i Mount 2235 mm 2175 kg 1 Pad (88" )1 (4795 lbs) ', 2235 mm 2075 kg Pad (88' (4575 Ibs) 2242 mm 1120 kg (2470 Pad (88.3" )1 lbs)2 742 mm 21.4 kg (47.2 Rack, (29.2") lbs) j Wall Aug. 9, 2018. CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 15 of 68 Dimensions include the 2" lifting flanges in product height. They do not include bottom anchor tabs, which interleave in installation and are not indicative of overall spacing.. For pallet width and depth dimensions, refer to the "Transportation and Storage Guidelines" document. 2 Maximum weight (weight changes depending on number of installed Powerstages, which are 55 kg/122 lb each) Product Configurations All Powerpack 1.5 and Powerpack 2 Systems use the Tesla Powerpack Inverter. However, they vary in power and energy ratings. Tesla configures two main variables for each Powerpack Inverter, according to system need: • 1 to 10 Powerstages • Four DC fuse variants: 5, 10, 15, or 20 pre -installed DC fuses (per phase), depending on the number of paired Powerpack Units per inverter NOTE: Inverter configurations are at Tesla's discretion. The inverter may be de -rated by changing software parameters to meet specific site restrictions and requirements. 4. Transportation Shipping Guidance The Powerpack 2 System Transportation and Storage Guidelines are available for guidance on shipping and transportation. The document provides packaged dimensions and weights, allowed storage conditions, and shipping guidance for land, sea, and air. Approximately nine (9) Powerpack Units can fit on a 45' long flatbed. Tesla recommends that Powerpack Units be covered by a tarp when being transported on a flatbed truck. NOTE: Powerpack System coolant is not a regulated substance according to the US Department of Transportation (USDOT). Refer to the specific MSDS for battery coolant. NOTE: Powerpack System refrigerant is a regulated substance according to the USDOT. Refer to the specific MSDS for R134a. CAUTION: Powerpack Units and the Powerpack Inverter must be transported and handled upright. CAUTION: Powerpack Units ship with a 25% State of Charge (SoC). If units are expected to sit for longer than 12 months between the date of manufacture and installation, the site manager must contact Tesla at Powerpacksupporta(�tesla.com to arrange for manual re- charging of any units that are approaching minimum SoC. Failure to recharge within 12 months can damage the hardware and would void the warranty, as described in the Limited Warranty. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 16 of 68 Emergency Response Guide A Tesla Lithium-lon Battery Emergency Response Guide is included with Powerpack Systems for shipping and transportation. The Guide provides an overview of the product materials, handling and use precautions, hazards, emergency response procedures, installation instructions, and storage and transportation instructions. The document serves as a comprehensive guide and replaces the traditional Safety Data Sheets (SDS) commonly associated with the health and safety of a chemical product. Tesla Powerpack products, as described in the Guide, meet the OSHA definition of "articles" and are therefore exempt from requiring a traditional MSDS (or the updated SDS format). Loading and Unloading The Powerpack Unit and Powerpack Inverter cabinets ship with protective covers and a temporary pallet for unloading with a forklift. C. CAUTION: Equipment must be strapped to the forklift while loading and unloading. Equipment can tip and fall if it is not secured. Load distribution must be adjusted to ensure the enclosure remains vertical during handling. The inverter pallet has 4-way handling access and 4x'/z-13" bolts securing the inverter to it. Pallet dimensions are 1118 x 1423 mm (44" x 56"). 025.4 mm 12.7 mm 025.4 mm 18 mm .�� 6mm 18 mm Figure 10: Lift Hole Dimensions, Inverter (Left) and Powerpack (Right) NOTE: The center of gravity for the Powerpack Inverter can shift depending on how many Powerstages it contains. A WARNING: When loading and unloading equipment, transporters must use suitable lifting equipment and lifting techniques for the weights specified in the Powerpack 2 System Transportation and Storage Guidelines. A WARNING: Prior to installation, inspect the unit to ensure the absence of transport or handling damage which could affect the integrity of the product. Failure to do so could result in Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 17 of 68 safety hazards. Unauthorized removal of necessary protection features, improper use, or incorrect installation or operation may lead to serious safety and shock hazards and/or equipment damage. CAUTION: Powerpack Units and inverters cannot be tilted or placed horizontally, even for a short time. Equipment cabinets contain coolant that could leak and sensitive equipment that could become damaged if not positioned upright. -=- -- CAUTION: Check all Tesla enclosures for deformation or damage and notify Tesla if any is found. Do not attempt to repair any damage. NOTE: Powerpack shipping covers are recyclable in any post-industrial plant, as recycle code #4. If a site has a large number of covers, contact your Tesla project engineer to arrange for return shipping. Staging Powerpack Units must be stored upright. Schedule Powerpack Unit delivery to minimize the storage time onsite. Batteries stored for longer than one month must be stored according to the following conditions: • Storage temperature between -20°C and 30°C • Humidity up to 95% non -condensing A WARNING: To reduce risk of fire: Do not store Powerpack Units for more than 24 hours at temperatures above 80°C (176°F). Do not expose Powerpack Units to temperatures above 150°C (302°F). Do not expose Powerpack Units to any localized heat sources or heating equipment. 5. Site Infrastructure Before the Powerpack System enclosures are anchored to the site, inspect the following work. Conduit All underground conduit must be provided and installed by the contractor. Underground conduit must be run between enclosures for power conductors and communication lines that are not enclosed in the wireways. Above -ground harness routing through wireways is covered in the section "Wireway Installation". An example underground conduit plan is shown in Figure 11. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 18 of 68 INVERTER CONTROLLER 16QY0' 400/480V S WITCH GEAR 3 4,5,6 Figure 11: Example Underground Conduit Plan 1 One communication conduit between inverter and Tesla Site Controller (CAT5e/CAT6) 2 One DC power conduit from inverter to Tesla Site Controller (only needed for microgrid) 3 Up to four AC power conduits from inverter to site AC switchgear 4 One conduit from Tesla Site Controller to battery meter (CAT5e/CAT6) 5 One conduit from Tesla Site Controller to site meter if applicable (CAT5e/CAT6) 6 One conduit from Tesla Site Controller to customer communication interface (CAT5e/CAT6) 7 One Tesla Site Controller AC power conduit from switchgear 400/480 VAC, 2-pole, 10 A circuit NOTE: Always consult local regulations and engineering plans of record for final sizing. Figure 12 shows dimensions to correctly align the Powerpack Inverter conduit entry window with the required underground conduit running to it. NOTE: All conduit stub -ups for the inverter must land inside the AC window. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 19 of 68 3' [0.07m} 8" [0.52m1 AC WINDOW 3" [0.07rni - 6" [0.16m] TOP VIEW Figure 12: Powerpack Inverter AC Conduit Window 4,14 CAUTION: Do not modify the outer enclosures of any Powerpack System component. Modification of any sort voids the warranty, as well as the certification and UL listing provided with the product. If underground AC conduit cannot be run to the inverter as shown, refer to the document "Powerpack Application Note: Non -Standard Installation Requirements" and contact Tesla to discuss alternatives. Tesla must approve the non-standard installation before work begins. Foundation Inspection Check the following pad (or skid) properties before beginning to anchor enclosures: • The top of the pad is above adjacent grade, 152mm (6 in) maximum, with the edge of the concrete a maximum of 305 mm (12 in) from the front of the Powerpack System. If the site does not allow this pad height, then the pad must extend a full 4 feet in front of all Powerpack Units and include a ramp to allow service cart access. • Six feet must be left clear in front of all Powerpack Units for unobstructed airflow. • The pad slopes a minimum of 1% and a maximum of 2% (0.6-1.15 degrees) to allow positive drainage from the pad/base or towards a drain. • The pad must be sloped in one plane. • Concrete finish has a smooth, even surface of uniform texture and appearance, free from bulges, depressions, and other imperfections that would impact equipment anchorage or foundation/base drainage. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 20 of 68 • Any walls installed around the pad are designed to prevent standing water (drain, weep holes, etc.) with sufficient clearance between the equipment and any walls or obstructions to allow for proper drainage. NOTE: If the completed pad has areas of unevenness that prevent proper clearances, door opening, etc., grout can be used to even the surface. Always have a structural engineer approve the modification before implementing. If any aspect of the foundation inspection does not pass, contact Tesla before proceeding. 6. Site Installation Site Access For Tesla personnel to perform later maintenance, Tesla must have the ability to remove any locks on Tesla equipment and access to the Tesla equipment. o For combination locks, the customer must provide the combination to PowerpackSupport@tesla.com and the Project Engineer to ensure maintenance access. Contact Tesla for a recommended combination when using the provided combination lock on all Tesla Inverters. o For keyed locks, a double hasp is required to allow Tesla access by unlocking Tesla's lock. Fencing A perimeter wall, screen, or fence may be used to enclose the installation to screen equipment from view, or to deter access by persons who are not qualified. When deterring access, fences no shorter than 2.1 m (7 ft) in height are suggested. The distance from any fence to the equipment shall match the clearance requirements in Table 1, or as noted per the exceptions below. Fencing shall be locked and posted with a placard stating "Authorized Users Only", or similar. If applicable, see 2018 IFC 1206.2.8.7.3. Exceptions: • If the installation is located within a property that already contains perimeter fencing to prevent unauthorized public access, additional fencing might not be required. • Permanent chain link fence without fill or slats can be installed as close as 1.5 m (5 ft) to the front of the equipment. • Removable chain link fencing (e.g. with a swing gate, or similar) without fill or slats may be installed as close as 15 cm (6 in) in front of the equipment. When removed, the fence and its support structure must allow unobstructed equipment maintenance access and clearance for equipment door swing. Clearances Ensure that all enclosures are installed according to the clearance requirements defined in Table 1. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 21 of 68 Table 1: Equipment Clearances E • ui • ment Front Sides ... ...._..... .... ... .__ _tee Powerpack 1830 mm 105 mm Unit (72") ' (4.1") Powerpack 1830 mm ' 105 mm" Inverter (72")' ; (4.1") Back 30 mm (1.25"),2 100 mm (4") Top 1524 mm (60") for combustible materials, 915 mm (36") for service clearance 915 mm (36") 'The clearance stated above is a minimum and should be increased to meet NEC 110.26 or local electrical building codes as necessary. 2 The back to back spacing of the Powerpack Units should be measured from the body of the enclosure. If the Powerpack Unit anchor template is not used, use a spacer to ensure that Powerpack Unit and Inverter enclosure walls are spaced at a minimum 90 mm (3.5") and maximum 150 mm (6") apart. NOTE: The vertical clearance for Powerpack System enclosures must extend the entire area of the service clearance. Some service equipment extends beyond the roof of the enclosure. NOTE: The required tolerance for the spacing between Powerpack Unit sides is +/- 6.4 mm (1/4"). NOTE: Using the Tesla-provided anchor templates during installation ensures that side and back enclosure spacing requirements are met. Sites must be laid out to allow full door swing for all Powerpack Units and inverters. The site layout must ensure that no wall or other structure interferes with any door opening fully. Trim landscaping to stay outside the clearance listed in Table 1. Maintain five feet of clearance above the unit that is clear of tree limbs and any other combustible obstructions, including but not limited to canopies and building overhangs. Combustible objects, such as wood fences, must also maintain a minimum 2' clearance from all sides of the Powerpack Unit. For any site that has signed a Capacity Maintenance Agreement (CMA), the site layout must provide adequate space to allow the addition of Powerpack Units for the duration of the contract. This includes room for an overhead lift to access the site, and clearance above the pad to place the additional Powerpack Units. Enclosure Installation NOTE: Modification of anchor tabs in any way is not permitted. Positioning the Enclosures 1. Place the inverter template (Tesla PN 1106829) on the pad with the AC window cut-out over the conduit stub -ups in the pad. 2. Mark and drill the inverter anchor holes according to the inverter template. 3. With the inverter template still in place, align the Powerpack Unit template (Tesla PN 1068864) to mark and drill Powerpack Unit anchor holes for rows C and D to the right of the inverter as viewed from the front (Figure 2, Figure 13). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 22 of 68 NOTE: The templates do not mate with an installed Powerpack Unit. Use two Powerpack Unit anchor templates to position back-to-back rows. Figure 13: Powerpack Unit Rows Relative to the Inverter 4. The inverter template does not mate directly with the Powerpack Unit template on its left side. Instead, align the inverter template holes (Figure 14, A) over the drilled inverter holes, then mark the inverter template slots (B). Remove the inverter template, then align the Powerpack Unit template holes (C) with the markings. Figure 14: Matching Powerpack Unit Template Holes to Inverter Holes 5. Complete marking and drilling the holes for Powerpack Unit rows A and B, to the left of the inverter. Anchoring the Enclosures Anchors are required for all enclosures. Stainless steel is required for outdoor installations. Note that anchors can differ by site and therefore are not provided by Tesla. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 23 of 68 NOTE: The rest of this procedure assumes use of Hilti KB-TZ 5/8" SS wedge anchors or similar. If the engineer of record recommends a different anchor, modify the procedure accordingly. 1. Cut the AC power and communication conduit stub -ups to a height no greater than 13 cm (5") above grade. This height ensures that the conduit does not stick up higher than the internal AC conduit window. 2. Open the Powerpack Inverter door and remove the AC floor panel at the front (Figure 15), to prevent damage when lifting the cabinet on top of the conduit stub -ups. Figure 15: AC Floor Panel 3. Remove the inverter accessory kit that is shipped inside the AC floor panel. Secure the door again before removing the cabinet from the pallet for anchoring. NOTE: Be sure to remove the metal templates from the pad before installing the enclosures. The templates are reusable tools for the installer. Mounting enclosures on top of the templates leaves an unacceptable gap underneath the unit. 4. For sites within 1 km of a shoreline or with a corrosion risk: Use a polyether based sealant such as Chem Link DuraLink 35 or similar. a. Before installation, apply additional sealant over the welds of the anchor bolt flanges at each corner of the Powerpack Unit and Powerpack Inverter enclosures. b. Lay two continuous beads within the edge of the base footprint of each enclosure after placing templates and drilling anchor holes, but before setting the enclosures on the pad. Set the tip of the applicator to lay each bead 6 mm (1/4") wide. Lay the first bead as close to the edge of the enclosure as possible, and the second about 26 mm (1") inside. 5. Use a lifting rig and crane, Gradall, or forklift that can lift equipment from the eyelets at the top of each enclosure. 6. Align the inverter enclosure over the pre -drilled anchor holes and anchor it in place. (Inverters do not require seismic washers, only Powerpack Units as described in the next step.) 7. Moving outward from each side of the inverter, set and anchor the Powerpack Units in each row (Al , then A2, etc.). Install a 0.375" thick seismic washer (provided by Tesla, PN 1057229) between each Powerpack Unit anchor tab and its anchor bolt head, one washer per anchor tab (Figure 16). Orient the washer so that it does not overhang the edges of the Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 24 of 68 Unit's anchor tab. Do NOT place the washer between the Powerpack Unit anchor tab and the ground. Figure 16: Seismic Washer 8. Install and torque the remaining anchors. For back-to-back configurations, use the custom anchor tool to torque the rear anchor bolts from the front of the enclosures: a. Draw lines on the socket as a visual indicator. b. Use the simple pulley/rope system to torque the rear interior bolts from the front of the Powerpack Units at the correct spacing. Fully engage the trigger and hold until completion. 9. Repeat until all Powerpack Units for that inverter block have been set. 10. Once all anchor bolts have been installed, verify the torque. 11. Use the four mounting holes, with an inner diameter of/4", in the back plate of the Tesla Site Controller enclosure to mount the unit vertically to a strut H-frame or rack (Figure 17). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 25 of 68 538 mm (21.18 in) �462 mm (18.18 in)-1 331 mm (13.03 in) 662 mm (26.06 in) 7. Wiring 05 mm (0.20 in) Figure 17: Tesla Site Controller Mounting Holes Wireway Installation Tesla provides a wireway to manage the cables that run between Powerpack Units, and from the Powerpack Units to the Powerpack Inverter. The wireway mechanically protects the cable harnesses and creates a continuous path that runs from the inverter to the last Powerpack Unit in each string (Figure 18). The kickplates that cover the face of each Powerpack Unit can only be accessed by opening the Powerpack Unit door. Because the door is interlocked with the Enable circuit of the inverter block, cable harness installation and maintenance can only be performed on a de -energized system. