Section J Attachment G EM PCC to ESC ICD Rev 1.0.1.pdf

UNCLASSIFIED//FOR OFFICIAL USE ONLY

Energy Magazine

Power Conversion Cabinet to Energy Storage Cabinet

Interface Control Document (ICD)

Revision 1.0.1

14 July 2020

Distribution Statement D: Distribution authorized to the Department of Defense and U.S.

DoD contractors only, Critical Technology, 23MAR2020. Other requests shall be referred to PMS 320, Electric Ships Office Program Manager I Director, or higher authority.

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Record of Changes

Revision Date Changes

1.0 3/23/2020 Initial Release for Energy Magazine Competition [Purchase Request N0002419NR59839]

1.0.1 7/14/2020 Removed the space requirement for the EM Control System from paragraph 2.2.2.

Energy Magazine

Power Conversion Cabinet to Energy Storage Cabinet

Interface Control Document (ICD)

Approved By

Vincent Kane Date

PMS 320 Technical Director

Table of Contents

1 Scope

1.1 Identification

1.2 System Overview

1.3 Document Overview

1.4 Relationship to other Acquisition Documents

2 Interface Design

2.1 Interface Identification and Diagrams

2.2 PCC to ESC Interface Details

2.2.1 Auxiliary Power Interface

2.2.2 Energy Magazine Control System and Energy Storage Cabinet (ESC) Controller Interface

2.2.3 Main Power Interface

2.2.4 E-Stop Interface

2.2.5 Thermal Management Interface

2.2.6 Control & Sensor Interface

2.2.7 Energy Management System Interface

List of Figures

Figure 1: Energy Magazine Cabinets Figure 2: Acquisition Documents for Energy Magazine Figure 3: PCC to ESC ICD Interface Overview

List of Tables

Table 1: PCC to ESC Interface Definition Table 2: Auxiliary Power Interface Signal Table 3: EM Controller Interface Table 4: LVDC Class III Type II Interface Signal Table 5: Remote E-Stop Interface Signal Table 6: Thermal Management Interface Table 7: Control & Sensor Interface Signal Table 8: Energy Management System Interface Signal

1 Scope

1.1 Identification

This document constitutes the Interface Control Document (ICD) for the interface between the Power Conversion Cabinet (PCC) and Energy Storage Cabinet (ESC) in support of the Energy Magazine (EM) procurement. Figure 1 illustrates the cabinet-level layout of the EM.

Figure 1: Energy Magazine Cabinets

1.2 System Overview

The EM as a system is comprised of power conversion elements, energy storage elements, and the controls necessary to safely operate each to meet performance requirements. The EM is to be inserted within distribution systems to provide improved power quality while enabling larger pulsed weapons and sensors. The EM can be back-fitted on existing ships maintaining MIL- STD-1399 electrical load interfaces and reducing the total amount of energy storage assets required to be integrated within the ship. The energy storage elements are contained in a cabinet referred to as the ESC. The ESC is an integral part of the EM enabling it to perform its mission.

The power conversion and other auxiliary components are contained within the PCC as described in the Technical Specification for Energy Magazine. Components of the ESC are also defined within the Technical Specification. This document applies to the interface between the PCC and ESC. Previous versions of EM relied on energy storage media contained within enclosure single unified EM cabinet, however, in order to enhance energy storage performance and ease shipboard integration, some EM applications will utilize a separate cabinet for the energy storage media. EM interconnections will consist of the interfaces defined in this document in Section 2.

1.3 Document Overview

This ICD emphasizes interfaces between the PCC and the ESC, detailing interactions accomplished via specific communication networks, individual discrete signals, power connections, as well as mechanical connections. The physical details supporting these interfaces will be described separately in the associated deliverables from the EM Contractor(s). This document is being provided to help the Contractor understand the scope of these interfaces and the impact on their design.

1.4 Relationship to other Acquisition Documents

Figure 2 shows the relation of this document with the other EM acquisition documents.

Figure 2: Acquisition Documents for Energy Magazine

2 Interface Design

2.1 Interface Identification and Diagrams

Figure 3 highlights the interfaces between the PCC and the ESC with numbered callout symbols.

Table 1 briefly identifies each numbered interface and identifies the section in this ICD where the interface is described in more detail. The separate ESC must meet all applicable requirements as specified within the Technical Specification for Energy Magazine.

• Fans

• Controls

• Humidity Controller

• Low Power ESM Charger

• Etc.

