Kakadu 120

Kakadu 120 is a lithium iron phosphate battery energy storage system housed in an outdoor-rated cabinet. Each cabinet holds two independent battery strings, and up to 16 cabinets can be paralleled into a single system.

Kakadu 120 is named for its 120 V DC class battery voltage. A string consists of one BMS and four battery modules connected in series. Each module is nominally 35.2 V and 11.05 kWh, giving a string a nominal 140.8 V and 44.2 kWh. Each cabinet contains two strings, giving 88.4 kWh (nominal; usable energy at the 90% depth of discharge is 79.6 kWh). Up to 16 cabinets may be connected in parallel, for a maximum system energy of 1.41 MWh.

• Modules slide into the cabinet and connect with quick-connect cabling.
• The two strings in a cabinet operate independently, so the system keeps operating if one string faults.
• The Battery Information Collector (BIC) design makes communication more stable and reduces system stoppages caused by communication faults.

Table 2.1 — Terms used in this manual

Danger — high voltage

Installation, termination and commissioning must be carried out only by a licensed electrical worker competent in battery energy storage systems, and must follow AS/NZS 3000 and AS/NZS 5139. Power cables and plugs carry high voltage from the battery at all times, including when the system is switched off.

Follow the safety requirements in this manual strictly when installing, commissioning, operating and maintaining the product. Incorrect operation or work may damage the product and other property, or cause injury or death to the operator or to third parties.

When fixing the product with screws or other fasteners, use the correct tool and tighten to the torque given in this manual or on the product label. Read this manual before installation to ensure the product is installed and used safely.

Warning

1. Installers and users must familiarise themselves with this manual before starting work.
2. Power cables and plugs carry high voltage from the battery. Take care when wiring.
3. Ensure correct PPE is used when installing and maintaining the system.
4. Battery modules weigh 91 kg. Use a mechanical lifting aid (module trolley, hoist or lifter) to position modules in the cabinet.

3.1Intended Use

• Kakadu 120 is designed to work with inverters rated for a 120 V DC class battery bank, in commercial and industrial (C&I) applications.
• Kakadu 120 is designed to work with the AERL Nexus Gateway as the system EMS (Energy Management System) and with CoolMax SRX 120 V charge controllers for optimum charging. The AERL Nexus platform also provides remote monitoring and firmware updates.
• The IP55 enclosure is rated for indoor or shaded outdoor installation — see section 5.1.
• Kakadu 120 is not suitable for powering life-sustaining medical equipment or mission-critical equipment. A UPS is recommended for those applications.

3.2Battery Module Leakage

Stop using a damaged battery immediately and dispose of it in accordance with local regulations. Damage to the battery may release electrolyte, which can cause breathing difficulties, skin irritation and chemical burns. Consult the Safety Data Sheet for more information.

If you come into contact with battery electrolyte, immediately:

• Eye contact — rinse gently with running water for at least 15 minutes and seek medical help promptly.
• Skin contact — rinse under running water for more than 15 minutes, remove any contaminated clothing and seek medical attention.
• Inhalation or ingestion — leave the contaminated area and seek medical assistance.

3.3Fire

Danger — battery fire

A battery fire may occur if the battery is exposed to flame, an excessive heat source or extreme temperatures. A burning battery may emit carbon monoxide, carbon dioxide and other toxic gases.

If a fire occurs, dial 000 (or your local emergency number). Isolate the system if it is safe to do so, then move immediately to a safe location. Firefighters should wear full-face self-contained breathing apparatus (SCBA) and full protective gear, and use a dry chemical extinguisher to cool and extinguish the battery and prevent the fire from spreading.

3.4Handling

• Take care during installation to avoid damaging the battery.
• If a battery is damaged before installation, contact AERL for advice before proceeding.
• Protect the battery from damage during transport and handling.

• DO NOT clean the battery with water or solvents, or allow foreign objects to enter it.
• DO NOT unplug any cable while the battery is operating.
• DO NOT use the battery together with batteries of other brands or types.
• DO NOT short-circuit the battery modules.
• DO NOT subject the battery to external forces, such as dragging it along the ground or placing heavy objects on it.

3.5Storage

• Recharge stored modules at least every six months to prevent irreversible damage from deep discharge. Keep the long-term storage temperature as close as possible to 25 °C.
• For short-term storage, keep the ambient temperature between 0 °C and 35 °C.

• DO NOT store battery modules or BMS units outdoors, or anywhere exposed to direct sunlight, high humidity, heat or water.

4.1What Is in the Box

Kakadu 120 ships as three separate consignments: the cabinet (with the accessories box packed inside), the BMS boxes and the battery boxes. Check all items against the list below before starting installation.