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 26 of 68. Figure 18: Cable Management Wireway Each row of Powerpack Units (A, B, C, and D) runs all power, ground/earth, and communication wires through its own wireway to a separate access plate in the base of the inverter. Figure 19: Inverter Block Diagram The inverter has access plates in front and in back, to accommodate Powerpack Unit cables from all four directions (Figure 20). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 27 of 68 Figure 20: Inverter Cable Access Plates, Front (Left) and Back (Right) A WARNING: Wireways must provide an effective ground -fault path. The wireway cover screws listed in the steps below are required to complete the ground path for the wireways. If you must commission or operate the system without the wireway covers installed, bond the wireway as needed to ensure an effective ground -fault current path. 1. Measure the length of wireway needed for each Powerpack Unit row, to reach that row's closest inverter access plate. 2. Cut the wireway (Tesla PN 1072786) to length. At the last Powerpack Unit in a row, cut the wireway to be even with the end of the last Powerpack Unit flap (Figure 21). File any rough edges. Figure 21: Wireway 3. Set the wireway in place. At corner locations, position wireway bottom trays with a gap of 0- 2" (Figure 22). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 28 of 68 Figure 22: Wireway Installation Gap 4. Use contractor -provided concrete screws (Tapcon screws or similar) to anchor each wireway section to the concrete pad in at least two locations. NOTE: For ease of installation, pre -drill concrete screw pilot holes in the wireway with a drill bit no larger than 3.4 mm (#29). 5. Use an 8mm (5/16") hex driver to remove the access plate(s) on the inverter base. Keep the bolts for re -use in the next step. 6. Use both re -used and additional shipped M5 0,8 x 16 mm bolts (Tesla PN 1002768-00) to install the right inverter interface (Tesla PN 1107828-00) and left inverter interface (Tesla PN 1107828-01) as needed onto the front inverter access plate openings. The left front interface window is for A -string Powerpack Units as shown in Figure 19; the right front interface is for C-string Powerpack Units. Figure 23: Powerpack Inverter Interfaces, Left and Right 7. Use both re -used and additional shipped M5 0,8 x 16 mm bolts (Tesla PN 1002768-00) to install the universal inverter interface (Tesla PN 1072854) as needed for Powerpack Unit rows B and D onto the rear inverter access plate openings (Figure 24). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 29 of 68 Figure 24: Powerpack Inverter Interface, Rear 8. Install inner wireway corners (Tesla PN 1072855) to connect the wireways for the Powerpack Unit rear rows to the wireways extending from the back of the inverter (Figure 25). Figure 25: Wireway Corners 9. Fasten each inverter interface (front and rear) and the wireway corners to the wireways with two Tesla-provided grounding screws (Figure 26). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 30 of 68 Figure 26: Wireway Grounding Screws Powerpack Unit Wiring Powerpack Unit DC Harness Installation The terminals for the DC cable harnesses, communication cable harnesses, and equipment grounding (protective earth) are recessed within the bottom section of the Powerpack Unit (Figure 27). Figure 27: Terminals Behind the Front Access Panel: Comm, Ground, DC DC harness lengths are pre-cut based on Powerpack Unit location relative to the Powerpack Inverter. Locations are assigned a Pack ID based on the naming convention shown in Figure 13 (e.g, Al, A2, B1, B2, etc). 1. For each Powerpack Unit, use a T30 Torx bit to remove the screws that attach the temporary cap over the DC terminals. Discard the cap and reinstall the screws for later reuse. 2. Lay out the Tesla-provided DC harness from each Powerpack Unit to the Powerpack Inverter. The positive (red) and negative (black) DC connectors have 3 prongs and 4 prongs respectively (Figure 28), which makes it impossible to connect to the wrong DC terminal at the Powerpack Unit. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 31 of 68 L ± Figure 28: DC Cable Harness Connectors at the Powerpack Unit 3. Inspect the end of each DC harness to ensure the metal contact ring around the connector is correctly seated and flush with the plastic. 4. Fully seat the DC harness connectors on the Unit terminals. When fully inserted, the flanges of the connectors are just beneath flush with the surface of the Unit. CAUTION: Fully seat the connectors before fastening the screws. Do not use powered tools for this connection. Using the screws to pull the connector closed can damage the terminals. 5. Use a T30 Torx bit to secure the DC harness to each Powerpack Unit DC terminal using the cap screws. Torque to 3.4 +/- 0.2 Nm (30 +/- 2 in-Ibs). If replacement screws are required, use 6 mm thread x 16 mm long hex cap head screws. Communication Harness and Ground Wire Installation 1. Install the Powerpack. Unit side of the Powerpack-to-inverter communication harness (PN 1068391, Figure 29) in the Powerpack Unit communication terminal closest to the Powerpack Inverter. Leave the inverter side loose for now. Each row has a different Powerpack-to-inverter communication harness. Callout Comm Harness Connection Harness Part Number A Powerpack Unit Al to Inverter 1068391-06 B Powerpack Unit B1 to Inverter 1068391-07 C Powerpack Unit Cl to Inverter 1068391-03 D Powerpack Unit D1 to Inverter 1068391-05 Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 32 of 68 Figure 29: Communication Harness Connector 2. Connect a Tesla-provided communication cable harness (Tesla PN 1068390, Figure 29) between each Powerpack Unit in series, from the one closest to the Powerpack Inverter to the end of that row. 3. Install the communication termination harness at the last Powerpack Unit in the row (Tesla PN 1071858, Figure 30). 400 Figure 30: Communication Termination Harness 4. Repeat the above steps for each row of Powerpack Units. 5. Ground each Powerpack Unit by attaching the contractor -provided #6 AWG copper conductor wire to the Powerpack Unit ground lugs. A single continuous equipment grounding conductor may be used to ground multiple Powerpack Units in a single string (e.g. Powerpack Units mounted side by side, with a maximum of five Powerpack Units in a string). The lug is copper with an electroplated tin finish, and is rated for use with bare copper grounding wire. NOTE: a grounding electrode conductor (direct connection to ground) is not required for the Powerpack Unit. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 33 of 68 Figure 31: Grounding the Powerpack Unit 6. Using a contractor -provided lug, attach the grounding conductor to the wireway itself at the end of each row farthest from the inverter Figure 32). Figure 32: Grounding the Wireway Powerpack Inverter Wiring: Customer Connection Side A DANGER: Refer to the Product Warnings section at the beginning of this document for full information on safety warnings and PPE recommendations before beginning any work in the inverter. Disconnecting Means The Powerpack Inverter includes a DC disconnect handle on the front door of the unit that can be locked in the open position (Figure 8). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 34 of 68 DC Harness Installation All harnesses entering or exiting the Customer Connection side of the Powerpack Inverter are routed through the opening in the bottom of the enclosure above grade. Unlike previous models of Powerpack System that required a DC Combiner Panel in a separate enclosure, the Powerpack Inverter aggregates the DC power from its assigned Powerpack Units in its Customer Connection section. Each inverter can be assigned between 1 and 20 Powerpack Units. The inverter has four DC bus bars, two positive and two negative, located on each side of the Customer Connection section. The DC cables are provided by Tesla, rated to 1000 V and rated for their protective 200 A fuses. The negative bus bar is located above the positive one, and DC cable lengths are offset to match those heights. Fuses are pre -installed in 5, 10, 15, or 20 sets of paired fuses, even if the inverter has fewer Powerpack Units attached. For example, an inverter assigned to 13 Powerpack Units may have 15 or 20 pairs of fuses installed. Strain relief plates are provided with cable ties for both the AC and DC cables. Cable ties are preinstalled for DC cables. Cable ties are provided for the AC cables and must be installed. 1. On the Powerpack Inverter, turn the DC disconnect switch to the "off' position. 2. Open the inverter door and lock out the DC disconnect switch. 3. Remove the high voltage shield. 4. Check with a properly rated voltmeter that there is no voltage on the DC bus before proceeding. Measure bus bar to bus bar, and each bus bar to ground. 5. Check that the customer connection section has the correct number of pre -installed fuses on the DC bus bars to match the number of Powerpack Units for that inverter block. If the inverter does not have enough fuses, contact Tesla. 6. Remove both strain relief brackets that run across the front of the busbar assemblies (Figure 33, 1). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 35 of 68 3 1 3 2 1. Strain relief Figure 33: Inverter Floor View 3. DC bus bars and fuses 2. DC cable floor panels 7. Remove the applicable modular DC cable floor panels (Figure 33, 2). 8. Lay all Powerpack Unit -terminated harnesses and ground wires in the wireways. Pull each Powerpack Unit row's bundle through its nearest Powerpack Inverter interface and up through the DC floor panels. 9. Remove the applicable caps in the floor panels where all DC cables and Powerpack Unit communication harnesses will run. Leave the other plugs in place to prevent dirt and pest ingress. 10. Identify the M50 cable glands that ship with the system in the accessory kit. If they arrive assembled, unscrew the gland halves and remove the rubber inserts. Set aside the correct number of glands for the total number of that inverter block's DC connections and comm/ground connections. The kit might have more glands than are required. (Glands for comm and ground wiring have inserts with smaller -diameter holes pre -drilled.) 0 Figure 34: DC Cable Gland and Inserts Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 36 of 68 11. Assemble the outer halves of the cable gland, top and bottom. Fasten each gland into a hole in the DC floor panel from the top face of the panel as pictured in Figure 33. NOTE: DC harnesses do not have assigned locations on the DC bus bars. However, for ease of maintenance, align the DC floor panel glands so that each Powerpack Unit row's connections are grouped together. NOTE: For ease of routing, reserve the front row of glands closest to the AC window for communication and grounding wiring in a later step. 12. Route each positive/negative DC harness pair through the inverter interface, under the inverter floor, and through an installed gland in a DC floor panel. 13. Terminate each DC harness to the DC bus bar pins (Figure 33, 3). The negative bus bar is on top, and the positive bus bar is below. Negative and positive terminations are pre - assembled at the appropriate heights. NOTE: Check that DC harnesses are securely terminated by ensuring the top tab clicks into place (Figure 35). Perform a push/pull test to ensure proper seating. Figure 35: Tabbed DC Harness Connector at the Inverter (red +, black -) 14. When all pairs of cables are routed, perform a 1000V insulation test from the HV DC+ bus bar to ground and from the HV DC- bus bar to ground with the DC disconnect open. Document the results in the Construction Checklist. 15. Fasten the strain relief zip tie below each terminal around its DC cable. 16. Leave the DC floor panels loose until the Powerpack Unit communication harnesses are installed in the next procedure. Powerpack Unit Communication Harness Installation and Testing This test verifies that all communication harnesses for each row of Powerpack Units are continuous, and all doors close and lock properly to engage the Enable circuit. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 37 of 68 1. Route the communication harnesses from the Powerpack Unit wireways (PN 1068391, one per row of Powerpack Units) through the inverter interfaces, inverter base, and DC floor panels (with cable glands already installed on the floor panels as described for the DC cables, above). 2. Close and lock all Powerpack Unit doors during the following continuity check. 3. Using a multimeter, perform a continuity check between pins 2 and 5 (the two middle pins) of each Powerpack-to-inverter communication harness connector (Figure 36). If a continuity check cannot be performed, substitute a resistance test where resistance must be less than 10 Ohms to pass. CAUTION: Be careful not to deform the communication harness contact sleeves by using large multimeter probes. Verify that the connection points on each communication harness are undamaged before terminating them in the board in the next step. Figure 36: Communication Harness Connector at the Interface Board 4. Identify the CAN termination points for the communication harnesses at the interface board (Figure 37). Figure 37: Interface Board Terminations Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 38 of 68 5. Terminate all required communication harnesses at the CAN inputs on the board (J14-J17). Populate the harnesses left to right in order, A B C D. 6. Install a jumper (Tesla PN 1071276) from the accessory kit onto any unused terminations. 7. If the site will be configured as a microgrid: a. Run a Tesla Site Controller DC backup cable from the interface board through the 1" DC conduit to the Tesla Site Controller. For cable lengths of 75 m (246 ft) or less, use 4 mm2 (12 AWG) cable. For longer lengths, check site plans or consult with Tesla. b. At the inverter interface board, connect the - wire in J6 as ground, and the + wire in pin 1 of J10 for 24V power (fused at 7 A). 8. If the Tesla Site Controller will be configured with hardwired jumpstart ability: a. Run a 12 V jumpstart cable from the interface board through the same 1" DC power conduit as the 24 V backup power to the Tesla Site Controller. For cable lengths of 25 m (82 ft) or less, use 4 mm2 (12 AWG) cable. For longer lengths, check site plans or consult with Tesla. b. At the inverter, insert the + wire for 12 V power and the — wire as ground into a TE connector (TE 2P RCPT VAL-U-LOK, 794954-2 or similar). Insert the TE connector into the J3 terminal on the interface board. Figure 38: TE Connector Polarity See "Installing the Tesla Site Controller" to land the other ends of these wires in the Tesla Site Controller. CAUTION: Do not connect any non-Tesla equipment to the inverter interface board terminals other than the microgrid or jumpstart lines as described. Non-Tesla equipment can damage the Powerpack System. NOTE: A fire -safe enclosure is required for equipment or parts of equipment that are connected to the 12 V and 24 V power customer terminals on the interface board. If such equipment is not installed inside the Powerpack Inverter enclosure itself, it requires a separate fire -safe enclosure. Powerpack Unit Grounding. The Powerpack Unit equipment grounding conductors terminate at the ground lugs located in the bottom section of the Customer Connection area (Figure 39). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 39 of 68 The grounding (protective earth) lugs are identified with the following symbol: 0 1. Ground the DC grounding connections of each Powerpack Unit row onto the four M6 studs with the Tesla-provided mechanical lugs. The lugs accept #14 to #4 AWG copper ground. Lugs are torqued to the bus bar at 5.6 Nm. Secure the wire in the lug and torque according to the wire size: • 14-10 AWG: 4 Nm (35 in-lbf) • 8 AWG: 4.5 Nm (40 in-lbf) • 6-4 AWG: 5 Nm (45 in-lbf) Figure 39: Customer Connection Ground Connections: AC Studs (1) and DC (2) 2. Replace and refasten the DC floor panel(s). 3. Unscrew the two halves of each cable gland and install the two halves of the rubber insert inside, around the cables, to prevent ingress. Fasten the cable gland outer halves together. Perform this step for both DC power cable glands and communication/ground cable glands. Figure 40: Completing Gland Installation Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 40 of 68 Tesla Site Controller Communication Wiring In addition to the communication harness, the interface board must also communicate with the Tesla Site Controller via a shielded CAT5e or CAT6 cable, provided and installed by the contractor and terminated at port EthO (Figure 37). 1. Install the field crimped Ethernet cable between the Tesla Site Controller and interface board using an EZ-RJ45 Crimp Tool or equal (Figure 41). Use a metal connector for the end that plugs into the Tesla Site Controller, and a plastic connector for the end that installs into the interface board. 2. Test field crimps using a VDV Scout Pro or Pro LT (VDV501-053 or 068) or equal. 3. Leave a paint pen mark on the cable as it passes. O/ 0 G/ BI BI/ G Br/ Br 568B Figure 41: Ethernet Wire Configuration Powerpack Inverter Wiring: AC Conductors A DANGER: Refer to the Product Warnings section at the beginning of this document for full information on safety warnings and PPE recommendations before beginning any work in the inverter. Each Powerpack Inverter requires a 4-wire, wye-grounded circuit (3 phases, neutral, and ground). Conductors enter the Powerpack Inverter via a bottom conduit window and terminate on the AC bus bars in the Customer Connection area. CAUTION: If not already clearly defined in the site plans, refer to the Powerpack 2 System Site Design Manual for neutral sizing requirements. The inverter is provided with four AC bus bars to connect three phases and the neutral. AC bus bars are made of tin-plated aluminum and drilled to allow the connection of up to four (4) 2-hole lugs (Figure 42). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 41 of 68 c O 0 -f O 0 0 0 321.3 [ 12.65' 109.1 [ 4.3' 213.2 8.39' ! 44.5 [ 1.75' ] 13.5 [ 0 53' ] [ 100 .94 445 1 75" ] C 44.5 [ 1.75' ] 0 ED Figure 42: Inverter Bus Bar Dimensions (in mm/in) The lug connections allow two lugs on each side of the bus bar with a maximum of: • Four (4) sets of 600 MCM (300 mm2) conductors per bus bar, or • Three (3) sets of 750 MCM (400mm2) conductors per bus bar, or • Two (2) sets of 1,000 MCM (500 mm2) conductors per bus bar The conductor connections are supplied by the customer and must comply with all local codes and regulations. Tesla requires that the bus bar not be modified in any way and that the Tesla supplied hardware be used as shown in Figure 43. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 42 of 68 Figure 43: AC Bus Bar Auxiliary power is not required for the inverter or the Powerpack Unit. The Powerpack Unit pulls auxiliary power for the control power and thermal management from the DC bus, and therefore requires no field work. 1. Keep the inverter cabinet power disconnected and locked out per the previous procedure. 