ES Media

ESC

Local E‐Stop

Remote E‐Stop

ESC

Controller

Main Power I/O Terminals

Auxiliary Power I/O Terminals

Thermal Management

System

EM SYSTEMS

NETWORK COMMUNICATIONS

MAIN POWER

AUXILIARY POWER

OTHER INTERFACES

CONTROLS & SENSORS

EM CONTROL POWER

PCC

Energy Management System

Figure 3: PCC to ESC ICD Interface Overview

Table 1: PCC to ESC Interface Definition

Callout in Figure 3

Name Description Reference

1 Auxiliary Power Interface

Power line (450VAC, 3ph) that will be used for ESC housekeeping power and maintenance charging of Energy Storage (ES) Media supplied by the PCC.

Section 2.2.1

2 EM Controller Power & Comms

A power connection, if used, to provide isolated power for EM Controller components required to provide a communication gateway between the ESC communications and the distributed EM control system. This interface also covers proprietary and non-proprietary communications involving distributed Energy Storage Management System and/or energy storage management system.

Section 2.2.2

3 Main Power Interface

Power cables (1kVDC) that will be used for high power interchange of ESC Power connected to the PCC.

Section 2.2.3

4 Remote E-Stop Interface

Discrete control signal received by the ESC supplied by the EM.

Section 2.2.4

5 Thermal Management Interface

No interface thermally between PCC and ESC.

Will have separate connections to ship’s chilled water per Technical Specification.

Section 2.2.5

6 Control and Sensor Interface

Digital communication network that will provide infrastructure to exchange status and commands between the ESC and PCC.

Section 2.2.6

7 Energy Management System Interface

Digital communication network (CAN2.0) that will provide infrastructure to exchange status and commands between the Energy Management System and EM.

Section 2.2.7

2.2 PCC to ESC Interface Details

2.2.1 Auxiliary Power Interface

Table 2 identifies the signal that constitutes the Auxiliary Power Interface Signal

Table 2: Auxiliary Power Interface Signal

Discrete Input Description Auxiliary Power A power line connection that will provide up to 70 Amps of 440VAC

3 phase power. The power cable will conform to LSTSGU-23 (MIL- DTL-24643) and the ESC must maintain its IP rating at the interface.

This will provide power for the ESC to create low voltage DC for all the ESC controllers and sensors required. This power connection can also be used for a maintenence charger(s) required by the ESC to maintain ES media assets. Any charger must limit current ripple harmonics below 5% Individual Harmonic Distortion (IHD) and 10% Total Harmonic Distortion (THD) (i.e., ESC not responsible for meeting 1399/300 current ripple requirement). (Technical Specification Section 3.3.2)

2.2.2 Energy Magazine Control System and Energy Storage Cabinet (ESC) Controller Interface The ESC controller is a cabinet controller designed to provide the cabinet status and sensing in accordance with Technical Specification for Energy Magazine. Table 3 identifies the signal that constitutes the ESC Controller Interface to the EM Application Controller Interface. The power is used to energize EM assets required to connect the ESC [and its ES media] to the EM distributed control system. The ESC will provide an IP54 sealed connection for this interface via SAE AS5015D or MIL-DTL-5015 connectors. The ESC Controller board will be able to communicate with, or host, the Energy Management System (EMS) and the ESC controller. The EMS is a self-contained control system designed to monitor and control the energy storage media within the ESC. The ESC controller is a cabinet controller designed to provide the cabinet status and sensing in accordance with Technical Specification for Energy Magazine.

Table 3: EM Controller Interface

Discrete Input Description EM Control Power A power line connection, if used, that will supply power to the

EM Control Board required to interface the local ESC controller with the EM Application Controller. (Technical Specification Section 3.3.2.3)

EM Controller Comms A network connection to provide communication between two EM Controller boards as part of the distributed EM controls.

2.2.3 Main Power Interface

Table 4 identifies Main 1kVDC Power characteristics as defined by the Technical Specification for Energy Magazine as a LVDC Class III Type II interface. This is a loosely to un-regulated bus that can vary with the inherent impedance of the energy storage media. Circuit protection, such as a circuit breaker or fuse, is required to limit the amount of fault current that the Battery System will source. Also, closure of the contactor/circuit breaker must have a precharge circuit to balance the voltage on both sides of the unit within 10% in order to protect the contacts. The power cable will conform to LSFSGU-200 (MIL-DTL-24643) and the ESC must maintain its IP rating at the interface.

Table 4: LVDC Class III Type II Interface Signal

Characteristic Definition Unregulated Value Steady State Output Voltage Range

Voltage at cabinet output terminals as established by energy storage media.