Accessories box contents

Table 4.1 — Accessories box checklist

Note

Communication cables and power cables between BMS units are not supplied. The connectors required to make them are in the accessories box — see steps 7 and 9.

• Use only the supplied cables and connectors.

4.2Functional Areas

Table 4.2 — BMS front panel

Table 4.3 — Battery module front panel

Letter	Label	Function
A	–	DC negative
B	+	DC positive
C	COM1	Communication port
D	COM2	Communication port

4.3Specifications

Table 4.4 — System specifications

Arc flash

Calculate the arc flash risk in accordance with AS/NZS 5139:2019 and follow its PPE requirements.

Table 4.5 — Battery module specifications

Tech note

Kakadu 120 requires an AERL Nexus Gateway to manage the battery communications and ensure the correct charging profile is applied by the inverter.

This section gives the requirements and the step-by-step procedure for installing Kakadu 120 safely. Take the installation procedure into account when designing the system.

5.1Requirements for the Installation Location

The installation location must be suitable for safe operation and long-term use, in accordance with AS/NZS 5139 Section 6. Choose a location where the battery can be easily connected and serviced. AERL also recommends the following.

• Keep the battery at least 5 m from any source of heat, such as fires, transformers and heaters, to avoid overheating.
• Ensure the environment is free of flammable and explosive materials.
• Battery life is maximised at an ambient temperature of 15–30 °C; the system operates from −10 to 50 °C (Table 4.4).
• Ensure the ground is flat and level.
• Keep the location away from sources of dust, corrosive gas and salt spray.
• Shade the cabinet from direct sun with an awning, a roof or its orientation. Direct sun raises the internal temperature and reduces charge and discharge capability.
• Ensure the location is well ventilated with good air circulation.
• Ensure the location is secure and away from children and animals.

5.2Tools

Safety shoes

Insulated gloves

Goggles

Screwdriver

Drill

Torque wrench

Hydraulic crimping pliers

Wire cutter

Utility knife

Adjustable spanner

Spirit level

Module lifter / trolley

5.3Placing the Cabinet

Installation space requirements

Note

The figures above are the minimum clearances for the installed system. Allow additional temporary working space — approximately 750 mm — to manoeuvre the cabinet into position during installation.

Foundation requirements

Notice

The foundation drawing is for reference only and must not be used as the final construction drawing. Verify the foundation design parameters for the energy storage system against the installation environment, ground load-bearing capacity, geological conditions and seismic requirements of the project site.

1. The energy storage system must be installed on concrete or another non-combustible surface. The installation surface must be level, solid and even, with sufficient load-bearing capacity and no depressions or slope.
2. Design the foundation for the total weight of the equipment.
3. Compact and level the base of the excavation to prevent subsidence or tilting over time.
4. After excavation, protect the foundation from water infiltration and disturbance. If the soil is disturbed by water, excavate further and replace the soil.
5. The level deviation between the foundation surface and the cabinet contact surface must not exceed 3 mm.
6. Build the foundation above the highest recorded flood level for the site, and at least 300 mm above the surrounding ground level.
7. Construct drainage in accordance with local geological conditions and municipal drainage requirements, so that water cannot accumulate around the foundation. The foundation drainage must cope with the highest recorded rainfall for the site, and all discharged water must be treated in compliance with local laws and regulations.
8. Allow for the cable routing of the energy storage system when constructing the foundation, and reserve cable trenches or inlet holes accordingly.
9. Seal all reserved foundation holes and cable inlet openings at the bottom of the equipment.

5.4Installation Steps

Each cabinet holds two strings. Carry out steps 1 to 8 for each string, then complete step 9.

Danger — battery terminals are always live

Battery module terminals are permanently energised. Do not insert anything into the quick-connect sockets. Use only the supplied cables and connectors.

Arc flash PPE: wear PPE in accordance with AS/NZS 5139 Table 3.3.

1

Install the BMS, then the modules

Install the BMS in the bottom position first, then install all four battery modules above it.

2

Secure every BMS and module

Lock all BMS units and battery modules in place with the washer bolts supplied. Tighten to 8 N·m.

5.5Paralleling Multiple Cabinets

Up to 16 cabinets may be connected in parallel. Series connection is not permitted.

1. Connect P+ and P– of every BMS to a DC combiner using the parallel power cables made up in step 9. Size the cables and the combiner for the total system current — see the Kakadu Combiner Box Installation Guide.
2. Continue the communication chain from cabinet to cabinet: connect OUT on the upper BMS of one cabinet to IN on the lower BMS of the next.
3. Connect the INV port of the first BMS in the chain to the AERL Nexus Gateway. This BMS is the master.
4. On the HMI, leave Master Unit lit on the master string only (section 6.3), and leave Last Unit lit on the final string in the chain only (section 6.4).
5. Confirm that every string's Run indicator is lit and that the inverter reports the combined system capacity before applying load.