2. Pull circuit conductors into the inverter via the AC bottom conduit window (Figure 33). 3. Conduct insulation testing at 500 V on the AC conductors for insulation resistance after running the conductors through the conduit, but before terminating the AC conductors on the inverter AC bus bars. Testing after termination results in the test failing. Document the results in the Construction Checklist. 4. Connect all AC conductors to the inverter bus bars using an approved connection method. Each Powerpack Inverter accessory kit includes the M12 bolts, washers, and nuts for attaching the AC lugs to the AC bus. Install the fasteners in this order: Bolt, flat washer, connector, bus bar, connector, flat washer, conical washer, nut (Figure 44). Torque to 36 Nm (26.6 ft-lbs). Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 43 of 68 0 0 \JP) Figure 44: Inverter Bus Bar Fasteners NOTE: The minimum electrical clearance between one bus bar and the next bus bar, including fasteners, is 3 mm (0.12 in). 5. Apply anti -oxide coating to each HV, field -torqued lug in the inverter and switchgear if required by the AHJ. 6. Replace both AC strain relief brackets that run across the front of the customer connection section of the inverter. 7. Use the provided ties to fasten the conductors to the strain relief bar. NOTE: Where possible, arrange and fasten the AC conductors toward the center to leave clear space open on both sides. This creates better maintenance access to the DC bus bar fuses and the Interface board. 8. Install the equipment ground conductor (EGC) on the inverter grounding bus bar using approved, contractor -provided lugs. The ground studs have the following dimensions: • Six M8 studs • NEMA 1.75 pitch between vertical sets Each Powerpack Inverter includes the M8 captive washer nuts for attaching the inverter ground lugs to the ground connections. Torque to 9.0 Nm (6.6 ft-lbs). Where metal conduits are used, conduits must have insulated ground bushings connected to equipment grounding conductors. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 44 of 68 Figure 45: AC Ground Lug Example akta CAUTION: The inverter output AC voltage is phase -rotation sensitive. The inverter will not start without proper phase rotation. 9. Check that the phases of the inverter are connected to the corresponding utility phases by using a Greenlee 5702 Phase Sequence Indicator or equal. (Check the manual for the phase indicator tool before use.) a) Connect the tester leads to phase 1, 2 and 3 of the inverter. Refer to the labels on the bus bar. b) Check that all phases show clockwise rotation. If any phases show counterclockwise rotation, swap phases 1 and 3 and retest. 10. Once all power and communication wires are installed for the inverter, apply a sealant to the edges of the AC window where the steel from the enclosure meets the concrete (plumber's foam or similar), rated for applicable fire resistance requirements. 11. Seal the conduit stub -ups using a material identified by the manufacturer as compatible with the cables and the conduit materials (duct seal, moldable putty, or similar), rated for applicable fire resistance requirements. (Figure 46 shows both sealants.) Ensure that all bottom plates in the inverter are completely sealed from dirt and pest ingress. CAUTION: Some foaming agents such as plumbing foam can degrade insulation and PVC conduit pipes. Ensure all sealants are compatible with site materials. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 45 of 68 Figure 46: Sealing Conduit Window 12. Perform a grounding resistance test. The system should show: • < 1 Ohm between each earth bar and the main system earth bar • < 1 Ohm between the system's exposed metal and the local earth bar • Only one neutral earth bond per system 13. Vacuum the interior of the inverter. Include the LV shelf and the customer connection area. Wireway Cover Installation Once all inverter and Powerpack Unit harnesses are installed and tested as needed, complete the installation of all covers and kickplates to protect wiring. 1. If not already done, use the door key (ships attached to the Powerpack Unit door) to open all Powerpack Unit doors. 2. Install the Powerpack Unit kickplates (Tesla PN 1072788, Figure 47) using 3 screws and an integrated lock washer for each (Tesla PN 1072856). See the grounding warning at the beginning of the Wireway Installation section. Make sure that: • The kickplate is centered between the Powerpack Unit's vertical flaps • The flanges on either end of the kickplate are fitted over the top of the Powerpack Unit horizontal flaps Figure 47: Powerpack Unit Kickplate Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 46 of 68 3. Install the inverter interface covers (Tesla PN 1107830-00, right and 1107830-01, left) (Figure 48). Figure 48: Wireway Covers: Inverter Interfaces (1), Top Caps (2), End Cap (3) 4. Cut the top cap (Tesla PN 1072787) to fit between Powerpack Units, and between the Units and the inverter, over the straight wireway segments. File any rough edges. Set the top cap over the wireway. NOTE: Do not cut the top cap with too tight a tolerance. A top cap that is too long can damage Powerpack Units during removal and installation, and makes servicing more difficult. 5. Screw the cap to the wireway using sheet metal screws (Tesla PN 1072829). See the grounding warning at the beginning of the Wireway Installation section. At least 2 screws are required between Powerpack Units. For segments greater than 6" in length, at least one screw is required on each end. 6. Slide on the corner cap (Tesla PN 1072801) and attach it using 4 sheet metal screws (Tesla PN 1072829). At least 2 of the 4 screws must be fastened. 7. At the end of each Powerpack Unit string, press the wireway end cap (Tesla PN 1072853) over the top edge of the kickplate. Optional: The end cap can be screwed to the tray using Tesla PN 1072829. 8. Tesla Site Controller The Tesla Site Controller can be powered from a 400 VAC or 480 VAC, 2-pole, 10 A circuit. The engineer of record must design the means and methods of pulling this circuit. In a multiple Powerpack Inverter scenario, this circuit can be provided from the AC switchboard. For AC and ground conductors, use a minimum of 2.5 mm2 (14 AWG) copper rated to 90 °C. Refer to the "Site Infrastructure" section of this manual to ensure all needed conduit is in place. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 47 of 68 Installing the Tesla Site Controller Figure 49: Tesla Site Controller Interior Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 48 of 68 1 Real -Time Automation Controller (RTAC): optional (PN 1129636r) 2 Terminals for computer power 3 Tesla Site Controller Computer 2 (optional, PN 1052303) 4 Tesla Site Controller Computer (primary): includes four RS-232/422/485 ports, Ethernet ports 5 RSP Network Switch: Connects both Tesla Site Controller computers to the inverter using Ethernet 6 DCDC converter and surge protector: Connector for 24 V backup power Jumpstart terminals (optional): used to connect a 12 V power supply that can jumpstart a microgrid inverter if needed 8 Grounding terminals 9 Terminals for transformer wiring 10 Fuse block between AC mains and transformer: Default configuration is shipped with 0.5A KLDR Fuse (PN: 1053860-00-A) for 480 VAC, other fuses are in the accessory kit 11 Transformer, 120/240/480 V NOTE: The components and wiring locations in the image above are correct, but wiring color may differ. Check the wiring diagrams below for wire colors. 1. Mount the Tesla Site Controller enclosure on a rack or wall using appropriate fasteners capable of supporting 22 kg (48 lbs). Mounting brackets are included. NOTE: The Tesla Site Controller is over 18 kg (40 Ibs). Use proper precautions in carrying and lifting the module. 2. Pull the AC conductors (phase and phase -neutral), min. 14 AWG, through the conduit from the switchgear, and up through the bottom of the Tesla Site Controller enclosure. Land them on terminals L1 and L2 of the fuse block (Figure 49, image callout 10). Land the AC ground wire on the ground terminal on the same DIN rail (callout 8). 3. Pull the Ethernet meter wiring through the conduit from the inverter(s) and up through the bottom of the Tesla Site Controller enclosure. Connect to the network switch (callout 5). 4. If the site is configured as a microgrid, pull the DC backup cable through the conduit from the inverter(s) interface boards. Connect the two wires to the Aux in/rtn terminals on the bottom of the DCDC converter (image callout 6). 5. If the Tesla Site Controller will be configured with hardwired jumpstart ability, pull the 12 V jumpstart cable through the conduit from the inverter(s) interface boards. Connect the two wires to the jumpstart terminals (callout 7). 6. For any region other than North America, replace the region -specific SIM card in the right- hand (primary) computer: a. Insert a long flathead screwdriver in the hole of the back mounting tab. Gently pry up on the mounting tab until it lifts free of the DIN rail. Set the computer in a stable place, being careful not to pull on the wires that are still connected. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 49 of 68 Figure 50: Removing Computer from DIN Rail b. Remove the Ethernet connector from the top of the primary computer. c. Use a small flathead screwdriver to remove the connector holding the + and — wires from the top of the primary computer. d. Use a Philips head screwdriver to remove the six screws from the computer back cover. Set the cover aside. e. Remove the SIM card from its slot. u i®im.rx r. Figure 51: Computer SIM Card Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 50 of 68 f. Replace the SIM card with the one that shipped with the system for this region. g. Replace the back cover. Fasten the six screws hand -tight. h. Replace the computer on the DIN rail. i. Replace the Ethernet, + and — wires. 7. If not already installed, install the internal antenna from the Tesla Site Controller accessory kit onto the connector in the top left corner of the computer. NOTE: If the internal antenna for the computer does not fit, contact Powerpack Support. 8. To install the second computer (if one was ordered for the site): a. Identify the space on the DIN rail to the left of the existing computer. b. Hook the second computer onto the DIN rail: align the two small hooks on the back of the computer under the rail first, then gently push until the top half of the mounting bracket snaps into place. c. Connect the included positive wire from the right side of the terminal block (callout 2) to the computer's + terminal. d. Connect the included negative wire from the left side of the terminal block (callout 2) to the computer's - terminal. e. If not already installed, install the antenna from the Tesla Site Controller accessory kit onto the connector in the top left corner of the computer. 9. To install the RTAC (if one was ordered for the site): a. Use a Philips head screwdriver to unfasten the two M5 screws holding the DIN rail to the top of the backplane of the enclosure. b. Snap the RTAC unit onto the DIN rail. c. Reinstall the DIN rail onto the enclosure backplane. Torque to 2.8 Nm (24.8 in -lb). d. Install the leads of 1.5 mm2 (16-14 AWG) wire that were provided with the system. Connect them to the power terminals on the top DIN rail (callout 2). e. Install the Tesla-provided Ethernet cable from the LAN1 port on the RTAC to the LAN1 port on the master computer. 10. Configure the transformer wiring according to the voltage of the incoming AC power. Choose the correct transformer procedure below for this site. Diagrams include the optional RTAC unit and optional second computer. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 51 of 68 Configuring the Transformer for 440, 450, or 480 VAC The Tesla Site Controller is already default -wired for 480 VAC sites. The transformer is wired directly into terminal blocks as shown below. NOTE: Configure 440 and 450 VAC input the same as for 480V. 5 A C RTAC J_ 1 Diode Redundancy Module Out In + - I - - + + 5 A C b +V -V out DC/DC SELV +V -V -V +V 24V Power Supply GND N Li IN IN SMC2 Coma Coma SMC Coons Com•. Ccmc Cons Com; Cons mov SWITCH Figure 52: Layout Diagram for 480 VAC transformer Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 52 of 68 Configuring the Transformer for 208, 240, or 400 VAC For 208 VAC, 240 VAC or 400 VAC line to neutral input: 1. Remove the brown and white wires altogether that run from the left side of the transformer to the top of the 1.6 A fuse block. 2. Replace the default fuses in the fuse block with the ones meant for 120 and 240 VAC configurations (1.5A ATQR Fuse, PN: 1453351-00-A). 3. Move the orange and white wires from the right side of the transformer to the top of the 1.6 A circuit breaker. The transformer should now be completely disconnected. CAUTION: 240 VAC may only be in LINE to NEUTRAL form. Wiring as split phase can cause a short in the system. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 53 of 68 5 A C b Diode Redundancy Module Out In + - I - - + + 5 A C 71 I, +V —V Out DC/DC SON in +V —V -V +V 24V Power Supply ONO N Li I _ * IN SMC 2 Coen? Corn] Coma Corn] cc, 1 mov Fuse Block IN SMC Coon? Com] Coma Come SWITCH transformer Figure 53: Layout Diagram for 240 VAC (L-N) Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 54 of 68 Configuring the Transformer for 120 VAC For 120 VAC: rewire the transformer to be used as a step-up and branch circuit protection at the source. 1. Ensure that all power is off to the Tesla Site Controller. 2. Disconnect the wires running to and from the transformer. 3. Replace the default fuses in the fuse block with the ones meant for 120 and 240 VAC configurations (1.5A ATQR Fuse, PN: 1453351-00-A). 4. On both the left and right sides of the transformer, use a Philips screwdriver to remove the tap connecting the two middle terminals. Install two taps that connect the middle to the outer terminals. The new taps ship in a bag inside the Tesla Site Controller enclosure. Figure 54: Transformer Taps 5. Connect the orange and white wires coming from the L1 and N terminals of the 24V power supply to the LEFT side of the transformer, the opposite side from which they were removed (shown in the image below). 6. Connect the brown and white wires coming from the top terminals of the 1.6 A circuit breaker to the RIGHT side of the transformer, the opposite side from which they were removed. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 55 of 68 RTAC Diode Redundancy Module Out In I +V -V t: 1 out DC/DC SELV +V 24V Power Supply GND N L1 T SMC SMC Cdn2 Cam] Ccm2 Csm4 Ccm4 Cnnt3 Can< Cun3 rxn mov Feu Block Figure 55: Layout Diagram for 120 VAC SWITCH transformer Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 56 of 68 Connecting a Demand Response Controller Australia installations might require a Demand Response Enabling Device (DRED) to be connected to the Powerpack System, to comply with utility regulations for controlling output power. Tesla supports the FuturePoint Sunspec Demand Response Controller (DRC), FuturePoint part number 006A-SUNS, as the interface hardware to translate the DRED signals into Modbus commands. The Sunspec is provided by the site or the contractor. The DRED is controlled by the Electricity Network Operator and, in turn, sends signals to the DRC that instruct the inverter via the Sunspec Interface to take the required action. NOTE: All regions except Australia can skip this procedure. 1. Choose an installation point for the Sunspec DRC enclosure, probably close to the Tesla Site Controller enclosure. 2. Mount the DRC vertically on a wall or similar structure with the conduit entry on the bottom, as described in the FuturePoint Sunspec DRC User Guide. 3. Provide a single phase, 230 VAC, minimum 10A circuit from the existing premise electrical system and connect it to the Sunspec DRC 230 VAC power supply terminals. The circuit shall be designed per installation code by the design engineer for the project. 4. Use an Ethernet cable to connect the Sunspec Ethernet port to the LAN1 port inside the Tesla Site Controller. The LAN1 port on the Tesla Site Controller functions as a DHCP client, and the TCP port on the Sunspec DRC has an inbuilt DHCP server. No other hardware is required for direct connection or control to the Powerpack Inverter(s). 5. Connect the AS4755 DRED input port on the Sunspec DRC to a site- or contractor -supplied AS4755 compliant Demand Response Enabling Device (DRED). For full installation details, refer to the FuturePoint Sunspec DRC User Guide. Connecting a VDE 4105 Protection Relay For installations that must comply with VDE 4105 requirements, configure the relay as specified below. NOTE: Regions that do not require VDE 4105 compliance can skip this procedure. 1. Procure an additional, contractor -provided contactor and protection relay that is VDE 0124 certified and is correctly sized to support the entire site. The protection relay is not required to have anti-islanding functionality. 2. Install the contactor and protection relay upstream of the Powerpack System. The installation must comply with all local and regional codes. 3. Wire the contactor such that loss of power to the relay results in an immediate trip for the Powerpack Inverter. 4. Configure the protection relay such that a loss of power for less than 3 seconds does not result in the loss of the last 5 trip error messages on the relay. 5. Set the relay to match the voltage and frequency ride -through settings listed in the table below. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 57 of 68 lay Setting Values Protective Function Protection Relay Setting Values* Voltage drop protection U< 0.8 Un < 100 ms Rise -in -voltage protection U> 1.1 Un ** < 100 ms Rise -in -voltage protection U» 1.15 Un < 100 ms Frequency decrease protection f< 47.5 Hz < 100 ms Frequency increase protection f> 51.5 Hz < 100 ms * The duration set point "<100 ms" for the protection relay setting value is based on the assumption that the maximum proper time for both NS protection and interface switch is also 100 ms. This leads to a maximum total disconnection time of 200 ms. If the proper time of a component is less than 100 ms (e.g., 50 ms), then this allows for a longer period during which to perform the measurements and evaluation of the protective function (e.g., up to 150 ms). This could then lead to a protection relay setting value higher than "<100 ms", i.e. "<150 ms". However, in that case, only the 100 ms shall be visualized as setting value at the NS protection. Still, the disconnection time of 200 ms shall not be exceeded under any circumstance. ** It shall be ensured that the voltage at the network connection point cannot fall below 1.1 Un. If compliance with this requirement is ensured by a central NS protection, then it is permissible to set the rise -in -voltage protection at the decentralized power generation unit or system to a value of up to 1.15 Un. In that case, the system erector should consider any possible effects on the customer installation. Combination of central NS protection (U>: 1.1 Un) and integrated NS protection (U>: 1.1 to 1.15 Un) is advisable, if the voltage drop in the house installation cannot be neglected. This is typically the case with longer connection lines. 