Variable between 1000Vdc to 680Vdc

NOTE - 1.1 p.u is allowed during high rate charging only

Output Voltage Ripple (rms)

Amplitude of the AC voltage component.

up to 30%

Transient Voltage Tolerance

Worst Case Output Voltage due to response of energy storage media to allowable load change slew rate. This range is not to be exceeded under any normal operational conditions.

0.68 puv to 1.05 puv

Maximum Positive Voltage Offset

Maximum Steady State Voltage Offset from Positive Terminal to Ground (Ship Hull) during ground fault.

+ 1.06 puv

Maximum Negative Voltage Offset

Maximum Steady State Voltage Offset from Negative Terminal to Ground (Ship Hull) during ground fault.

- 1.06 puv

Unregulated Bus Grounding Method

Method that the internal power components interconnect with ground.

Ungrounded.

Max. Capacitance AC Isolation at output terminals (Line-Hull).

≤ 1 μF

Min. Resistance DC Isolation at output terminals (Line-Hull).

≥ 10 MΩ

Current Ripple 1000 VDC rms ripple current produced by the output load due to the output load's pulse

100% Load Steps

Characteristic Definition Unregulated Value repetition frequency or any other operational scenario.

Load Change Slew Rate For startup and mode changes the output load’s load change must be less than or equal to the slew rate requirement. This does not include emergency shutdown.

200 MW/sec

Maximum Power over steady state voltage range. Defines 1.0 per unit power (1 pup = Full Load Rating) Steady-state line to line voltage at module input terminals as established by no load voltage (i.e. open circuit voltage). Defines 1.0 per unit voltage. (1puv = Output Voltage (1000 V nominal for table 4)

2.2.4 E-Stop Interface

Table 5 identifies the signal that constitutes the Remote E-Stop Interface Signal. The ESC will provide an IP54 sealed connection for this interface via MIL-DTL-5015 connector.

Table 5: Remote E-Stop Interface Signal

Discrete Input Description Remote E-Stop Hardwired discrete signal between the PCC and ESC (contact closure) as defined in the Technical Specification for Energy Magazine. When the contact is opened, the Remote E-Stop Signal is activated. The Remote E-Stop Signal remains activated as long as the contact remains open. (Technical Specification Section 3.3.2.5) Note that multiple external E-Stop switches may be connected in series to this single input. Opening any single switch will activate the remote E-Stop. A local E-Stop switch will be connected in series with the remote E-Stop signal.

2.2.5 Thermal Management Interface

Table 6 identifies attributes for the Thermal Management Interface.

Table 6: Thermal Management Interface

Discrete Input Description Thermal Management The connections type to the ESC chilled water system per

Technical Specification for Energy Magazine (Section 3.3.15) for both the inlet and outlet. Connections from the ESC chilled water system shall be able to accommodate the motion of the ESC under shock. The chilled water shall meet the requirements as specified in Technical Specification for Energy Magazine.

The ESC will be required to control the flow of its own cooling in order to maintain safe operation and storage of the GFE Battery System and will not be fed from PCC.

2.2.6 Control & Sensor Interface

Table 7 identifies the signal that constitutes the Control & Sensor Interface. This signal is the network communication between the ESC controller and the EM Application Controller board to be installed within the ESC. The ESC controller is a cabinet controller designed to provide the cabinet status and sensing in accordance with Technical Specification for Energy Magazine Functions typically associated with the cabinet controller will be reporting of status and control of door switches, leak sensors, temperature and humidity sensors, leak sensors, smoke and gas sensors and main input contactor/circuit breaker. Additional functionality will be control of maintenance charger(s) and precharge circuit. In doing these functions, the ESC controller will need to be receiving status and permission signals from the EMS.

Table 7: Control & Sensor Interface Signal

Discrete Input Description Control & Sensor Refer to the energy storage control and cabinet sensor signals iaw

Technical Specification for Energy Magazine (Section 3.3.2 & 3.3.17)

2.2.7 Energy Management System Interface

Table 8 identifies the signal that constitutes the Energy Management System Interface Signal.

Table 8: Energy Management System Interface Signal

Discrete Input Description Energy Management System

This signal is the network communication between the EMS, the ESC Controller, and the EM Application Controller boards. The EMS is a self-contained control system designed to monitor and control the energy storage media within the ESC in accordance with Technical Specification of the EM. The EMS will be composed of electronics, control elements, and sensors to autonomously control, monitor, and report the status of the Energy Storage Media to the ESC Controller and the EM Application Controller. The data interface shall be via a CAN Bus (Version 2.0B) allowing communication of energy storage media status, as well as, control of charging and special modes of the EMS operation. Refer to the EM Storage Media Management System in accordance with the Technical Specification for Energy Magazine (Section 3.3.3)