The HMI presents real-time system data at a glance and provides direct control of black start and string identification.

It shows the running status and state of charge of the battery, and lets you trigger a black start, set the terminating string and identify individual strings in a paralleled system.

123456

1

SOC indicatorsFive bars, each representing 20% of system energy.

2

Black Start buttonStarts the inverter from the battery in an off-grid system.

3

Master Unit buttonIdentifies the master BMS and sets the terminating resistor for the Nexus Gateway link.

4

Last Unit buttonIdentifies the last string in the system.

5

BMS statusRun and Alarm indicators.

6

Module statusOne indicator per battery module.

6.1SOC Status

The SOC indicator shows the current state of charge of the system. Each lit LED represents 20% of the battery's energy.

• While discharging, the last lit LED flashes once per second (1 Hz).
• While charging, the last lit LED flashes once every two seconds (0.5 Hz).

Table 6.1 — SOC indication

6.2Black Start

Black start is designed for off-grid systems. It lets Kakadu 120 supply energy to the inverter so the inverter can start the system.

In an off-grid system, power up the system and then press and hold Black Start for three seconds to activate it. Once the inverter starts working, black start terminates automatically and the LED goes out.

6.3Master Unit

Master Unit identifies the master BMS — the string connected directly to the Nexus Gateway — and sets the terminating resistor. It should be on for the master BMS only.

All Master Unit LEDs are on initially. Press Master Unit on each string that is not the master and confirm that its LED goes out, leaving only the master string's LED on.

6.4Last Unit

Last Unit confirms which string is last in the system and completes the communication circuit.

All Last Unit LEDs are solid on by default. To complete the communication circuit, make sure that Last Unit is on for the last string only. Press the button on each of the other strings and confirm that its LED goes out.

6.5Alarm

When the system is working normally, Alarm stays off. An orange light is displayed when a serious fault occurs, such as over-voltage or over-current.

6.6Run

When the system is working normally, Run lights green. When the system is powered off, Run is off.

6.7Module Status Indicators

This area shows the status of every module in the string. Kakadu 120 has four battery modules per string, so indicators 1 to 4 correspond to the four modules; indicators 5 to 9 are not used and stay off.

When a module is working correctly, its indicator is off. If a module fails, its number lights orange.

7.1System Startup

Before starting the system, confirm that every cable is connected as described in this manual, and that all MCBs and DC breakers — where fitted — are off.

1. Turn on the MCB on each BMS  ①
2. Press the ON/OFF button on each BMS  ②

The RUN and SOC indicators light once the system starts working.

7.2System Shutdown

1. On each BMS, press and hold the ON/OFF button for three seconds  ①
2. The MCB trips automatically. Verify that the handle is in the OFF position  ②

Warning

Isolate the system power supply before operating on or maintaining the battery system. Working on energised equipment may damage the battery system or cause electric shock. All work must be carried out by authorised personnel only.

8.1Every Six Months

• Check the system SOC using the SOC indicator on the BMS and in AERL Nexus, and confirm there is nothing abnormal.
• Check every cable connection for damage, looseness and ageing.
• Check the system working logs in AERL Nexus and confirm there are no abnormal events.
• Check that the ON/OFF button and any external emergency stop are working correctly.
• Clean dust from external surfaces and the door vents with a dry cloth or brush.
• Check cell voltages, module temperatures and SOH in AERL Nexus.
• Inspect all metal components for corrosion.

8.2Every Year

Make sure the system is completely shut down before carrying out the following checks. Shutting down opens the MCB but does not de-energise the battery modules. Wear arc flash PPE in accordance with AS/NZS 5139 when working on the battery.

• Check that every quick-connect power plug is fully latched, and that the module and BMS washer bolts are tight (8 N·m).
• Check the power and control cables for damage, particularly where a surface in contact with metal may have been cut.
• Confirm that all cable entry points are properly sealed.
• Check that the cable layout is correct and that there are no short circuits.
• Check for loose screws.

When disposing of Kakadu 120, return the unit to AERL, or follow local regulations for electronic waste and used batteries and observe the following requirements.

• DO NOT dispose of the product with household waste.
• DO NOT leave waste batteries in direct sunlight or at high temperature.
• DO NOT dispose of used batteries in high-humidity or corrosive environments.

To find the product's date of manufacture, locate the serial number on the nameplate.

Kakadu 120 is covered by a 10-year warranty; conditions apply. The full terms and the claim procedure are in the Kakadu 120 Warranty Statement at aerl.com.au. For a claim, contact AERL technical support.