9. Energy Meters Every site requires a "battery meter" that measures the AC energy output of the battery system (Figure 56). A "site meter" (that measures the net load of the site with the battery system included) is optional, but required for some control functions. An additional "solar meter" (or "generator meter") might also be required for sites involving PV installations. See the Powerpack 2 System Site Design Manual for further meter details. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 58 of 68 Tesla Powerpack System Powerpack Controller • aT i g i= On -site Generation bH� ,arc PV Array ESS Pane! Board kwh Electrical Infrastructure Powerpack Point of Connection (PoC) Battery Meter Revenue Meter kWh Generation Meter Main Site Distribution Board kWh —A Site Existing Meter Metering Existing Grid Infrastructure Figure 56: Metering Overview Site toads (multiple circuits) Connection Requirements All meters are connected to the Tesla Site Controller using Ethernet cable. NOTE: RS485 connections are no longer supported. a, CAUTION: Payparticular attention to meters during installation. The Powerpack System cannot operate correctly without the correct meter wiring and meter installation. Ethernet connection requirements: • Shielded CAT5e or CAT6 • Field -crimped Ethernet cables must be tested with a LAN tester, at minimum Connecting Meters to the Tesla Site Controller Connect a direct line between the meter and the Tesla Site Controller, from the meter(s) into an available port (ports 2-5) of the Ethernet switch. Use a metal connector for the end that plugs into the Tesla Site Controller, and a plastic connector for the end that installs into the meter. Ensure the Ethernet switch is also connected to LAN2. If the Tesla Site Controller is communicating over an external, third party network, connect the external third party network to LAN1. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 59 of 68 NOTE: If the site is using multiple external communication devices that use LAN1 (such as a customer interface, utility monitoring device, or external -network meter), a second Ethernet switch is required. Contact Tesla for details. CT Installation in the AC Panel or Switchboard 1. Check meter -specific requirements to determine whether to use core CTs or Rogowski coils. Figure 57: CT Types, Core (Left) and Rogowski (Right) 2. Verify that the CTs used match the chosen meter's specifications. NOTE: Tesla is not responsible for the correct installation of the meter on the AC side. The Powerpack System will not operate correctly with incorrect CT installation or wiring to the meters. This is a common point of installation failure, and requires careful installer attention. 3. Read the label on each CT to verify the CT ratio and the arrow that indicates the direction of flow. Record each meter's make, model, serial number, and CT ratio on the Construction Checklist. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 60 of 68 k .CURRENT TRANSFORMER 31� C.,1.0 0 SeC. — IOW OIL ORE ® MADE ea Ld18'1NOt. DII- USA >� Rio No. E186575 Figure 58: CT Ratio and Arrow 4. All meters are phase -sensitive. For each meter, use color -coded wires to help identify phases on voltage references and CT leads. NOTE: Each phase's voltage wiring must correspond to the same phase of current wiring, and the positive and negative polarity of each phase must be installed correctly to match the sign convention in Figure 59. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 61 of 68 Generation 1=1,* Utility (Site Meter) I Elz* 4= II Battery Loads Figure 59: Metering Sign Convention NOTE: Be sure to install shorting blocks for core CTs. Shorting blocks are not required for Rogowski coils. NOTE: Do not field -extend the leads on a Rogowski coil. Doing so can degrade signal accuracy. If longer leads are required, reach out to the appropriate manufacturer for a project specific order. 5. Install the battery meter wiring on the battery AC panel so that only the Powerpack System output is measured. 6. If using a site meter, install wiring so that all customer loads including the Powerpack System output are captured. Site meter wiring is typically installed adjacent to the utility meter or at the site's point of common coupling (PCC). 7. If using a generation meter, install wiring so that all solar generation is measured. Some sites might require more than one solar meter; refer to site drawings. 8. If using a consumption (facility load) meter, install wiring to measure the facility load only (excluding all Powerpack System activity and generation sources). 9. For each meter, perform a resistance check between the positive and negative terminals from each CT: • Core CTs: Ensure resistance between each CT pair is —0 Ohms. • Rogowski coils: Ensure resistance between each CT pair is 20-60 Ohms, and resistance from one pair to another pair is open (-100 kOhms or more). 10. On the meter UI, set the CT ratio per the installed CTs and document in the Construction Checklist. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 62 of 68 Meter Configuration Once AC -side and Tesla Site Controller wiring is complete, turn on the meter(s) and set the following parameters as described in the meter manual: For Ethernet Using LAN1: Contact Tesla for IP address settings. For Ethernet Using LAN2: • Assign the meters to static IP addresses . Meters are assigned addresses in batches by meter type: • Battery = 192.168.90.201 to 192.168.90.209 (first battery meter starting at 201, next at 202, etc.) • Site = 192.168.90.210 to 219 (first site meter starting at 210, next at 211, etc.) • PV = 192.168.90.220 to 229 (first PV meter starting at 220, next at 221 , etc.) • Busway = 192.168.90.230 to 239 (first busway at 230, next at 231, etc.) • Set the Subnet Mask to 255.255.255.0. • Set the Default Gateway to 192.168.90.1. NOTE: If the installation is using SolarCity SEL735 meters, also refer to the SEL735 Meter Guide on the Grid portal for complete configuration instructions. NOTE: To save the IP address settings, the meter must be turned off, then turned back on. 10. Commissioning Shutdown For an emergency or unknown behavior: 1. Open the upstream AC breaker (if one is present). 2. Open the DC Disconnect switch on each affected inverter to isolate the Powerpack Units from the inverter (Figure 6). 3. Open the AC disconnect device connected to the AC output of each affected inverter, to isolate the inverter from the grid or other energy sources. CAUTION: Wait a minimum of 5 minutes before closing the DC disconnect any time the DC disconnect has been opened. Equipment can be damaged if the DC disconnect is closed too fast. For a planned shutdown: The procedure varies depending on site configuration. Refer to the Powerpack 2 System Operation and Maintenance Manual for details. A WARNING: Any work inside enclosures not explicitly mentioned in the Powerpack 2 System Installation Manual should only be performed by Tesla or Tesla approved service Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 63 of 68 technicians who are qualified and have lockout/tagout equipment. Qualified personnel can find further safety and verification directions in the Powerpack System Service Manual. Locating Enclosure Serial Numbers The serial number locations of each type of enclosure are shown in the images below. These images are examples; the exact appearance of a site's enclosures might vary. Figure 60: Serial Numbers on Powerpack Unit (left) and Inverter (right) Figure 61: Tesla Site Controller VIN Location Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 64 of 68 Tesla Commissioning Responsibility After the installation contractor completes the entire installation and the Construction Checklist, Tesla is responsible for commissioning the Tesla Site Controller communication with the Powerpack Inverter and initial start-up of the Powerpack System. This includes: 1. Tesla Site Controller communication with the Tesla Server 2. Tesla Site Controller communication with the Powerpack Inverter 3. Powerpack Inverter communication with Powerpack Units and basic functionality 4. Inverter block and system level performance testing 5. System start-up sequence checklist NOTE: Owner and site manager responsibilities are detailed in the Powerpack 2 System Operation and Maintenance Manual. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 65 of 68 Revision Log Revision # Date Description 1.00 02-03-2017 Initial Release 1.01 02-07-2017 • Fixed rounding error on inverter weight • Added specs for Powerpack Unit 2, 2-hour 1.02 04-06-2017 • Added megger testing for AC conductors before termination • Added DRC section for Australia installations • Listed all Powerpack Inverter part numbers according to number of Powerstages • Added a pointer to the Site Design Manual to check transformer configuration if one is present • Added diagrams of Powerpack Inverter's center of gravity points with minimum and maximum Powerstages installed • Updated pad construction pre -checks • Updated wiring spec and diagram for RS-485 meter wiring • Added note about applying anti -oxide coating to each HV, field -torqued lug in the inverter and switchgear in the "Inverter Wiring: AC Connectors" section • Added DC insulation test at the inverter bus bar, clarified details of AC conductor insulation test 1.03 05-12-2017 • Added section to "Wiring" to describe VDE 4105 relay installation where applicable • Defined in "Site Construction" that the site requires a lockable AC breaker upstream of each inverter • Expanded CT Installation instructions • Updated clearances above units • Removed appendix of vocabulary terms as not relevant to installers, and simplified product overview • Added shutdown procedure details 1.04 07-28-2017 • Added cautions to not use paint, solvents, or non- Tesla-approved parts • Fixed image error showing DC bus bars • Added comparison of system variants for 1.5 and 2 in "Product Configurations" 1.05 10-30-2017 • Added AC conductor specs in case of only using 2 wires per phase • Updated inverter and 2-hr Powerpack weights to be more precise in "System Specifications" • Changed megger tests from pass/fail to recording results on the Construction Checklist • Removed need for special top cap for inverter interface covers; inverter covers are now longer. Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 66 of 68 Revision # Date Description • Added details about inverter bus bar fasteners and dimensions. • Updated nameplate rating from 62.5 kVA per Powerstage to current rating of 65 kVA each. • Added details to Controller and jumpstart wiring on the inverter interface board. • Specified that CAT5e or CAT6 must be shielded. • Updated top clearances in "Clearances". • Added reminder in "Anchoring the Enclosures" to remove anchor templates before landing the enclosures on the pad. 2.0 03-06-2018 • Updated back to back spacing figures in "Clearances". • Added caution not to use the DC harness screws to seat the connectors on the Unit. • Updated enclosure shipped weights. • Fixed typos in DC ground lug torques. • Moved details about wiring choice and site design to the Site Design Manual. • Added information about the Controller throughout. • Added minimum electrical clearances between AC bus bars. 2.1 08-09-2018 • Added mounting hole dimensions for Controller • Added bolt PNs and a note about bolt re -use for the inverter interfaces in "Wireway Installation" • Added wire routing guidance in `Powerpack Inverter Wiring: AC Conductors" • Changed DC cable megger test from 500 V to 1000 V in "Powerpack Inverter Wiring: Customer Connection Side" • Clarified that only the new Controller and Ethernet (not RS485), are now supported • Removed snow -specific site spacing • Added site access information to "Site Installation" • Added corrosion prevention steps to "Anchoring the Enclosures" • Renamed Controller to Tesla Site Controller for clarity • Added sealing and vacuuming steps to `Powerpack Inverter Wiring: AC Conductors" 2.2 10-08-2018 • Modified all mentions of "Site Controller" and "Controller" to "Tesla Site Controller" Aug. 9, 2018 CONFIDENTIAL INFORMATION - SHARED UNDER NDA ONLY Page 67 of 68 CORE STATES GROUP October 21, 2019 Building Plan Check -Permit no. 1720-2019 RE: Hoag Hospital Tesla Battery 1 Hoag Dr. Newport Beach, CA 92663 Per Fire comments dated 10/8/19 (attached), please see below responses and revised drawings incorporating said changes. FIRE COMMENTS (Todd Letterman): Per CFC Section 1.1.3.2 State regulated buildings, structures and applications. This is an OSHPOD facility and needs to be reviewed by the governing authority. General acute care hospitals, acute psychiatric hospitals, skilled nursing and/or intermediate care facilities, clinics licensed by the Department of Public Health and correctional treatment centers regulated by the Office of Statewide Health Planning and Development. See Section 1.10 for additional scope provisions. 1.10.1 OSHPD. Specific scope of application of the agency responsible for enforcement, enforcement agency and the specific authority to adopt and enforce such provisions of this code, unless otherwise stated. 1. Provide construction documents in accordance with California Fire Code (CFC) Section 608.1.2. CFC 608.1.2 requires the following: 1. Location and layout diagram of the room in which the stationary storage battery system is to be installed. a. Response: This is os Sheet 2.0. Haw 's NOT a room, but an existing equipment area for Methane Filtration Equipment 2. Details on hourly fire -resistant -rated assemblies provided. a. Response: System is a UL listed assembly, not installed within a room or within a structure. Installation manual has been provided, as well as fire testing documentation from manufacturer with this resubmittal. 3. Quantities and types of storage batteries and battery systems. www.core-enq.com georgia . new jersey . massachusetts . texas. missouri . florida . north carolina washington . arkansas california . pennsylvania CORE STATES .I®r►■ GROUP a. Response: This info can be found in the Installation manual provided with resubmittal, as well as the title sheet table with battery chemistry listed. 4. Manufacturers specifications, ratings and listings of storage batteries and battery systems. a. Response: Tesla installation manual has all of this info, and has been provided with resubmittal. 5. Details on Energy Management systems. a. Response: The system is a premanufactured, UL listed assembly that includes the Energy Management System/Controls. 6. Location and content of signage. a. Response: See sheet 5.0 for required signage. 7. Details on fire suppression, smoke detection and ventilation systems. a. Response: Outdoor installation, not required. 8. Rack storage arrangement, including seismic support criteria. a. Response: This is a UL listed assembly. Seismic support and rack storage arrangement are under the required listings. 2. Provide a hazard analysis per CFC Section 608.1.3. 608.1.3.1 and 608.1.3.2 Response: Hazard Analysis provided with resubmittal from manufacturer. 3. Indicate ratings of all separations. Response: We are not in a building or room per 608.2.2. No separation included in design as this is an exterior installation that is fenced, accessible only to qualified personnel. 4. Indicate maximum allowable quantities per CFC Section 608.3 Response: This is not a "Fire area within building(s) containing stationary battery systems" per the referenced code section. In our opinion, this section does not apply to our design. 5. Indicate the battery storage system comply with UIL 1973 and UL 9540 per CFC Section 608.4.1 Response: This system complies with UL1973 and UL 9540, both included in installation manual, and included with resubmittal. www.core-eng.com georgia . new jersey . massachusetts . texas. missouri . florida . north carolina . washington . arkansas . california . pennsylvania CORE STATES .Ir1111111r.■ 6. Indicate a type of Energy management system per CFC Section 608.4.3 GROUP Response: The Energy Management System is provided as part of the "listed pre-engineered or pre -packaged stationary storage battery system". This Energy Management System has been approved by SCE for this installation. 7. Indicate battery chargers per CFC Section 608.4.4 Response: Battery chargers are provided "as part of a listed pre-engineered or pre -packaged stationary storage battery system" per code section 608.4.4. See attached Design and Installation Manual outlining all UL listings this system includes. 8. Indicate the listings for the inverters per CFC Section 608.4.5 Response: Inverters are UL1741 listed per 608.4.5, this information can be found in the SYSTEM RATINGS Table on sheet 3.0. Also, see attached Design and Installation Manual outlining all UL listings this system includes. 9. Indicate compliance with Thermal runaway per CFC Section 608.4.7 Response: Per section 608.4.7, Thermal runaway is only applicable when required by Section 608.6. Per Section 608.6, lithium ion does not require thermal runaway protection, only specific signage is required. That said, the fire testing done my BESS manufacturer has been provided with this resubmittal for your review. 10. Indicate that the room has adequate fire suppression system installed per CFC Section 608.5.1 Response: This is an outdoor BESS installation, this section does not apply. 11. Is smoke detections provided within the room per CFC Section 608.5.2? Response: This is an outdoor BESS installation, this section does not apply. 12. Indicate if there is a gas detection system per CFC Section 608.5.4. Response: This is an outdoor BESS installation, this section does not apply. 13. Indicate per CFC Section 608.2.3 stationary battery arrays. Storage batteries per -packaged stationary storage battery systems and pre-engineered stationary storage battery systems shall be segregated into stationary battery arrays not exceeding 50 kWh each. Each stationary battery array shall be spaced a minimum 3 feet from other stationary battery arrays and from walls in the storage room or area. The storage arrangements shall comply with Chapter 10. www.core-eng.com georgia new jersey . massachusetts . texas. missouri . florida . north carolina . washington arkansas california pennsylvania CORE STATES MPTAINUIZIN NW/MINIMUM GROUP Response: Exception #2 in CFC Section 608.2.3 allows Listed Pre -Engineered systems to have higher listings than 50kWh, up to 250kWh. This system is a UL listed assembly, and the installation manual proving that has been provided with this resubmittal. 