DC electrical interface
Connector class, cable routing, fuse/breaker coordination and HVIL documented in interface drawings.
- DC window
- 1,050–1,500 Vdc
- Rated current
- 2,000 A continuous
- HVIL
- Dual path demo
- Clearance
- Per IEC demo class
PCS / INVERTER INTERFACE
Define every boundary between battery and power conversion equipment
Interface baseline TC-PCS-IF-26-013 DEMO DATA · PCS-IF-01 · 2026-W32
Engineering interface delivery for DC connection, protection, pre-charge, power commands, status feedback, mechanical layout, thermal boundaries and joint verification.
- Voltage
- 1,050–1,500 Vdc
- Power
- 1.25 MW
- Current
- 2,000 A cont.
- Comm
- CAN-FD / Modbus TCP
- Pre-charge
- SEQ-07 · FROZEN
- Stop policy
- Safe stop · ≤100 ms
- ICD
- ICD-PCS-2608-111-D
- Open items
- 3 demo
- Physical link
- 92% demo
INTERFACE WALL · five layers in sync BESS PCS
- DC power OEM ↔ PCS
- Signal / data OEM ↔ PCS
- Safety interlock OEM ↔ PCS
- Thermal / env OEM ↔ PCS
- Physical / service OEM ↔ PCS
-
Responsibility matrix
Layer ownership RACI
-
DC connection & protection
Bus, fuse and contactor
-
Pre-charge & power commands
Energization handshake
-
Interlocks & joint FAT
Hardwired safety chain
Responsibility matrix · who owns each interface layer
Battery OEM, PCS supplier and integrator boundaries documented before build · not resolved at commissioning.
| Interface layer | Battery OEM | PCS supplier | Integrator |
|---|---|---|---|
| DC bus & protection | R | C | A |
| Pre-charge sequence | R | R | A |
| Power limit map | R | C | A |
| Status / fault comm | R | R | I |
| Hardwired interlock | R | R | A |
Interface wall · five layers in sync
- DC bus & protection
- Pre-charge sequence
- Power limit map
- Status / fault comm
- Hardwired interlock
An interface is not a checklist — it is a set of boundaries that must close together
Battery cabinet → interface integration skid → PCS · five paths must handshake before energization. DEMO · schematic only
Battery cabinet DC bus · BMS · HVIL
Interface integration skid Shared boundary closure
PCS Power conversion · commands
- Energy
- Signal
- Safety
- Thermal
- Physical
- Ownership handoff
- OEM · PCS · SI roles frozen in ICD
- Closure rule
- All five paths agree before enable
DEMO · schematic values
DC electrical · pre-charge sequence · power arbitration
Three columns close the energization boundary — connection specs, timing ownership, and command/limit arbitration.
Pre-charge / energize / shutdown
Sequence ownership, timing budgets and authority handoff between BMS and PCS controllers.
- Request PCS enable · BMS permission check
- Pre-charge Resistor close · ΔV ≤ 5%
- Main close Contactor · SOP authority live
- Run / stop Power cmd · fault map ICD §4
Power command & limit arbitration
Who wins when EMS, BMS and PCS limits disagree — priority stack before enable.
DEMO · priority stack
- Hard limit PCS hardware trip · absolute ceiling
- BMS cap SOC / temp / cell ΔV derate
- EMS setpoint Dispatch P/Q within remaining headroom
- Soft ramp Rate limit · anti-windup on enable
Safety interlocks must stay deterministic across device boundaries
Seven-step closed loop from trigger to ownership — hardwired and supervised paths agree before reset. DEMO DATA · PCS-IF-01 · 2026-W32
- Trigger source E-stop · fire · door · BMS trip
- Detect / request Hardwire + comm dual path
- Execute isolate PCS stop · DC contactor open
- Feedback confirm Status bits · dry contact echo
- Isolation done HVIL open · DC-Link verified
- Reset allow Local clear · remote permission
- Action ownership OEM / PCS / EMS RACI
- Hardwired path
- Supervised comm
- Feedback echo
- Ownership handoff
DEMO · sample values
Communication I/O · mechanical clearance · thermal / env · derating
Four interface cards at the battery–PCS boundary — tables and demo curve, not a photo collage.
Communication & I/O
| Channel | BESS | PCS |
|---|---|---|
| CAN-FD | 500 k · BMS | Gateway / adapter |
| Modbus TCP | Optional EMS | Primary PCS port |
| Ethernet | O&M jump | Service NIC |
| Dry contact | Fire / door | E-stop chain |
Mechanical / service clearance
- Rear aisle
- 800 mm · contactor access
- Side gap
- ≥100 mm · cable tray
- Wall penetration
- Sealed HV gland · fire stop
- EMI separation
- Shielded tray · 300 mm
Thermal / environment
- Ambient
- −20–45 °C (OEM)
- Altitude base
- 1,000 m rated
- Max altitude
- ≤2,000 m (derate)
- Exhaust
- Plenum · no recirculation
Combined derating curve
Demo SVG · altitude × ambient · not a measured chart
DEMO · acceptance sample
Fault mapping · ICD governance · V-model · acceptance matrix
Interface Factory Acceptance evidence before site energization — demo tables labeled.
- Interface wiring QA CLOSED
TC-DEMO-PCS-WIR-111 - Pre-charge HIL CLOSED
TC-DEMO-PCS-HIL-111 - Joint FAT CONDITIONAL
TC-DEMO-PCS-FAT-111 - ICD release REVIEW
ICD-PCS-2608-111-D
Fault mapping matrix
| Fault | Source | PCS action | Recovery |
|---|---|---|---|
| CAN loss | BMS / PCS | Safe stop | Auto after link |
| E-stop | Hardwire | Immediate isolate | Local reset |
| Overtemp | PCS / thermal | Derate → trip | Cool-down |
| ΔV exceed | BMS | Block enable | Cell balance |
Interface type & adaptation
| Type | Scope | Owner |
|---|---|---|
| Common | DC bus · HVIL · E-stop | OEM + PCS |
| Optional | Modbus map · coolant | Project SI |
| Project-specific | Fire panel · site EMS | EPC |
ICD governance
| Rev | Change | Gate | Status |
|---|---|---|---|
| A | Initial draft | Kickoff | CLOSED |
| B | Pre-charge SEQ-07 | HIL | CLOSED |
| C | Fault map §4 | Joint FAT | CONDITIONAL |
| D | Sign-off pack | Release | REVIEW |
V-model verification steps
- URS / ICD Requirements freeze
- Architecture Five-layer wall
- Detailed design Drawings · maps
- Unit test Contactor · HVIL
- Integration Skid handshake
- HIL Pre-charge SEQ
- Joint FAT Witnessed evidence
- Site SAT Energization
- Acceptance Conditional close
- As-built Baseline lock
Acceptance matrix
| Item | Criteria | Result | Note |
|---|---|---|---|
| DC continuity | ≤ demo Ω | PASS | Demo |
| Pre-charge time | ≤ 3 s demo | PASS | SEQ-07 |
| Interlock chain | ≤ 100 ms | PASS | Hardwire |
| Comm heartbeat | 3× timeout | CONDITIONAL | Site verify |
| Thermal clearance | 800 mm rear | PASS | Layout |
| ICD pack | Rev D signed | REVIEW | Open 3 |