H.E.R.P.S — Energy Storage & Switching System

System Overview — Energy Flow & Architecture

Volume 16 defines the hybrid energy management core of the H.E.R.P.S system. This subsystem integrates AC mains, pump motor drive, energy recovery generator, battery bank, supercapacitor module, inverter unit, automatic transfer switch and control electronics into a unified energy switching and storage architecture.

• Power Sources: AC Mains, Pump Drive Motor, Energy Recovery Generator
• Hybrid Power Control Unit: Power Management, Switching, PLC/SCADA CPU
• Energy Storage: LiFePO₄ Battery Bank (400 VDC), Supercapacitor Module (400 VDC)
• Outputs: Pump Motor Drive, Auxiliary Plant Loads
• Flow Lines: AC Power, DC Power, Control/Data, Monitoring/Feedback

Battery Bank Assembly — Layout & Dimensions

• Front View: 1200 × 1200 × 350 mm
• Side View: 800 × 1200 × 350 mm

Battery Bank Specifications

• Type: LiFePO₄
• Nominal Voltage: 400 VDC
• Total Capacity: 200 Ah
• Energy Storage: 80 kWh
• Module Capacity: 20 Ah
• Configuration: 10S × 20P
• Max Continuous Current: 200 A
• Operating Temperature: 0°C to +40°C
• Dimensions: 1200 × 800 × 1200 mm
• Weight: ~800 kg

Power Conversion & Inverter Unit

• Front View: 1000 × 1000 × 100 mm
• Side View: 800 × 1000 × 100 mm

Inverter/Converter Specifications

• Type: DC/AC Inverter
• Rated Power: 200 kVA
• Input Voltage: 400 VDC
• AC Bus Voltage: 400 VAC
• Frequency: 50/60 Hz
• Power Factor: ≥ 0.95
• Cooling: Forced Air
• Efficiency: ≥ 95%
• Dimensions: 1000 × 800 × 1000 mm
• Weight: ~400 kg

Automatic Transfer Switch (ATS)

• Front View: 800 × 1200 mm
• Side View: 400 × 1200 mm

ATS Specifications

• Rated Current: 630 A
• Rated Voltage: 400 VAC
• Frequency: 50/60 Hz
• Poles: 4 N
• Transfer Time: ≤ 100 ms
• Control Voltage: 24 VDC
• Electrical Life: 5,000 Operations
• Protection Class: IP54

Supercapacitor Module

• Front View: 600 × 1000 mm
• Side View: 500 × 1000 mm

Supercapacitor Specifications

• Capacitance: 165 F
• Nominal Voltage: 400 VDC
• Energy Storage: 13.2 kWh
• Max Continuous Current: 100 A
• Peak Current: 500 A
• Charge/Discharge Efficiency: ≥ 95%
• Operating Temperature: −10°C to +40°C
• Dimensions: 600 × 500 × 1000 mm
• Weight: ~180 kg

DC Busbar & Distribution Panel

• Front View: 1000 × 1000 mm
• Side View: 400 × 1000 mm

Distribution Specifications

• DC Bus Voltage: 400–800 VDC
• Rated Current: 1000 A
• Busbar Material: Copper
• Cross Section: 100 × 10 mm
• Protection Class: IP54
• Dimensions: 1000 × 400 × 1000 mm
• Weight: ~250 kg

Control Cabinet & Electronics

• Front View: 1000 × 1000 mm
• Side View: 800 × 1000 mm

Controller Specifications

• Main Controller: Industrial PLC
• PLC Model: Siemens S7‑1500
• HMI Model: Siemens TP‑1200
• Communication: Ethernet / Modbus
• Operating Voltage: 24 VDC
• Protection Class: IP54
• Dimensions: 1000 × 800 × 1000 mm
• Weight: ~300 kg

Wiring & Connection Diagram (Simplified)

• AC Mains → ATS → Inverter → AC Loads
• Battery Bank → DC Bus → Inverter
• Supercapacitor Module → DC Bus → Inverter
• Energy Recovery Generator → DC Bus
• Flow Lines: AC (green), DC (red), Control/Data (purple)

System Protection & Safety

• Overvoltage Protection: SPD + MOV
• Undervoltage Protection: Software + Relay
• Overcurrent Protection: Breaker + Relay
• Short Circuit Protection: Main Disconnect
• Over Temperature Protection: Sensor + Alarm
• Isolation Monitoring: Isolation Monitor
• Emergency Stop: Manual Stop Switch
• Fire Detection (Optional): Smoke + Heat Sensor

Engineering Notes

• All dimensions in millimeters
• Electrical components must be industrial grade
• Installation must comply with IEC 61319, IEC 62040 and local codes
• Battery & supercapacitor modules require ventilation