14. Provide information on how class and division and location was determined. California Electrical Code (CEC) Section 500.4 Response: As -Built documents of the Methane Processing area show classified areas per CEC Section 500.4. We have included these with our resubmittal. 15. Get approval from MEP City of Newport Beach Response: Electrical has approved, Mechanical and Plumbing are not required. 16. Detail and specify listed fittings, locations, and procedure for installation, at hazardous locations. CEC 500 and 501. Detail and bubble locations on riser diagrams, this include all voltages. Response: This request was made by Electrical, and approved with the last submittal. We added the required info on Detail 7 Sheet 4.0 with last submittal. 17. Indicate distances to property lines and buildings. Response: See updated sheet 2.0 for dimensions from BESS to property lines and building. Feel free to contact me directly with any questions or concerns. Respectfully, Cheree Naes Project Coordinator Core States Group 4240 E. Jurupa St. Ste.402 Ontario, CA 91761 909-471-1895 www.core-eng.com georgia . new jersey . massachusetts . texas. missouri Florida . north carolina . washington . arkansas . california . pennsylvania 1ks�� LA vilViCflc/k FIXTURE. 75 WATT MERCURY VAPOR. STANCHION MOUNTING ENCLOSED AND GASSIIFTED WITH HIGH PF BALLAST (1 GLOBE, GUARD AND 30 CROUSE HINDS LAN OR EQUAL. 1 1/2. CONDUIT. TO LONG WITH 2 /12 AS INDICATED ON PINS CONDUIT FRTRD AS REQ'D 1 1/2' STANCH/ON MOUNT LIGHT POLE DETAIL NEVI 4' WF PIPE SUPPORT PIPE SUPPORT AT 2 PLACES -BOLT LIGHT FIXTURE TO NTS LEGEND LIGHT POLE • GROUND WELL • EXOTHERMIC WELD - - GROUND WIRE UNDERGROUND CONDUIT NOTES. EXPOSED CONDUIT 1. REF SHEET E-1 FOR CONDUIT AND WIRE SPECIFICATIONS. 2. ALL EXOTHERMIC WELDS TO BE MADE WITH THE PROPER SIZE MOLDS AND LOADS. 3. ALL GROUNDING TAILS TO BE ENCASED IN 3/4 SCHEDULE 40 PVC SLEEVES TO EXTEND MINIMUM 6' ABOVE FINISH CONCRETE. INSURE THAT THEY ARE INSTALLED PLUMB. 4. CONNECTIONS TO EQUIPMENT TO BE BOLTED TIPS 5. INSTALL PHOTO -CELLS FOR LIGHTS ON TOP OF PANEIBOARD LP-1. INSTALL H.OA SWITCHES FOR LIGHTS AT THE GATE. MOUNT SWITCHES ON 6' CHANNEL AT +4' ABOVE GRADE. 6. AREA BELOW GRADE IS CS ASSMIED AS CLASS I, DIV 2. ALL WIRING IN THIS AREA SHALL COMPLY WITH SECTION 501 OF THE LATEST EDITION OF THE NEC. ALL CONDUITS PENETRATING FINISH GRADE SHALL BE FH ICU WITH SEAL -OFF FITTINGS. 7. AREA WITHIN 60' RADIUS OF PROCESS EQUIPMENT IS CLASSIFIED AS CLASS 1, DN 2. ALL WIRING IN THIS AREA SHALL COMPLY WITH SECTION 501 OF THE LATEST VERSION OF THE NEC. 8. ALL ELECTRICAL PANELS, RACKS, ETC. SHALL BE FACTORY TREATED WITH CORROSION RESISTANT PAINT FOR SEVERE MARINE ENVIRONMENTS. ALL EXPOSED UNISTRUT TYPE SHALL BE FACTORY GALVANIZED. ALL CUT ENDS SHALL BE PAINTED WITH APPROVED GALVANIZE PAINT. FRYSMM memannopmenn MOOR ON =KW* EXTENTS OF CLASS 1, DPI 2 CLASSIFIED HAZARDOUS LOCATION RP SECS) SEE DETAIL TIISHT 480V MCC SEAL ALL BELOW GRADE CONDUITS ENTERING PANEL. ETS SEAL 3/4'C, 2112 3J4'C, 4 /12 fJ 20 AMP 3/4'C, FOR CHILLER PACYACE _ 1t13G 2 TO 3'C,3 40,PAINEL /6 HP (SEE NOTE 6) (4) 1' C.O. STUB -OUTS Y 3/'r ry 1' C.O. STUB-OUT(LP41_5'C, )2/12 ` 3/4'C 4 /12 t I(TO MCC) i3/4'C 3) /14 TRANSF./PANELBOARD LP1 i (iiOO /V PHOTOCELL CKT LPT-5 CIO*I \ PHOTOCELL CLP1-3 FLAME SAFEGUARD ♦ H /4/0 �6 ' / MP CHIL_ED WATER PUMP 1 HP, 480V MP 2 CHI WATER PUMP i H 480V / iSBURIER DRIVE MOTOR 30 1P. 480V 3/4'C. 7 /12 ,I i ___ (TO MCC) 1'C, 3/6, 1 0/ i-- - 3/4'MC (TO MCC) (TO MCC) EXTENTS OF CLASS 1, DN 2�� CLASSIFIED HAZARDOUS LOCATION MAIN CONTROL PANEL SEAL ALL BELOW GRADE CONDUITS ENTERING PANEL �T3b4C gg/�12 LIGIfO11G PANEL x i SEE NOTE 5 r� r MOUNT UGNT FROM H2S GAS SUPPORT /4/0 BLOWER /1 FANMOM4 1/4FP, 60V BLOWER /1 CRC PULP y,Hp, 46or 3/4'C, 2/12 SEAL FLAME SCANNER (+20) IGNITOR (+20') 4 0 COPPER GROUND GRID AIIN 24' BELOW FINISH GRADE) JUN 1 4 2CO2 S BLULT GROUND ROD & WELL SEE _. _. _._._._ -.-.- _.- _-_ _ 4DEfAIL 1. P;HEET E-3 TWO H.OA SWITCHES FOR LIGHTING CIRCUITS LP1-3 & LP1-5 C-H EDS 21273 2 AWG GROUND TO FENCE POST USE BURNDY GAR SERIES CLAMP (TIP 8 PLACES) EXOTHERMIC WELD (TYPICAL) ,pe NO. 96035 E 6/13/01 AS BUILT D 7/20/01 ADD CHILLER CH-1, EXCH E-1 C 8/20/90 AS BUILT B 10/31/2I REV PER CRY PLAN CHECK NOTES A 6/3/97 RE -ISSUED FOR PLAN CHECK DRAWN RWB HOAG MEMORIAL HOSPITAL PRESBYTERIAN ✓SG DATE 6/2/97 ART BEACH CALIFORNIA JOG°® SULFUR TREATMENT SYSTEM JOG APPROVED POWER WIRING & GROUNDING 'SG APPROVED CONDUIT & WIRE LAYOUT RNB IASI UPDATE P\, yV wOADVII,..a., 7,17orn - 06n4/7002 HEW CAD FILE: WADE/ REIN DATE DESCRIPTION REVISIONS BY 041 APP SCALE HOOBS—BANNERMAN ENGINEERING, INC. "M+G Na REV CERRITOS, CAUFORNIA 196035-E-04 E CITY OF NEWPORT BEACH FIRE DEPARTMENT Life Safety Services 100 Civic Center Drive I P.O. Box 1769 I Newport Beach, CA 92658-8915 www_newportbeachca.gov 949- 644-3200 PLAN REVIEW CORRECTIONS Plan Check No. 1720-2019 Project Description Energy Storage System Project Address 1 Hoag Drive Reviewed By Todd Letterman CFPS, CET, Fire Plans Examiner FNS Prevention Group tletterman@nbfd net (951) 691-7993 Date Comments Issued 8/12/19/10/8/19 Provide written responses to all corrections. Clearly indicate any necessary changes by using Bubble and delta on plans. 1. Provide construction documents in accordance with California Fire Code (CFC) Section 608.1.2. 2. Provide a hazard analysis per CFC Section 608.1.3, 608.1.3.1 and 608.1.3.2 3. Indicate ratings of all separations. 4. Indicate maximum allowable quantities per CFC Section 608.3 5. Indicate the battery storage system comply with UIL 1973 and UL 9540 per CFC Section 608.4.1 Per 608.6, this isn't 6. Indicate a type of Energy management system per CFC Section 608.4.3 required for lithium 7. Indicate battery chargers per CFC 608.4.4 ion, but might get 8. Indicate the listings for the inverters per CFC Section 608.4.5 k report from Tesla just 9. Indicate compliance with Thermal runaway per CFC Section 608.4.7 in case. 10. Indicate that the room has adequate fire suppression system installed per CFC Section 608.5.1 11. Is smoke detection provided within the room per CFC Section 608.5.2? 12. Indicate if there is a gas detection system per CFC Section 608.5.4 13. Indicate per CFC 608.2.3 stationary battery arrays. Storage batteries, per -packaged stationary storage battery systems and pre-engineered stationary storage battery systems shall be segregated into stationary battery arrays not exceeding 50 kWh each. Each stationary battery array shall be spaced a minimum 3 feet from other stationary battery arrays and from walls in the storage room or area. The storage arrangements shall comply with Chapter 10. 14. Provide information on how class and division and location was determined. California Electrical Code (CEC) Section 500.4 15. Get approval from MEP City of Newport Beach 16. Detail and specify listed fittings, locations, and procedure for installation, at hazardous locations. CEC 500 and 501. Detail and bubble locations on riser diagrams, this include all voltages. 17. Indicate distances to property lines and buildings. 2 Sou 0 Mltlga0pe Scheme81 - 1 MNlptbn Scheme •2 MNIpt10n Scheteg3 Mitigations Scheme 04 4 Mitigation Scheme PS - Potential Haan Severity ' Ukelhood Hazard Risk Hazard Number (HDjJ - Indicators Controls lizard fond Number (HCNa) Hand Risk Number (HRN� Indicators CaNmk Huard Control limber (HCN>a) Hazard Risk Manbe (NflNil indicators Hurd Control Controls Number )HO) Hazard Risk Manner Ndkatas Controls Corms Nunbe (HOL) ward Risk Numbr (HRNa) Indicators Controls Hazard Control Nunoe (HCNs) Hazard Pitt Numbs (HRNs) anal Solution Heed Hazard Risk Number IH ) Notes - - BKIRICALIWAIDS HEIIRIGLIWNDS eammuNA2ARDS ELECTRICAL WANDS BRC1RIGlHAWAIDS DC Block Short Grcuit 5 4 20 None Battery Cells are galvanically isohted through power electronics from DC Output to lout huh current 0.2 4 Vow 'Sensor to measurepod a oi.. voltage V Srlsor w/feetlback to MS. Power voltage drtrania divblr mow Verified fall below threshold Verfed through testing ICoi1°ted in Mitigation Scheme l) (Counted in Mingatim Scheme II None Every Powerpak is hued. using Colleted firer, at bath positive and negative inside DC combiner 0.5 2 2 Powerpack External Short Groat 5 4 20 None Battery Cells aregalvanically isolated IWmugh power electrons Rom DC Qatyut to limit fault current 0.2 4 Voltage sensor measure pod output voltage V.smsor w/feedbae to BMS. Power electronics disables output if voltage fall below threshold. Verified through testing 1 Counted in. Mitigation Scheme 11 1 Counted In Mitigation Scheme l) None Every Dot is fined, wing UL fisted fuses, at bath pozitiveand negative terminals inside the Powerpack pac 0.5 2 2 Pod ErteNl Short Oront 5 3 15 None Battery Ceps areplvniolN isolated through power electra,s from DC Output totorso[ faun current 0.2 3 Voltage Sensor measure pod output voltage mV-sear w/fenahar ckto BMS. Power electronics divblr output If voltage fall below threshold. Verified through testing I counted In Mitigation Scheme ll 1 Corned in Mitigation Scheme l) None Every pod isued, Cuing M.fisted fines, at both positive and negative terminals inside the pow t eon: 1.5 1.5 Battery Module Hard Start Grtut 5 2 SO None Charge Interrupt Device (OD) is an intemNtleviceinside Me cell that rill activate when Men internal gas pressure inside the cell rises. Verified through testing 0.7 ] No^e Every cell is individually (medal both the positive and negative terminals. Mthe event da battery module snot Are. the fuses will Wen. 0.0 2.8 2.8 Cell Internal Short Grcuil (elm- Thermal Ru^awaY) d 5 20 Norw Cell supplier manufacturing line quality and pears anon[ 0.9 18 None Every Cell is individually and tested prior to be being assembled immabattry module. 0.3 5.d Voltage Sensor to measure brisk sod tage V-Sensor w/feedback to BMS. BMS alplhrbns detect for intmW cell short Mcuts antl1.296 prevent charging if detected. 0.6 124 None Every cell is individually fused at both the positive and negative terminals. o the event ofa hard inter, shed Moot the fuzes will Wen preventing parallel cells from feeding energy into the short rircurt. 0.4 1.296 Over Voltage Overcharge (DC Bin Lehr) 5 6 30 None Battery Cells are galvanically isolated through power electronics from DC Output 0.1 3 Vohap$ensor tomeasure pod VSmsor w/feedbackto Beds. Power dertrmir disables output HwlaBe rises above threshold. Verified through testing 0.3 0.9 0.9 Over Current Overcharge la Bin Level) 6 30 None Battery Cells are gahanirally isolated through power electronics from DC OutPul 0.1 3 None Power electronics have a toed power capability and can therefore only accept a lindted amount ofcurrent 0.1 0.3 0.3 Over Voltage Over Charge (Brick/ module Leval) 5 3 15 Nee Charge Interrupt Devoe (OD) is an internal device inside the cell flat vrill activate when then internal gas pravme inside [heed' rises due ovrcharging Verified through Testing 0.] 10.5 Voltage Sensor to measure brisk voltage V-Sensor w/feedback to BMS. Software protection divblr changing if cells are above threshold. Verified Waulgh trtin8 0.3 3.35 Hardware voltage comparator to measure brick voltage V<amPavlorw/ feedback to MS Hartlwar<rrrlim divblr charging if cells are above threshold Verified through tutu, 0.2 663 Volta8e 5msorro measure nodule voltage V-Sensor w/feedback ta BMS. Software protection drsables charging is above threrfgld VrMed thrwgM1 testing 0.3 6189 Voha8e5msorro sure nodule mead a V<amParrtorw/feedback t0 BMS Hardware Prmectim disables changing H module is above threshold. 0.2 0.03]8 603]8 Highligfited portions are part at Energy Management Slstem Over Current Over Charge (Brick / Module Level) 5 15 Hone Charge Interrupt Device (CID) is an internal device inside the cell Mal will activate when then internal gas pressure inside the cell rises don overcharging. Verified through testing 10.5 None N< Power electronics have a foes power capability and theelor<are incapable pa providing current for ve an or current over Marge 0.1 ].OS Sm HighliEhted portionsare partof Energy Management System Over Voltage Over Charge (Cell Leal) 5 3 15 None Charge Interrupt Licorice (CIO) is an intemal device inside the cell that QM activate wlsen then internal gas pressure Inside the cell rises due overcharging Verified through erting 67 10.5 Voltage Sensor to measure brick voltage V-Sensor w/feedback to MS. Software protection divblr charging if cells are above MrcsM1dd Verified though testing 0.3 115 Hardware voltage cmtparaor to measure brisk voltage St -comparator w/ feedback to 13MS. Hardware prrmtion disables charging H cells are above threshold Verified through h., 0.2 663 0.63 Highlight. portions are part of Energy Management System Over Current Over Charge ICNl Level) 5 3 15 None Charge Interrupt Desire (OD) san mat device inside the cell that will activate when then internal gas pressure inside Me cell rises due overcharging Verified through testing • 0.7 10.5 None Every cell is individually fused at both the positive and negative terminals. M Me event afa hard internal short circuit Me fines will Wen preventing pamllN cells from feeding energy intone short circuit 0.4 4.2 None Power elettronr have power rozpcapabilityand therefore are incapable of providing mwgilcuent fee an over anent overcharge. 0.3 126 1.26 Highlighted por0ons are part of Energy Management System Over Discharge (DC Btu Ieoel) 3 3 9 None Battery Cells are gaIse nirally isolated Mrwgh power electronics horn DC Output 0.1 0.9 es Over Discharge (BriM/Module level) 3 3 9 None Charge Interrupt Device (OD) is an internal device inside the cell that will activate when then internal gas prrsureinside Me cell nixes due over discharging Verified Mrwgh [rung 0.] 6.3 Voltage Sensor t eawre brick °r°e08 V-smsorw/feedback to EMS. Software pnrrtion Ambles dischargingtRdd are below threshold Verified through testing 0.3 189 Hardware voltage comparator to measageure brick voltage below Vcobparatar w/ feedback to MS Hardware protection divblr discharging ifcNk are tbeslold. Verified through tem^g 0.2 0.378 Voltage Smwr to measure module eavoltage VSensor w/feedback to bMS Software protection divblr discharging if is B threshold. Verified through testing 0.3 0.113d 0.1134 Over Discharge (Cell Level) 3 3 9 None Charge Interrupt Device (OD) is an internal device inside the cdl that wi0 actintexhm Men internal gas pressure inside the cell rises due over discharging Verified Mrwgh testing. 0.7 6.3 Voltage Sensor to measure brisk f°wlWe V-Sensor w/feedback to BMS. Software protection disables tlisWrginBilcelk are below threshold Verified Mr.., testing 03 ]89 Hardware voltage comparator to measure brick voltage below Vcwnpararor w/ feedback to BMS Mrdware protection disables disdarglrr if cells are threshold Verified through Costing. 0.2 0.3]8 0.37e THERMAL HAZARDS 3HBWlALHA2MD5'INBlgAEWARDS INBeAItI WIZARDS: - THERMAL WARDS Spontaneous Single Cell Thermal Runaway w/PolmWlfr External Pro' fir Icoch ] 5 35 None Every hanery cells in certifies to M. 1642ro more the cell thermal runaway not result in projectiles 0.2 7 None rUS Conduct passive propagation rntarce testing in accordance with 19]3 and internal test standards, ensure re single cell runaway does torwt spread to neighbour cells. 0.2 lA None steel Battery ells are endosed ina ry c pod to nest heat transfer to additional.. vPeds 0.3 642 enginered dreclMrmal None pathways pa Steel batty Pods have an exhaust pathway to runaway gases out the top of Me E55. Flout ko Ka Prevents build up ofinternA pressure Mat cola resuh in ESS rupture. Verified through testing 0.3 0.126 None al of the battery pods are red inside of a steel enclosure to resist Me heat Vamfr roue outside environment. 0.4 0.0504 60504 • External Fire up to4E0 kW (K 20 min No../ 4 26 None All of the banery pods are stored inside of a steel endmureto resist the heat transfer from the environment to the boned pods 0.4 9.6 None Banerycells are enclosed In a steel p0tl to further resist Me heat transfer horn the environment to the cells. 04 3.84 Nene Battery pack has ma the pass criteria of the U119)3 External Fre Tat Tales has conducted more aggressive (has. an heat flux) external fire testing to show Mat calk do not go into thermal runaway for this level exposure. 0.1 0.384 0.384 External Fire up t0400 kW (> 20 min Fmopre) 3 10 None Ag 0f the boned Pods are stored inside of a steel enclosure toresist ale hertb transfer from the environment. the batted pods 0.4 ).2 None Battery cell are enclosed Ina steel pad to further rm... heat transfer from the environment to the cells. 0A 288 None Steel battery pods have an engineered abaust pathway to direct thermal runaway gases out the top afthe E55. Exhaust6 Pathways also prevents buildup of internal pressure that could result In E55 rupture. Verified through testing 0.6 3.)18 1.728 Internal Component Failure Fire 5 3 15 None Battery calk are encosed m a steel pod tofurther rust the heat transfer in the event of a component fire in the main batted cabinet 0.6 6 None Ba aery pack has met the pass enter.. of the UL 1973 External Fire Test Tale has conducted more aggressive (based on heat flux) external fire testing. show that cells do not go into thermal runaway for this level exposure. 0.1 0.6 0.6 koperableCoding SYrtem 5 3 15 Temperature ensas to measure cell tcmperetuna Temp Sensor w/feedback t0 BMS.Temp BMSderates battery 0utpm power, and heat generatien, i/ cell tempM.res sMabwe threslcld Verified througM1 rating. 0.8 12 Temperature ensorst0 measure tale temperature BM555NII tls46leopsor back to BMS operation if t temperatures get above threshold. Verified through testing 0.3 3.6 T� pera.resensorsm measure ecNk temperatures, Temp Sensor w/feedWck to BMS. Hardware temperature based taus will disable opebtbnircell temperatures get above threshold. Verified through testing 0.2 0R 0.J2 fuolam leak 5 3 15 None Every cooling system is positive pressure leakterted at pressure above the maximum Pump output pressure. 0.6 9 None Every battery cells in certified to UL 1642 to ensure that cell thermal not result in runuwaY billprojectiles 0.2 1.8 None Conduct passive PrOpaR0on resistance testing in accordance rwith UL 1973 and internal test ndar.. to ensure single cell runaway does not spread prea neighbour cells. 0.2 036 None Steel batterypods Iowan engineered exhaust pathway to direct Perna, runaway and other Rea red thelop of the ESS Exhaust pathways also prevents build up of internal pressure that could result in E55 rupture. Verified through testing 0.6 0.21fi 0.36 MECHANICAL HAZARDS MECHANIC/UNA/ MDS MCaUM[W. HAZARDS M1104.411G1LHB2AlD5 .NEAP /IL.W12lYm5 Inspect(<=1W) ] 9 9 None Battery ce sore enclosed in a steel pod to !knit mechanical intrusion. Ercnsure tested to UL 19731mpact Tat and showed nosigns of mechanical damage«electrical shorting 0 0 0 Impact Is1D) 6 3 10 None Battery cells are enclosed in a steel pod to resist mechanical intrusion. Enclosure tested. UL 1973 Impact Test 0.7 12.6 hone Battery pods stored inside ofa steel endoune with gaps between pod and oMen wall to resist mechanical intrusion. 