Energy Storage Asset Operation and Maintenance Management Manual
Chapter 0 New System Delivery Acceptance Procedure (FAT/SAT)
0.1 到货开箱检验（Arrival Inspection）
⚠ If transportation damage is found, take photos immediately and send a written claim notice to the supplier within 24 hours. If the time limit is exceeded, the customer will be deemed to have accepted that there is no damage.
0.2 Static detection before power-on (Pre-Energization)
It must be executed in a completely power-off state, and the executor is: L2 level engineer or above.
DC insulation resistance test: 1000V megger, positive pole to ground, negative pole to ground, requirement ≥2MΩ
AC insulation resistance test: 500V megger, L line to ground, N line to ground, requirement ≥1MΩ
Ground continuity test: Use a milliohmmeter to verify the cabinet shell ground resistance, requiring ≤0.1Ω
DC polarity check: Use a multimeter to confirm that the positive and negative poles of the battery are connected correctly, and be careful not to reverse the connection.
AC phase sequence confirmation: The phase sequence table confirms that the three-phase inverter L1/L2/L3 sequence is correct (if applicable)
Bolt torque spot check: randomly select 5 main circuit terminals to verify the torque (M8: 12N·m, M10: 25N·m)
0.3 First power-on function verification (Energization Test)
⚠ The first power-on must be supervised by a CoreTect L2 or above engineer on-site throughout the entire process. Agents are strictly prohibited from performing this alone.
0.4 72-hour trial operation (Burn-In Test)
Continuous operation for 72 hours, Level 1 cloud daily remote inspection data
Qualification standards: Single cell pressure difference ≤ 20mV, maximum temperature rise ≤ 10°C, no P1/P2 level alarm
After passing the test within 72 hours, a "SAT Acceptance Certificate" will be issued as the legal basis for the SLA contract to officially take effect.
If a fault occurs and is resolved within 72 hours, reset the timer and start timing again.
0.5 Customer handover (Handover Checklist)
Chapter 1 General Principles and Overview of Operation and Maintenance Management System
1.1 Operation and maintenance vision and service concept
CoreTect abandons the traditional "break-fix" model and is committed to building a "data-driven O&M" system: through standardized on-site operations and cloud data monitoring, preventive maintenance is fully implemented and gradually evolves to predictive maintenance as data is accumulated, maximizing the life cycle of energy storage assets and eliminating safety accidents.
1.2 Scope of application and service boundaries
Scope of jurisdiction (SLA coverage area): Industrial and commercial/residential energy storage system cabinets, BMS communication links, cloud gateways (4G DTU/ESP32) and temperature control security subsystems authorized by CoreTect to leave the factory and take over.
1.3 Core terms and definitions (Glossary)
1.4 Operation and maintenance organizational structure and work order flow
Chapter 2 Monthly/Quarterly Standard Inspection and Maintenance Procedures
2.1 Prerequisites for operation - PPE and tools
2.2 Safety isolation and electrical testing (LOTO SOP)
Switch the system to "standby" through CoreTect Cloud or local screen and confirm that the current shows 0A
Disconnect the external AC main circuit breaker of the energy storage cabinet, hang a warning sign saying "Someone is working, closing is prohibited" and lock it with a physical lock.
Disconnect the DC main circuit breaker of the high-voltage control box and also tag out and lock it.
Forced static discharge: wait 15 minutes to completely discharge the large DC-Link capacitor inside the PCS
High-voltage electricity test: Use the multimeter at DC 1000V to measure the voltage between the positive pole and the negative pole of the DC busbar and the positive pole and the ground.
⚠ Judgment criteria: Voltage <36V DC is considered safe before subsequent physical contact operations can be carried out. Contact is strictly prohibited if it does not meet the standards!