0.7 682 8.82 Battery pack pop 5 4 20 Noe Battery cell are enclosed in a steel Co d to resist mechanical intrusion. Enclosure tested t0 U11973 Impact Test 0.7 10 None Battery pods stored inside of a steel enclosure with gaps between pod and aver wall. resist mechanical9P intrusion. 0.7 9.8 Shock During Shipping 2 10 20 None Battery modules are enclosed in a steel pod to endure mechanical loadng Shock testing up to 15g, slaws nosigns of mechanical damage or electrical shorting 0.1 2 2 Vibration During Pipping 2 10 20 None Battery modulo are enclosed in a steel pad to endure mehadcal loading. Vibration testing slows no signs of mechanical damage or electrical shorting 0.1 2 /MUNK HAZARDS., NATURAL WIZARDS. NATURAL HAZARDS "7NRRANRHAZARDS NATURAL HATAM5: NATURAL fWARDS- Vibration 6 2 12 N000 Battery cells are securely mounted . mechenicallaatlngor cell and limit mehani.I deflectionof module. O.J 8.4 None Selsmk bracing mounted in packs installed nsblletl in areas with high seismic activity. Tested to IEEE 693 and achieved a 'High Performance level' D2L.L 1.68 IEEE 69316gh Performance (l.08ZPA 2%Damping) Level Achieved Conductive fluid Ingress(External Flooding) 5 15 Noneinches The 100 of the mounting pad for omd0or installations shall be 6 above expected flood Notion, 0.8 12 Nonetested Powerpark enclosure is rated and to NEMA3R 0.8 9.6 None Internal batted pods rated and tested tot �)'bmersien 03 288 288 Ugidrdng(0ke.) 7 2 16 None Batted pack enclosure is made of 12 gage steel which acts as a faraday cage protecting the cells.9.8 0.7 9.8 No specific requirement for lightning protection systems, in accordance with NfPA JBo, in New Yak Building Code. owner may coi.der the insbllauon of a NEPA 780 complaint lightning protection system, as needed, as part 0f the overall design and installation process Lightning(Indirect/ 5 3 15 None PR metal components are grounded to earth using a 6 AWG wire to grounding rod inthe event da indirect IigM1tringimke a3 4.5 None Elec.. components are pr.ected with surge prdection circuitry in to event of a indrmt IighMing strike. 0.7 3,15 3.15 - ' SYSTEM HAZARDS s- SYSTEM NAT/NM , 5Y51BAHAZABD5 ST5f9ANAZARDS SnIBA HAZARDS' SYSTEM HAZARDS Maintenance Pasonn8 Exposedto Nigh Voltage 7 Special tools /key required to access bcations with NV present .5 28 None Tech safe connectors used for al Pawerpack high witage<onne.ons 0.3 8A 8.4 I 1 S� CSA GROUP'" Letter of Attestation Document: 70196542 Master Contract: N/A Project: 70196542 Date Issued: June 28, 2019 Issued to: DNV GL PVEL LLC 1360 5th Street Berkeley, California 94710 United States Attention: Michael Mills -Price CSA Group hereby confirms that it has completed an evaluation of Witness customer method of evaluating thermal runaway fire propagation in BESS, Model: Powerpack Generation 2 by Tesla Inc. CSA Group hereby attests that the products identified above and described in Document 100118434-HOU-R-02-E Issue E dated 4 June 2019 complies with the following test plan, to the extent applicable: Powerpack IFC Testing Instrumentation Map and Setup — Test 2 (October, 2018) Issued by: Anuj Amin CSA Group THIS LETTER OF ATTESTATION DOES NOT AUTHORIZE THE USE OF THE CSA MARK ON THE SUBJECT PRODUCTS. QUOTATIONS FROM THE TEST REPORT OR THE USE OF THE NAME OF THE CANADIAN STANDARDS ASSOCIATION AND CSA GROUP OR ITS REGISTERED TRADEMARK, IN ANY WAY, IS NOT PERMITTED WITHOUT PRIOR WRITTEN CONSENT OF CSA GROUP. DOD 507.10 Rev 2018-11-12 Page 1 DNV•GL Live Fire Test of Tesla Powerpacks Tesla, Inc. DNV GL Doc. No.: 10118434-HOU-R-02-E Issue: E; Status: Release Issue Date: June 4th, 2019 IMPORTANT NOTICE AND DISCLAIMER 1. This document is intended for the sole use of the Customer as detailed on the front page of this document to whom the document is addressed and who has entered into a written agreement with the DNV GL entity issuing this document ("DNV GL"). To the extent permitted by law, neither DNV GL nor any group company (the "Group") assumes any responsibility whether in contract, tort including without limitation negligence, or otherwise howsoever, to third parties (being persons other than the Customer), and no company in the Group other than DNV GL shall be liable for any loss or damage whatsoever suffered by virtue of any act, omission or default (whether arising by negligence or otherwise) by DNV GL, the Group or any of its or their servants, subcontractors or agents. This document must be read in its entirety and is subject to any assumptions and qualifications expressed therein as well as in any other relevant communications in connection with it. 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Except and to the extent that checking or verification of information or data is expressly agreed within the written scope of its services, DNV GL shall not be responsible in any way in connection with erroneous information or data provided to it by the Customer or any third party, or for the effects of any such erroneous information or data whether or not contained or referred to in this document. 4. Any energy forecasts, estimates, or predictions are subject to factors not all of which are within the scope of the probability and uncertainties contained or referred to in this document and nothing in this document guarantees any particular energy output, including factors such as wind speed or irradiance. Strictly Confidential Private and Confidential Commercial in Confidence DNV GL only Customer's Discretion Published KEY TO DOCUMENT CLASSIFICATION For disclosure only to named individuals within the Customer's organization. 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DNV GL - Document No.: 100118434-HOU-R-02-E, Issue: E, Status: Release Page iii www.dnvgl.com Report title: Customer: Live Fire Test of Tesla Powerpacks Tesla Inc Contact person: Saad Tanvir Date of issue: 4 June 2019 Project No.: 10118434 Proposal Reference: Document No.: 100118434-HOU-R-02-E Issue/Status E/Release DNV GL - Energy KEMA-Powertest, LLC 5777 Frantz Rd Dublin, OH 43017 Tel: +1-614-761-1214 Task and objective: This report presents the results of testing performed by DNV GL and Rescue Methods on Tesla Powerpacks intended to satisfy code officials and allow for permitting of large scale systems Prepared by: Nick Warner Senior Test Engineer Verified by: Approved by: Ben Gully Senior Environmental Consultant Anthony DeRose Senior Engineer ❑ Strictly Confidential ❑ Private and Confidential ❑ Commercial in Confidence O DNV GL only ® Customer's Discretion O Published Keywords: Fire test, battery, energy © 2019 DNV GL Energy Insight, LLC All rights reserved. Reference to part of this report which may lead to misinterpretation is not permissible. A 21 January 2019 Draft B 3 March 2019 Draft C 8 April 2019 Release Draft D 17 April 2019 Release E 4 June 2019 Release N. Warner N. Warner N. Warner N. Warner N. Warner B. Gully B. Gully B. Gully A. DeRose A. DeRose DNV GL — Document No.: 100118434-HOU-R-02-E, Issue: E, Status: Release Page iv www.dnvgl.com Table of Contents EXECUTIVE SUMMARY 9 1 INTRODUCTION 10 2 TEST SETUP 10 2.1 Test Plan 10 2.2 Equipment and Sensors 13 2.3 Test Setup - Outdoor Installation 15 2.4 Sensor Placement 18 3 OBJECTIVES 20 4 RESULTS 20 4.1 Outdoor Installation Test 20 4.1.1 Temperature Data 21 4.1.2 Heat Flux Data 30 4.1.3 Gas Data and Venting Pictures 34 5 CONCLUSION 41 DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page v www.dnvgl.com Figures Figure 2-1 Top view of test layout 10 Figure 2-2 Cartridge heater positions within the initiating module 11 Figure 2-3 Front view of the Powerpack initiator 12 Figure 2-4 Rendering of open Powerpack fully populated with initiator pack thermocouple placement 13 Figure 2-5 Gas analysis setup 14 Figure 2-6 Signal breakout board, NI cDAQ and control laptop 15 Figure 2-7 Wide view of test setup from the south with heat flux gauges 15 Figure 2-8 Tight view of Powerpacks with wall thermocouples 16 Figure 2-9 East wall sensor diagram 17 Figure 2-10 North wall sensor diagram 17 Figure 2-11 Target pack module internal thermocouple setup 18 Figure 2-12 Target pack module external thermocouple setup 18 Figure 2-13 External sensor placement through initiator Powerpack 19 Figure 2-14 Heat flux gauge external setup 19 Figure 4-1 Ceiling temperatures above DUT (fire side) 21 Figure 4-2 North wall, fire side temperatures 22 Figure 4-3 North wall, back side temperatures 22 Figure 4-4 East wall, fire side temperatures 23 Figure 4-5 East wall, back side temperatures 23 Figure 4-6 Fire from DUT on east wall 24 Figure 4-7 Temperatures inside the initiating module in DUT 25 Figure 4-8 Temperatures in the adjacent modules to the initiating module 26 Figure 4-9 Additional DUT temperatures 26 Figure 4-10 DUT initiator module external temperatures 27 Figure 4-11 Temperatures inside module 7 of neighboring Powerpacks 28 Figure 4-12 Temperatures on the outside of module 7 of neighboring Powerpacks 28 Figure 4-13 Temperatures inside the module 16 of neighboring Powerpacks 29 Figure 4-14 Temperatures on the outside of module 16 in neighboring Powerpacks 29 Figure 4-15 East wall heat flux 30 Figure 4-16 North wall heat flux 31 DNV GL — Document No.: 10118434-1-IOU-R-02-E, Issue: E, Status: Release Page vi www.dnvgl.com Figure 4-17 West neighbor heat flux 31 Figure 4-18 Heat fluxes in front of unit at 8 and loft 32 Figure 4-19 Heat fluxes in front of unit at 15 and 20ft 33 Figure 4-20 Heat fluxes to side of unit at 4, 8 and 12ft 33 Figure 4-21 Test during peak heat release rate 34 Figure 4-22 LEL during test 35 Figure 4-23 Hydrogen gas concentration during test 35 Figure 4-24 Flammable hydrocarbon gases during test 36 Figure 4-25 Halides and hydrogen cyanide during test (all in confidence range) 37 Figure 4-26 Benzene and Toluene levels during test (all in confidence range) 37 Figure 4-27 Several seconds after initial gas venting 38 Figure 4-28 Continued gas production 39 Figure 4-29 Smoke and gas emanating from unit moments before energetic gas expansion 40 Figure 4-30 Combustion seconds after the door opens fully 40 Figure 4-31 Pressure inside DUT modules 41 DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page vii www.dnvgl.com List of abbreviations BESS CO CO2 DAQ DNV GL DUT FTIR IFC HCI HCN HF LEL N FPA NMC PPM Battery energy storage system Carbon monoxide Carbon dioxide Data acquisition system DNV GL Energy Insights, LLC Device under test. In this case, DUT describes the Powerpack that houses the initiating module and is also referred to as the initiating Powerpack or initiator Fourier transform infrared gas analyzer International Fire Code Hydrogen chloride Hydrogen cyanide Hydrogen fluoride Lower explosive limit National Fire Protection Association Nickel manganese cobalt oxide battery Parts per million DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page viii www.dnvgl.com EXECUTIVE SUMMARY On October 17th, 2018, DNV GL conducted large scale fire testing for Tesla Inc on their Powerpack Generation 2 (Powerpack) energy storage system (ESS). The testing saw four units one fully populated test pack (16 modules) and three "dummy" packs with only two modules, placed at typical installation spacing, subject to fire originating from within the test pack. All live modules were charged to 100% SOC. To achieve this, multiple cells in the center module of the test pack were sent into thermal runway to ensure a propagating fire. This fire spread through the initial module, creating a fire which ultimately escaped the module. The module burned for a period of time before stopping, likely as a result of consuming its fuel. Following this cessation of combustion, heat transfer ultimately allowed the module fire to eventually propagate to adjacent modules, and ultimately the full pack. Multiple takeaways with respect to fire code requirements were observed, and are listed below: • Though the test pack was completely consumed, the fire did not propagate to adjacent packs at the test spacing, which was 4" on the sides and 2" to the pack on the back. • On the other side of the test pack, 18" away, a two-hour fire resistance rated wall saw no breaching. Additionally, no adverse temperatures on the back side of the wall were observed. • The ceiling, which was comprised of two layers of 5/8" Type-X drywall also saw no breaching. • Heat flux measurements around the test setup were taken during testing. Heat flux in the egress pathways were observed and are provided with timelines. • No water or other suppression was applied to the system during testing. The system was allowed to burn itself out completely which resulted in the end of test. 20' 1 INTRODUCTION Tesla Inc has retained DNV GL to perform large scale fire testing on their modular, large scale energy storage product, the Tesla Powerpack, to satisfy code requirements specified by the 2018 edition of the International Fire Code (IFC) and the 2018 NFPA Fire Code Chapter 52. Chapter 12 of the International Fire Code lays out a number of requirements for energy storage systems in the built environment. 2 TEST SETUP 2.1 Test Plan The test plan, developed by Tesla, is shown as an overview below in Figure 2-1. This layout, intended to demonstrate the ability of systems at this spacing to resist pack to pack propagation, was also intended to determine the effectiveness of a two hour rated fire wall to resist the heat and even flame impingement. East Wall Northwest Neighbor Top View @s• • Heat Flux sensor @15' ID20' Figure 2-1 Top view of test layout The initiating Powerpack, shown in red above, is populated completely with 16 modules, the seventh from bottom of which is fitted with a number of cartridge heaters placed amongst the cells which are intended to drive the cells into thermal runaway (Figure 2-2). To ensure a complete failure of the module via cell to cell propagation, Tesla has placed numerous heaters within a grouping of cells with a backup location should the primary location fail to achieve propagation. When the test is performed, these heaters are run in a pre-engineered cycle to increase the likelihood of propagating failure. DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 10 www.dnvgl.com 0000000ee fl®0000� 000 410.0411410000 0 0000041• 0 0 00000000000 0000000Zee 0000004Meit 00000110See 000• : 00 00000 �s0 0000 :: 00000 600 000.® 000009004100 000o0l000ip9e€, l00000ee :qbr*: solos* : 0e 00000 - " CO ®®00410000 000000000 000000000 0000000000 O000000•000 900000090 Iii00000000 0009004106 .400000000 Heater Primary Location Secondary Location Figure 2-2 Cartridge heater positions within the initiating module Figure 2-3 shows the front view of the initiator Powerpack for testing. This unit contained a fan and radiator setup on the front door, but it was not operational for testing. Figure 2-4 shows a rendered view of inside the Powerpack with captions describing the placement of the 20 thermocouples inside the initiator unit. The modules are numbered from the bottom with module 7 being the initiating modules. 1 Throughout this document, the initiating Powerpack is also referred to as the device under test (DUT) or simply the initiator and refers to the initiating Powerpack itself as well as all modules within. In cases where a reference is made to the initiating module, it will be referred to fully as such. DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 11 www.dnvgl.com ;NNUN.N..N- wu..wN•w�n,L. .....uw N.�w ::a: LinsW M Mimi i7 .N. ::.wu. µ .::::Nu:.N' �'n'•NN•...N::w:::::.ui PillMiliMMLUMMII :Y !1®callO�1lli!�11l "MrIHIB 1I 1 .w.�. NNN....�M; .w.w.. rarigi ilSRI iiianifultmhfflimmunam in siiwaaaaeiaaealiaiaaaes._6 !!_!!®!•tRC-HEREIN J �aiaa��Ei sul�lgitudininiaffim —IEMl i qi linemsualmn Figure 2-3 Front view of the Powerpack initiator DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 12 www.dnvgl.com TC 18-19 —. TC 16-17 —I► TC 14-15 TC 12-13 —+ TC 10-11 TC 0-1, 2-3 '+ TC 4-5 --I' TC 6-7 -�► TC 8-9 —' Initiator Module Figure 2-4 Rendering of open Powerpack fully populated with initiator pack thermocouple placement Three target, or dummy, Powerpacks were placed around the initiating Powerpack with the intent of assessing internal temperatures within those packs as well as within the modules they housed. Inside the target Powerpacks, only module 7 and 16 are in position, with the remaining space left empty. Temperatures inside the packs and modules were observed with the intent of monitoring for adversely high temperatures in these neighboring systems. Additionally, should even a single cell within one of the target packs go into thermal runway, which would result in the production of smoke from a target exhaust duct, the test would be considered a failure for this spacing and setup. All live modules in the initiating Powerpack and in the target Powerpacks were charged to 100% SOC. 2.2 Equipment and Sensors To provide data necessary to assess deflagration hazards when installed inside rooms and spaces and to provide information generally on gases generated for the purpose of responding to AHJ inquiries, DNV GL measured a number of gases coming from the test using three different sensors. The primary sensor, who's air handling unit also provides temperature and humidity control as well as filtering for the other sensors, was the Gasmet DX-4000 FTIR (Fourier Transform Infrared) gas analyzer. As FTIR analysis is not capable of detecting diatomic gases, the sensor is fitted a with a crystalline oxygen sensor in the air handler and is supplemented by an MSA Optima-X catalytic bead LEL (lower explosive DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 13 www.dnvgl.com limit) sensor as well as a Hy -Scan 720E hydrogen sensor. The LEL sensor is propane calibrated and reports a 0-100% range while the hydrogen sensor reports a 0-5% hydrogen. The following gases were analyzed during testing: Water Vapor (H20, %) Nitrogen Monoxide (NO, ppm) Methane (CH4, ppm) Hydrogen Chloride (HCI, ppm) Benzene (ppm) Methanol (ppm) Hydrogen (H2%) Carbon Dioxide (CO2, %) Nitrogen Dioxide (NO2, ppm) Ethane (ppm) Hydrogen Fluoride (HF, ppm) Toluene (ppm) Propane (ppm) LEL (%) Figure 2-5 Gas analysis setup Carbon Monoxide (CO, ppm) Acetonitrile (ppm) Ethylene (C2H4) Hydrogen Cyanide (HCN, ppm) Ethanol (ppm) Oxygen (02, %) DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release www.dnvgl.com Page 14 Figure 2-6 Signal breakout board, NI cDAQ and control laptop In addition to the gas analysis. Numerous heat flux gauges, pressure sensors, and thermocouples measurements were collected via an eight port National Instruments cDAQ. These wires were sent to a custom built breakout board for ease of collection and wire management. The cDAQ was run from National Instrument's LabVIEW software. In addition to these measurements, numerous cameras were placed around the test setup including two thermal IR cameras. 2.3 Test Setup - Outdoor Installation Figure 2-7 Wide view of test setup from the south with heat flux gauges DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 15 www.dnvgl.com As Tesla currently aims to install systems outdoors, upon rooftops, and in open parking garages, the primary purpose of testing was to ensure a lack of pack to pack propagation based on the tested spacing of 4" between laterally adjacent units and 2" between the unit behind. As a secondary objective, Tesla sought to demonstrate the effectiveness of two hour -rated fire walls and to demonstrate a lack of other unforeseen effects when experiencing failure in open atmosphere. A large black room was constructed with double layer 5/8" Gypsum Type-X drywall as shown below. Per UL standards, the effectiveness of the wall was determined based on temperatures recorded on the back side. Figure 2-8 Tight view of Powerpacks with wall thermocouples Burn damage seen in Figure 2-7 and Figure 2-8 is a result of previous testing where the packs were briefly exposed to flame. Temperatures inside the packs and modules did not reach adverse levels and this previous exposure had no impact on this test. For additional reference, the back wall shown in Figure 2-8 is the North Wall, while the wall to the right of the units is the East Wall DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 16 www.dnvgl.com East Wall - Walls and ceiling are 2hr fire rated backed by wood studs spaced 16" apart. As shown 10 TCs are on the exposed side of the wall. There will be 10 TCs collocated with these TCs on the unexposed side. Key: -Schmidt-Boelter Total Heat Flue � -Type K Thermocouple (24 ge.) + Figure 2-9 East wall sensor diagram North Wall • As shown 8 TCs are on the exposed side of the wall. There will be 8 TCs collocated with these TCs on the unexposed side. Key: -Schmidt-Boelter Total Heat Flue � -Type K Thermocouple (24 ge.) -I- Figure 2-10 North wall sensor diagram To demonstrate walls with two-hour fire -resistance -ratings can withstand an event of this magnitude, and to collect as much useful data as possible, thermocouples were placed in vertical arrays along the walls as shown. On the east wall (Figure 2-9), starting at 3', thermocouples were placed every 12" up to the ceiling. This was done on both the fire side as well as on the unexposed back side, where the opposing side of the wall was drywalled within the appropriate bay between the studs, which were spaced a typical 16". On the north wall (Figure 2-10), a similar placement and construction was used, though the thermocouples started at 4' instead of 3'. The heat flux gauges were located colinearly within this instrument line at the appropriate heights. DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 17 www.dnvgl.com 2.4 Sensor Placement Thermocouples were placed through the target Powerpacks to determine the heat transfer into the units during the test unit's combustion. Two thermocouples were placed within each module in the ::•r::® oemmeloilmo North Powerpack West Powerpack Northwest Powerpack Figure 2-11 Target pack module internal thermocouple setup target Powerpacks. Two were placed internally (Figure 2-11) while a single thermocouple was placed on the exterior of the module directionally toward the initiator unit (Figure 2-12). West Powerpack i North West Powerpack North Powerpack Figure 2-12 Target pack module external thermocouple setup Four additional thermocouples were placed through the outer rack —but still within the enclosure —of the initiator Powerpack. These are shown below in Figure 2-13 along with the placement of the four pressure transducer probe inlets. Also shown in Figure 2-13, from the rear view seen on the right, is the exhaust plenum. This design feature allows gas generated inside the modules to be safely released. This is done by way of a flanged exhaust duct on the module which is seated tightly against a corresponding flange on the front of the plenum, which can be seen from the back of the figure as the elongated hexagonal shape running up the spine of the Powerpack. When gas is generated, this gas freely exits the module through the duct opening into the plenum, where is travels upwards and out a weather protected port on the top of the Powerpack. DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 18 www.dnvgl.com *TC 21 in pod 7 exhaust Figure 2-13 External sensor placement through initiator Powerpack Figure 2-14 Heat flux gauge external setup DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release www.dnvgl.com Page 19 As per Figure 2-1, a number of Schmidt-Boelter heat flux gauges were also placed to the front and to the side of the initiator pack. These water-cooled gauges were placed on stands at 4' elevation. All gauges were carefully aimed at the front center of the initiator pack. The gauges ranged from 10- 100kW/m2 based on expected heat fluxes at each distance. Though not pictured, one heat flux gauge was also placed in the back and side wall appropriately of the adjacent target packs. Shown in Figure 2-1 but not pictured, these gauges were placed at 6' from the floor. 3 OBJECTIVES The objective of the test was to demonstrate, via large scale testing by an approved laboratory, that the Tesla Powerpack, when subjected to internal thermal runaway sufficient to propagate module to module: 1. Does not pose a propagation risk to neighboring units or exposures based on the spacing observed in testing, even when no suppression or water is applied over the entire course of the event. 2. May be contained and sufficiently blocked by two hour fire resistance rated walls which do not show appreciable temperature rise on their back sides relative to the fire exposure. 3. Generate data via heat flux and temperature that allows for the modelling of thermal exposure from the unit for the purpose of assessing spacings necessary relative to exposures identified by relevant codes and standards language. 4 RESULTS 4.1 Outdoor Installation Test Testing was performed on the morning of October 17th, 2018. Weather was clear with temperatures in the mid 50s°F with winds out of the west-southwest blowing 15-20mph with gusts up to 25mph. These winds were blowing into and along the open side of the test area. Prior to testing, a final check of all data acquisition was performed along with a safety briefing with all personnel on site. Table 4-1 below shows the time of relevant events during testing. Cartridge heaters inside the unit were powered as part of a ten minute "pre -warming" period before which time they were turned to full power. During the initial combustion event, a single audible pop was heard during combustion, but the event failed to impact the DUT. Following cessation of the initial combustion event, the DUT sat idle for almost 90 minutes before the heat transfer within the DUT allowed the failure to propagate to neighboring modules. This resulted in a small deflagration event which succeeded in opening the already fire exposed front door of the DUT. Once the fire propagated to neighboring modules within the DUT, it burned one module at a time for approximately 45 minutes before reaching a point at which multiple modules began burning simultaneously and which resulted in a more violent conflagration. In the plots below showing the results, a blue vertical dashed line is shown in most figures indicating the first thermal runaway. A second red vertical dashed line is shown to indicate the first visible flame from the unit. DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 20 www.dnvgl.com Table 4-1 Test time stamps Event Time Time After mm (HH:mm) DAQ Start 11:17:50 DAQ Start First Thermal Runaway Heater Start 12:12 55 (0:55) N/A First audible event (thermal runaway)2 12:24 67 (1:07) 0 First visible flame (door open)3 12:42 85 (1:25) 18 (0:18) 2nd Module Ignition 14:14 177 (2:57) 110 (1:50) End of Test 15:43 266 (4:26) 199 (3:19) 4.1.1 Temperature Data 4.1.1.1 Ceiling and Wall Temperatures Temperature (°C) 1000 900 800 700 600 500 400 300 200 100 Ceiling Temperatures (Directly Above Unit) 50 2ft from wall 3ft from wall 4ft from wall Blue line represents initial audible event Red line represents first visible flame 'i ri r ' 7 !I ick 100 150 200 time (m) 250 300 Figure 4-1 Ceiling temperatures above DUT (fire side) It should be noted that throughout the results section, a number of plots show instantaneous, extreme data points which are out of sync with data in the set. These artifacts are sometimes a result of a split second, physical event, such as a strong gust of wind but more frequently are a result of instantaneous errors in the sensor or software which effect an entire 1 second data point. In 2 Shown as a dashed blue line in all plots 3 Shown as a dashed red line in all plots DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 21 www.dnvgl.com particular, these artifacts are present in the pre -thermal runaway portion of Figure 4-3 and during testing in Figure 4-5 at around the 225 minute mark. 1100 1000 900 800 0 700 E 600 Io n 500 E I— 400 300 200 100 North Wall Fire Side 4ft 5ft 6ft 7ft 8ft 9ft 10ft 11ft 50 40 10 0 -10 50 100 150 200 time (m) 250 Figure 4-2 North wall, fire side temperatures North Wall Back Side 300 4ft 5ft 6ft 7ft 8ft 9ft 10ft 11ft 0 50 100 150 time (m) 200 250 Figure 4-3 North wall, back side temperatures DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 22 www.dnvgl.com 1500 1000 m L a. E a, I— 500 Temperature (°C) 120 100 80 60 40 20 0 0 East Wall Fire Side 2ft 3ft — 4ft 5ft 6ft 7ft 8ft - 9ft 10ft - 11ft anti. 50 100 150 time (m) 200 250 Figure 4-4 East wall, fire side temperatures 2ft 3ft — 4ft 5ft 6ft - — 7ft 8ft - 9ft 10ft 11ft 50 East Wall Back Side 100 150 time (m) 200 250 Figure 4-5 East wall, back side temperatures 300 300 DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 23 www.dnvgl.com The figures above show temperatures recorded on the fire side and the back side of the drywall walls during testing. The ceiling above the device saw high temperatures as would be expected from an event directly below, however, it was the east wall, that nearest the DUT, which saw the highest fireside temperatures. This was a result primarily on the geometry of the unit and test setup, where the open door directed flames out of the unit towards the wall as well as overall proximity. An example of this is below, in Figure 4-6. Figure 4-6 Fire from DUT on east wall Though there were high temperatures on the fire side of the east wall, temperatures on the back side of the two-hour fire resistance rated wall remained safe, not exceeding 35°C, as shown in Figure 4-5 except for a brief instance where it was believed wind blew the fire around the wall. Despite being oriented away from the fire and with the exhaust hood pulling ventilation above, the fire side of the north wall saw higher than expected temperatures, likely as a result of roll over across the ceiling and of the westerly winds pushing heat back into the test area. Though one side of the test area was open to atmosphere and fire was directed that way, and though the exhaust hood with several thousand CFM of exhaust was above the DUT, temperatures on the fire side of north wall still reached nearly 600°C, as seen in Figure 4-2. Like the east wall though, the back side of the north wall saw temperatures raise less than 10°C above ambient at their peak, again providing confidence as to the ability of the two-hour fire resistance rated fire wall to protect adjacent rooms and areas from the high heat load. 4.1.1.2 DUT Temperatures Though visually the fire appeared intense, with internal temperatures briefly exceeding 1500°C4 at times, external temperatures failed to exceed half that, staying below 700°C. While internal temperatures in excess of 1000°C are common for lithium ion battery fires, data for the external temperatures on the unit show that was mostly retained inside the unit or, much like the visual flame, was directional. This is evident through high ceiling temperatures as well as east side wall 4 A number of plots later in this document show temperature artifacts between 2200 and 2250°C. This is the open circuit value of the TC and is an instantaneous (or permanent) sensor failure. These are frequently caused by temporary direct flame exposure or high temperatures and pressure which can cause mechanical stress. As these points are almost always instantaneous and non -continuous, it is believed these "measurements" are in fact errors in the dataset. DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 24 www.dnvgl.com temperatures, which exceeded 700°C or more while the north wall, despite heat roll over from the ceiling, stayed below 600°C. 2500 2000 (13 1500 a) a) a_ E 1000 Ia) 500 0 Tesla 0-3, Initiating Module, Mod-7 Init-mod-ctr Init-mod-ctr Init-mod-ext Init-mod-ext 0 50 100 150 time (m) 200 250 300 Figure 4-7 Temperatures inside the initiating module in DUT DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 25 www.dnvgl.com U °-- 1500 aD ID L a) Q E 1000 IF- Tesla 4-11 (Mod 6,4,2,8) 50 100 150 200 time (m) Mod-6.0 Mod-6.1 Mod-4.0 Mod-4.1 Mod-2.0 Mod-2.1 Mod-8.0 Mod-B.1 250 Figure 4-8 Temperatures in the adjacent modules to the initiating module 2500 2000 U 1500 w L ID ca L a) a. 1000 I- 500 Tesla 12-19 (Mod 10, 12, 14, 16) I Mod-10.0 Mod-10.1 Mod-12.0 Mod-12.1 Mod-12.0 Mod-14.1 Mod-16.0 Mod-16.1 50 100 150 200 250 300 time (m) Figure 4-9 Additional DUT temperatures DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 26 www.dnvgl.com Temperature (°C) 1000 900 800 700 600 500 400 300 200 100 Tesla Initiator External TCs Init-back-lower-ext Init-mod7-exhaust — Init-back-upper-ext Init-exhaust-outlet 50 100 150 200 time (m) 250 Figure 4-10 DUT initiator module external temperatures 300 4.1.1.3 Adjacent Powerpack Temperatures Near the end of the test, fire impingement on the thermocouple cables running from the north neighboring Powerpack resulted in shorting and open circuit failures, which show non -continuous and abnormally high values and ultimately fail at values of approximately 2200°C. All of these values are in fact erroneous measurements. Outside of erroneous failure values from the north neighboring Powerpack, temperatures within the three neighboring Powerpacks remained at safe levels. Despite high temperatures on the outside of module 16 on the west and northwest neighboring Powerpacks, temperatures inside the modules stayed at safe levels as a result of the thermal mass of the modules. These high external temperatures were likely a result of peak flame emanating from the initiator Powerpack finally transferring heat into the neighboring Powerpacks, which were also missing a considerable quantity of their typical 44001bs of thermal mass from the missing 14 unpopulated modules. Ultimately though, there was no propagation of the fire from the test Powerpack to the neighboring Powerpacks and despite these briefly high temperatures at the end of the test, temperatures of the cells inside the modules again remained at safe levels. DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 27 www.dnvgl.com 2500 2000 a) Q E 1000 500 Neighboring Module 7 Internal TCs North-int-mod7.0-TC29 North-int-mod7.1-TC30 — West-int-mod7.0-TC25 West-int-mod7.1-TC26 Northwest-i n t-mod 7.0-TC 27 Northwest-int-mod7.1-TC28 50 100 150 200 250 300 time (m) Figure 4-11 Temperatures inside module 7 of neighboring Powerpacks 2000 a 1000 E Ia) 500 Neighboring Module 7 External TCs North-mod7-TC39 West-mod7-TC37 -- Northwest-mod7-TC38 50 100 150 200 time (m) X: 249.3 Y: 80.08 250 300 Figure 4-12 Temperatures on the outside of module 7 of neighboring Powerpacks DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 28 www.dnvgl.com 2500 2000 U ° . 1500 a) 500 0 Neighboring Module 16 Internal TCs I I North-int-mod16.0-TC35 North-int-mod 16.1-TC36 West-int-mod 16.0-TC31 West-int-mod 16.1-TC32 Northwest-int-mod 16.0-TC33 Northwest-int-mod 16.1-TC34 d4 0 50 100 150 200 250 300 time (m) Figure 4-13 Temperatures inside the module 16 of neighboring Powerpacks Temperature (°C) 1000 900 800 700 600 500 400 300 200 100 Neighboring Module 16 External TCs North -mod 16-TC42 West -mod 16-TC40 Northwest-modl6-TC41 0 0 50 100 150 200 250 300 time (m) Figure 4-14 Temperatures on the outside of module 16 in neighboring Powerpacks DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 29 www.dnvgl.com 4.1.2 Heat Flux Data In addition to temperature measurements, the heat flux from the DUT was taken at multiple points with a particular focus on egress pathways and adjacent exposures. As expected, heat flux against the east wall (Figure 4-15) was the highest, exceeded only by the heat flux at 6ft in front of the unit, which was hit by a large initial heat and pressure wave that damaged the sensor. Heat flux along the north wall, again oriented opposite from the opening of the DUT, briefly exceeded 5kW/m2. This result would not be expected in a true open air atmosphere, whereas in this case the ceilings are believed to have aided in reflecting heat; as would also be the case for units placed under a ceiling or covering. It is also of note that this value was seen for only a few brief seconds several minutes after the initial thermal runaway and smoke release (and when the unit was clearly emitting flame) and was not seen again until nearly three hours after the initial thermal runaway when the system reached full flame involvement. 1500 -- 1000 E X L_ (0 a) = 500 East Wall Heat Flux Lower HFG (3ft) Upper HFG (8ft) 50 100 150 200 250 300 time (m) Figure 4-15 East wall heat flux DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 30 www.dnvgl.com 160 140 120 NE 100 3 Y x 80 LT id i 60 I 40 20 50 North Wall Heat Flux 100 150 time (m) 200 Figure 4-16 North wall heat flux West Neighbor Heat Flux 250 300 I 0 50 100 150 200 250 300 time (m) Figure 4-17 West neighbor heat flux With expectedly high heat fluxes at the adjacent walls and neighbour, in part due to proximity of the test unit, heat flux emanating from the front of the unit is considered a key factor, as both the fire is directed that way and likely paths of egress will cross in front of it. To that end, multiple heat flux DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 31 www.dnvgl.com gauges were placed in front and to the side of the unit, as discussed above. Early in testing, the closest heat flux gauge, six feet from the front door, was damaged almost as soon as thermal activity began, negating the results from the device. High quality data was obtained from all other units though and is presented below in Figure 4-18, Figure 4-19, and Figure 4-20. As expected, the heat flux at 8 and loft measured consistently once a fully involved fire developed and was sustained by the unit nearly two and a half hours after initial thermal runaway (minute 210). At these distances, the heat flux exceeded 20 and 10kW/m2 respectively for sustainable periods of time. Likewise, the heat flux at 15 and 20ft also showed sustained values after extensive indication of smoke and fire from the unit. Despite very short lived pulses of high heat flux prior to these sustained events, DNV GL believes that the unit provides ample indication of thermal risk prior to reaching high heat flux levels and thus practical egress pathways are sufficient for escape from the area until flame has developed, at which point further distances or alternative routes will be necessary. 80 70 60 50 NE �- 30 m a) = 20 10 0 -10 Heat Flux at 8ft and 10ft From Door M 4 8ft 10ft 0 50 100 150 200 250 300 time (m) Figure 4-18 Heat fluxes in front of unit at 8 and loft DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 32 www.dnvgl.com Heat Flux (kw/m2) 10 9 8 7 6 5 4 3 2 1 Heat Flux at 15ft and 20ft From Door 20 18 16 14 12 10 8 6 4 2- 0 50 I I I I I I I I I I I I I I I I I I 50 100 150 200 time (m) 15ft 20ft 250 Figure 4-19 Heat fluxes in front of unit at 15 and 20ft Heat fluxes to the Side of Door 100 150 200 4ft 8ft 12ft 250 Figure 4-20 Heat fluxes to side of unit at 4, 8 and 12ft 300 300 DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 33 www.dnvgl.com Figure 4-21 Test during peak heat release rate 4.1.3 Gas Data and Venting Pictures Following the initial thermal runaway, the unit began emitting flammable gas. It released a quantity of gas which exceeded 100% LEL5 at the probe inlet within three minutes. Following this initial event, the sensor remained saturated for the remainder of the test as a result of the combustion gases being fed through it. Once the initial 100% was reached, the sensor value is no longer credible. The probe inlet was placed approximately 12" above the dedicated exhaust plenum, or "chimney" outlet. This device was built in to the system to manage offgas from the failing cells and as the bulk of offgas from the battery was expected to vent from this point, made the logical choice for probe placement. During initial failure, nearly 100% of the smoke and offgas escaped safely from this point, though as the failure propagated through the initiating module and gas production increased, some quantity of the gas did eventually sink lower into the Powerpack over the course of several minutes. 5 Based on propane calibrated, nonspecific catalytic bead LEL sensor DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 34 www.dnvgl.com 120 100 80 J 60 w J 40 20 0 Lower Explosive Limit (%) Lower Explosive Limit (% 100 80 a' 60 W J 40 20 0 - - - - _ ^ 1 »-r til - - - - M' ..LL .. 1 1-41 .. r . MM. d r. fMi . 50 100 150 200 time (m) 5 0 t 4 L C a) 0 C 0 3 U 250 300 65 Figure 4-22 LEL during test CO2 and H2 During Test 70 75 time (m) 80 L CO2 H2 4.L 50 100 150 200 250 300 time (m) Figure 4-23 Hydrogen gas concentration during test 85 With hydrogen detection, one can see its presence in the offgas of the battery prior to the ignition event in Figure 4-23, exceeding the explosive limit of hydrogen at the onset of fire from the DUT. Once fire and high temperatures are observed within the test setup, hydrogen levels quickly drop as the gas is ignited within the system. Initially, increased CO levels were seen similarly at the onset of gas release, but, as with hydrogen, diminished greatly once steady combustion was obtained as the gas was consumed in the conflagration, as shown in Figure 4-24. DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 35 www.dnvgl.corn 3.5 E a 2.5 0 0.5 x 104 High Concentration Gases During Test Carbon Monoxide Methane Ehtylene 1 I1 I• I I al !h►.l „— 0 50 100 150 200 250 time (m) Figure 4-24 Flammable hydrocarbon gases during test Despite data exceeding the max value, Figure 4-24 is capped at 40000ppm. This value equates roughly to the edge of the linear confidence range for carbon monoxide for the sensor and while the actual value may exceed 40000ppm, it cannot be measured reliably for this test. Confidence ranges for methane and ethylene are considerably lower, at approximately 4000ppm each, but are shown on the same plot to highlight the quantity present during pre -conflagration events. In all cases, the values shown are below the individual LEL values for the cases, which is 120,000ppm for CO, 50,000ppm for methane, and 27,000ppm for ethylene. DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 36 www.dnvgl.com 2000 1800 1600 1400 E a Q 1200 0 1000 0 800 C O U 600 400 200 0 Toxic Gases HCI HF — HCN 0 50 100 150 time (m) r 200 250 300 Figure 4-25 Halides and hydrogen cyanide during test (all in confidence range) 4000 3500 3000 E La- 2500 0 2000 C m 0 1500 0 1000 500 0 Benzene and Toluene During Test 0 L Benzene Toluene LLA 50 100 150 200 250 300 time (m) Figure 4-26 Benzene and Toluene levels during test (all in confidence range) DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 37 www.dnvgl.com Figure 4-27 Several seconds after initial gas venting Figure 4-27 above shows offgas production several seconds after initial visible smoke production following the first thermal runaway. Initially 100% of gas escapes from the vent. Overtime, offgas accumulates in the area as production from the vent increases. Though most offgas is escaping through the exhaust hood overhead or out the front of the test area, some offgas lingers or sinks lower into the test area, as shown in Figure 4-28. Ultimately, as gas production within the unit continues and increases, this gas escapes from the sides and front of the unit. This gas, which also collects inside the unit, was ignited and expanded shortly after Figure 4-29 was taken. This expansion, while mild, did generate enough force to allow the door —which had already released from the latch following earlier heat exposure— to swing open safely. This allowed additional gas, pressure and flame to emanate safely from the front of the unit while the door also remained on its hinges through the remainder of the test. Following this event, most of the generated off gas was consumed via combustion as seen in Figure 4-30. DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 38 www.dnvgl.com Figure 4 28 Continued gas production DNV GL - Document No.: 101184aowR-o-,Iea:E, Status: Release Page 39 www.dnvgl.com Figure 4-29 Smoke and gas emanating from unit moments before energetic gas expansion Figure 4-30 Combustion seconds after the door opens fully DNV GL — Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 40 www.dnvgl.com 4.1.3.1 Pressure Data With the exception of two small, low pressure events within the DUT at the onset of testing, no noticeable explosions occurred. While fire production was intense and directional, it too failed to create a dangerous pressure situation within the enclosure. 1.8 1.6 1.4 cn 1.2 n a> U) U) a) 0.8 0.6 0.4 0.2 Tesla Pressure Sensors P1 P2 - P3 P4 50 100 150 200 250 300 time (m) Figure 4-31 Pressure inside DUT modules 5 CONCLUSION A single large scale test of the Tesla Powerpack was performed. A completely live pack, consisting of 16 modules, was placed in a square formation with three target packs. Within the DUT, the center module was outfitted to induce thermal runaway within a number of cells, ensuring a fire capable of propagating, following a pre-engineered period of heat exposure. While individual cell thermal runaways are audible during the test early on, one potential energetic release exceeded the audible level of the cells failures. A second, mild overpressure event occurred which resulted in the opening of the test pack door. Following this event, a steady conflagration from the center module burned for some time before burning out. Eventually, heat transfer resulted in propagation of the event to adjacent modules within the initiating Powerpack, resulting in a second conflagration which lead to the complete consumption of all cells within the pack over nearly four hours. The test showed that for the spacings used in the test, which are the current recommended installation spacings per the manufacturer, propagation from Powerpack to Powerpack and from Powerpack to exposure did not occur. Though one minor audible event was heard within the unit and a second energetic release within the unit caused the door to gently open; neither event posed a risk to the egress pathway or exposures. There was no observed deflagration outside the unit and no observed physical debris escaping the unit. The fire that followed the door opening proceeded to burn to completion over a nearly three and half hour period which saw one significant lull following combustion in the first module before propagation to the next internal module occurred approximately an hour and a half later. That fire ultimately propagated through the entire Powerpack over the DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 41 www.dnvgl.com remainder of the test. Upon complete burnout of the Powerpack and completion of the test, the unit was cooled with water and showed no adverse effects from this cooling. DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 42 www.dnvgl.com APPENDIX A Gas Data at Select Times DNV GL - Document No.: 10118434-I-10U-R-02-E, Issue: E, Status: Release Page 43 www.dnvgl.com Table 2A Gas data at select points during testing lime Water vapor (%) Carbon dioxide Coo(%( Carbon monoxide CO Nitrogen momelde NO Nitrogen dioxide NO2 Methane 014 Ethane C2116 Ethylene C2144 Propane C3118 Hydrogen chloride 90 Hydrogen fluoride HE Hydrogen cyanide HCN &tend Toluene C7M9 Ethanol C2H60 Methanol ONO Aretenittle C2H3N Oxygen (%( 12:25:41 1:07:46 -0.05 456 219887 0 54 21683 64.33 30848 19.77 3.49 192 1.49 0 D 0 0 0 1416 12:25:48 1:07:53 .0.05 0.24 130693 0 4180 126.51 49.62 18255 1646 3.21 25 0 1815 D 0 0 0 15.94 12:25:55 1:08:00 .0.13 032 150153 0 4293 146.02 50.71 220.83 15.4E 8.43 268 031 0 0 0 0 0 14.13 12:26:02 1:08:07 -001 0.3E 164160 0 49.32 163.79 63.49 230.85 18.53 3.85 0 0 61.47 0 0 0 0 14.67 12:16:08 1:68:13 .0.07 0.16 977.06 0 3213 72.48 45 149.27 11.97 499 699 0 67.13 0 0 0 0 15.64 12:26:15 1:08:20 -001 00l 563.72 0 19.23 9697 2874 95.72 7.88 0.16 3.01 0.31 7.65 62 0 0 0 1613 1126:22 1:08:27 .0.09 005 34L8 0 7.83 60.05 1859 64 5.99 0 171 069 3289 6.61 0 0 0 1636 1126:29 1:08:34 .0.14 105 21683 0 10.67 2607 13.54 4804 119 182 189 1.19 11.93 161 0 123 0 1646 12:26:35 1:08:40 .069 0.22 103244 0 216 115.66 34.08 19134 1101 27 119 0 0 0 0 0 0 1183 17,1642 1:03:47 -0.01 1.5 14812.56 D 3121 2334.23 40.5 4448.12 19418 167E 123 0 0 D 0 84.22 0 7.54 12:26A9 1:08:54 .0.01 1.33 15087.513 D 55295 1707.32 425.8 360688 1217 22.62 0.77 0 0 0 0 85.72 D 1415 12:25:56 0:9:01 .0.01 1.69 14495.43 0 539.35 3217.61 441.96 470253 217.11 30.35 0 0 0 0 0 127.13 0 7.96 12:27:02 1:03:07 .Q.01 139 12589.42 0 531.81 1950.56 384.55 2996.3 11831 20.46 1.99 2.81 0 3.98 0 9528 0 1145 122109 1:03:14 -0.01 139 13766.77 0 33509 2193.74 3165 335137 1418 29.65 L64 0 0 0 0 107.28 0 815 12:27:16 1309:21 .0.01 0.72 14795.97 0 84223 3275.35 516.17 3569.6 19122 19.83 0 0 0 0 24539 1417 0 863 1127:23 109:28 .001 117 143E6.41 0 71476 4398.39 678.25 658235 20115 45.18 0.8 3.62 0 0 0 227.38 0 7.37 12:2129 109:34 .0.01 147 12614.77 0 38615 2187.93 370.42 360107 20693 3147 0.14 0 0 D 157.48 13619 0 9.38 12:27:36 1:03:41 .0.01 1.08 10939.3 0 4E0.61 141422 311135 2242.93 105.8 2867 0 7.52 0 1131 0 87.34 D 1115 12:27:43 1:09:48 .0.02 0.90 7339.49 0 34832 79248 218.76 827.03 77.57 17.2 2.38 0 0 0 136.24 3653 593.21 1183 12:27:50 109:55 .0.01 162 12983.3 0 664.94 332629 429.86 4179.51 109.38 3387 0 0 0 0 31121 128.17 0 4.68 12:27:56 1:1001 -001 14 21615.61 0 385554 12346.31 1017.3 16785.65 191.65 6678 0 0 0 0 1759.53 3866 0 269 12:000 1:1008 .Q01 181 25126.15 0 3941.13 1E053.02 1437.05 24356.85 347.6 93.06 0.11 0 0 0 3110.50 53251 0 Q98 12:38:58 1:2103 0.54 118 6104.49 D 93239 1759.27 52693 0 277.3 14168 81 5.03 0 59147 7793 496.53 226039 7.16 12:39:05 1:21:10 0.57 0.8 398606 0 62109 720.62 389.77 0 27238 120.97 11.09 0.86 0 489.85 877.6 389.63 1694E 7.89 12:39:12 1:21:17 0.40 0.68 3162.58 0 56189 659.9 291.41 0 303.04 129.03 7.63 4.33 0 441.21 1406.18 37638 31228E 8.44 12:39:19 1:21:24 Q56 Q45 2055.63 0 515.13 550.77 237.69 0 256.96 103.4 7.76 0 0 38158 1316.09 325.89 2892.12 9.14 12:39:25 1:21:30 Q51 132 1523.2 0 337.51 D 293.0E 0 167.91 1118E 609 5.95 0 36113 7432 33632 19E9.27 9.58 1239:32 1:21:37 Q49 028 1235.66 0 301.45 21181 1766 0 197.59 11265 7.23 0 0 330.16 0 211.83 3188.99 1609 123939 1:21:44 133 008 94185 0 13657 43226 209.87 0 13142 9103 7.56 21 0 27804 408.04 26197 582.43 1056 12:3946 1:21:51 135 Q03 669.76 D 110.14 269.25 189.44 D 11662 9621 80.9 D 0 24027 0 266.99 2792.21 1108 12:3952 12157 0.55 Q02 71192 0 186.01 69.38 13471 0 144.44 9044 9.09 127 D 269.44 0 140.75 283152 1128 12:39:59 122024 0.54 0.03 64682 D 148.24 10264 1187E 0 13187 91.76 9.13 1.46 0 252.7 257.49 144.19 0 11.85 12:40:06 1:22:11 1,29 0.05 52838 0 59.32 62.87 146.12 0 87.31 7688 6.87 0 0 197.36 195.31 8230 607 1213 12:40:13 1:22:18 Q52 0.18 907.73 0 157.69 155.12 10678 0 11895 9283 8.65 181 0 23.59 30115 119.82 0 1224 12:4019 1:22:24 0.45 0.03 697.79 0 1058 21406 9593 0 11126 85.59 8.25 0 0 22179 27215 103.29 75191 1263 124026 12231 0.46 Q3 12581 0 16251 41187 134 0 1266 77.5 514 178 0 259.3E 57.15 10113 10172 11.85 12:4033 1:2238 049 0.27 1050.28 0 175.46 565.44 1.33.48 0 12243 78.87 567 D.76 0 249.75 0 6249 165337 12.47 12:4040 122:45 143 0.04 720.37 0 4233 182.34 17178 0 7117 66.42 691 0 0 198.5 0 18149 71 1265 12:40.46 1:2151 0.6 0.01 711.17 0 1146E 224.2 113.03 0 10178 7098 466 0.15 0 21133 0 817E 118563 131E 12:4053 1:22:58 0.47 0.01 518.14 0 107.22 37118 91.01 0 9537 7421 6.36 0 0 201.42 8855 56.23 939 1144 12:41,30 1:23:05 057 002 63281 0 10212 331.38 82.02 01 9172 68 8.2E 0 D 19142 120 9113 1368.26 1154 12:41:07 1:23:12 Q62 604 71211 0 86.76 105.51 99.46 0 85.79 74.1 6.89 0 0 190.43 9285 653 103163 13.33 1141:13 1:23:18 L43 0.02 449.89 0 0 159.91 12806 0 59.97 5236 7.01 Q92 0 16179 79.0E 6275 0 117E 12:41:20 1:23:25 0.61 005 36435 0 66.61 5113 7122 0 75.71 67.75 9.39 061 0 16800 14226 8819 7817 1425 12:41:27 1:23:32 Q57 0.06 319.16 0 57.35 107.36 55.44 0 70.94 6427 9.58 0 D 16L17 18805 31.48 570.13 14.46 114134 1:23:39 0.57 0.01 457.92 0 5104 176.41 68.05 0 73.2 76.41 9.14 0 0 16219 13824 47.82 631.47 14.26 12:4141 1:23:46 0,51 0.0E 354.5 0 6199 65.75 66.5 0 6677 64.51 656 0 0 153.81 13635 32.41 7263 1455 12:41:47 1:2352 056 Q05 35623 0 6163 10207 64.45 0 6117 6172 622 0 0 147.53 13354 519 81276 1463 12:41:54 123s9 D.57 0183 418.42 0 6607 117.47 67.76 0 6279 69.67 815 0 0 146.83 124.27 42 70846 1443 12:42:01 1:2406 0.48 Q07 356.16 0 4863 244.07 59.19 0 6279 EQ77 7.97 0 0 14159 11162 57.75 70175 14.7E 124208 12413 0.48 Q05 56184 0 6567 26106 6865 0 6524 629E 505 0 0 15173 9151 3189 107434 1438 13:56:19 2:33:24 -0.07 0 48833 0 4139 19199 76615 517.84 9951 1251 5.74 632 820.9 0 0 57.47 0 1626 13:56:26 2:38:31 .0.02 1.03 4988.1 0 167.26 1161.1 827.71 468.59 127.12 17.62 6.74 0 0 0 0 0 2038.14 14.65 13:56,32 2:38:37 -0.02 1.04 13331.65 0 2056.18 3258.46 1788.82 2674.1 59.28 43.81 3.97 0 0 34.81 763148 695 12293.63 11.67 135639 2:38:44 -0.01 1.2 25071.59 825835 275559.91 14932.94 3245,98 5843.32 0 47.63 644 0.61 230153 253.86 763148 17491 12293.83 6.37 13:56:46 23851 -001 1.09 26027.4 7887,79 414760.19 14374.63 3930.01 955161 0 54.E 7.72 0 20E9.13 37682 7631.48 237.55 12293.63 7.15 115453 23859 .0.03 13 49E37.47 15822.95 55358631 21765.98 4320.56 14176.96 0 77.22 179 1539 170655 63608 763148 27175 12293.13 19 13:55:53 2:3104 .404 L42 32804.64 20931.35 828478.13 48810.41 180127 8318.93 0 7104 5.83 3542 185E 65059 7E31.48 33256 12293.63 465 13:57:06 2:3911 .0.1 195 63742.32 10864.46 165031138 153394.15 0 36237.59 0 1187 0 66.75 175831 979.32 763148 68636 12293.63 0 14:1259 2:55:04 .0.05 0 1209 0 0 2142 2208 576 20.72 431 827 2.1 23.24 26.17 0 0 D 16.67 14:1105 2:55:10 .0.01 0.04 307.31 0 0 59.01 58.16 19.74 31.17 3.01 7.50 0.52 30.71 0 0 3.63 0 1633 14:13:12 2:55:17 0 0.06 32296 0 0 45.31 6529 14.87 36.05 294 695 0.8E 0 0 0 0 0 1645 14:13:19 25924 -0.01 0.04 2165 0 0 37.48 49.79 667 3178 0.61 8.16 146 10.28 D 0 Q39 0 1663 14:1126 2:5931 .001 Q03 177.01 0 0 2896 48.8 3.33 3106 486 7.83 D.18 2145 0 0 0 0 1674 14:13:32 2:55:37 .101 0.02 11294 0 0 27.03 3156 0 27.4 166 88 0 123 1115 0 5.75 0 1696 14:13:39 2:55:44 .0.06 0.01 9159 0 0 5.22 250E 0 2187 218 955 0 47 169 0 21.81 0 17.05 14:13:45 2:55:51 -0.26 0.03 10448 0 0 0 3231 0 19.13 1 128 1.83 18.3 13.07 0 0 0 16.94 1413:53 2:55:58 .0.01 0.14 36499 0 0 5497 51.24 9.69 30.69 426 6.24 1.49 1624 0 0 0 0 1645 14:37:58 3:2003 -0.01 0.16 747.05 0 0 53.50 46.43 815 4204 877 186 0 0 30.61 0 19.21 0 1696 14:39:05 3:2010 .0.01 0.55 111116 0 0 49.96 45.65 1655 41.85 8.61 1.92 0 0 2187 0 1543 0 1673 14:38:12 3:2017 0 113 196242 D 0 9175 5198 382E 4252 224 165 0 0 21163 0 0 0 1623 14:38:18 3:2023 0 101 194191 0 0 11195 56.64 46.28 45.84 1005 534 167 0 1418 0 0 0 16.45 14:38:25 11030 .0.01 083 150441 0 0 83.39 5271 34.37 4406 282 5.99 0 281E 1638 0 0 0 1696 14:38:32 3:2037 0 0.6E 1276.57 0 269 85.13 4105 4414 45.53 274 3.85 0 0 15.73 0 869 0 1643 14:38:39 3:20:44 0 0.89 136136 0 0 11035 46.1 2608 4009 4.92 4 0 D 2039 0 0 0 1673 14:38:45 3:2050 .0.01 1 151163 0 0 73.33 40.72 2156 4496 215 284 5.04 4.3 20.19 0 0 0 1655 14:38:52 3:10:57 0 0.68 2554.16 0 0 123.06 6E92 5416 5055 1.55 3,65 134 0 1159 0 653 0 1624 1450:01 34006 154 114 7188 190.44 0 0 66.22 18.71 14132 0 18119 0.73 677 1117 27.44 1E57 1418 10.44 14:58:07 04012 287 216 3939.43 176.56 0 454.49 124.54 44144 14234 240.22 155.64 115 3164 0 0 1661.3E 939.55 9.66 1458:14 14019 232 201 7716E 192.4 0 657.25 183.E 732.11 13126 27188 11898 6.43 27.5 0 0 0 49179 9.57 14:58:21 040.25 212 209 10717.88 229.83 449.34 963.9E 107.53 91237 131.61 418.27 117.87 639 0 6147 0 0 431E 9.13 14:58:28 3:4033 1.88 2.11 12014.38 247.42 894.05 822.62 13866 497.96 128.6 479.37 115,37 0 0 2658 0 0 37287 9.16 14:58:34 3:4039 1.34 1.86 10312.93 244.22 1155.70 1007.87 187.01 99118 14132 53826 98.77 11.4 0 79.2E 0 16635 32538 9.57 14:58:41 14046 1.22 191 9266.5 254.26 1615.07 1046.72 2526 104185 155.76 297 83.68 126E 0 179.96 0 16686 33449 935 145849 3:4053 121 1.87 60011.56 236.3 1441.47 11853 293.65 93173 171.54 0 81.38 102 0 137.64 0 21235 334.47 856 Unless stated, all measurements are in ppm (02, CO2,Water Vapor are % by volume) DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release www.dnvgl.com Page 44 ABOUT DNV GL Driven by our purpose of safeguarding life, property and the environment, DNV GL enables organizations to advance the safety and sustainability of their business. We provide classification, technical assurance, software and independent expert advisory services to the maritime, oil & gas and energy industries. We also provide certification services to customers across a wide range of industries. Combining leading technical and operational expertise, risk methodology and in-depth industry knowledge, we empower our customers' decisions and actions with trust and confidence. We continuously invest in research and collaborative innovation to provide customers and society with operational and technological foresight. Operating in more than 100 countries, our professionals are dedicated to helping customers make the world safer, smarter and greener. DNV GL - Document No.: 10118434-HOU-R-02-E, Issue: E, Status: Release Page 45 www.dnvgl.com