2.3 Monthly appearance inspection (once a month, L1 level or above)
2.4 Quarterly in-depth maintenance (once per quarter, L2 level and above)
2.4.1 Thermal imaging scan (executed in charged and fully loaded state)
2.4.2 Insulation test and torque retightening (performed after power off)
DC system insulation: 1000V megger, positive pole to ground, negative pole to ground. Requirements: ≥2MΩ safe; <1MΩ closing is strictly prohibited
AC system insulation: 500V megger, L/N line to ground. Requirements: ≥1MΩ
Torque retightening: For abnormal points in thermal imaging, use an insulated torque wrench to retighten (M6: 5N·m, M8: 12N·m, M12: 45N·m)
2.4.3 BMS data verification
2.5 CoreTect Cloud automated inspection mechanism
2:00 a.m. every day: The cloud automatically generates a daily health report with green/yellow/red markings, and pushes it to the customer and operation and maintenance center.
🟢 90-100 points (Excellent): normal maintenance cycle
🟡 70-89 points (Fair): sub-healthy, the system will push an early warning and come with a life extension maintenance quote.
🔴 <70 points (Critical): High-risk status, triggering manual intervention work order
2.6 Job ending and data closed loop
Count tools: Be careful to prevent short circuits caused by leftover metal tools. The number of items entering and leaving the tool bag must be consistent.
BMS data extraction: forced download of underlying operating log archives for the past 30 days
Restore power supply: remove the LOTO lock, close the circuit breaker, and issue a power-on command from the cloud
Wait for 15 minutes before evacuating if there is no alarm.
Work order closed loop: Upload inspection photos with time watermark on the mobile terminal, and customer electronic signature
Chapter 3 Core Component Replacement and On-site Repair Procedures
⚠ All operations must be performed by CoreTect certified engineers. Before any disassembly, the LOTO safety isolation procedures in Section 2.2 must be completed.
3.1 Golden principles for troubleshooting
Fatal warning: Reversing the order of disassembling and assembling the wiring harness will cause an instant short circuit in the collection line, burn the motherboard, and even cause arc burns!
Disassembly sequence (strictly follow)
Cut off weak current: First unplug all cell voltage/temperature sampling cables (white multi-core cables)
Disconnect communication: Unplug the RS485/CAN communication network cable and screen cable
Disconnect the main negative output: remove the black main negative wire connected to BMS P- (load terminal)
Disconnect the battery negative input: Finally remove the total negative input line connected to BMS B- (battery terminal)
Installation sequence (completely opposite to disassembly)
Connect the battery terminal: Connect the battery negative copper bar to the B- terminal of the new BMS, torque 12N·m, and draw the anti-loosening line
Connect to the output terminal: Connect the negative pole of the external output to the P- terminal of the BMS
Sampling line verification and connection: Use a multimeter to measure each pin of the cable in sequence, confirm that the voltage increases in steps of 3.2V/6.4V/9.6V and then insert it.
Restore communication: Plug back the 4G DTU network cable and temperature measurement NTC probe
Software burning and verification
Turn on the DC circuit breaker, power on, and connect the laptop via USB to RS485 cable
Load CoreTect's exclusive parameter package for this model of battery (overvoltage 3.65V, undervoltage 2.70V, etc.)
The cloud backend confirms that the device is back online, completes the trial run for 15 minutes, and submits the replacement SN code.
3.3 Procedure for replacing the entire inverter main board
Applicable scenarios: The resistance between IGBT D-S ≈ 0Ω; the inverter reports hardware protection (E006/F10) when it is powered on and cannot be reset.
⚠ Before replacement, photos must be taken to collect evidence (full view of the inside of the cabinet, close-up of IGBT, distribution box, seal status) as RCA legal evidence!
Execute LOTO and confirm that the DC BUS voltage is <36V
Unplug all communication cables and loosen the connecting cables between the driver board and power board.
Remove the radiator fixing screws, remove the old thermal grease, and clean the radiator aluminum base plate
Install the new motherboard and evenly apply thermal grease (thickness 0.1-0.2mm)
Tighten according to the specified torque (M6: 5N·m, M8: 12N·m)
Do not connect the load, only close the DC circuit breaker, and observe whether the bus voltage rises normally.
Import CoreTect standard parameter configuration file, especially verify the 60Hz frequency setting
Turn on the no-load inverter and measure the AC output with a multimeter: it should be 220V/60Hz sine wave
Gradually load to 50% rated power, and monitor the IGBT temperature rise (personnel must stay at all times for the first 30 minutes)
3.4 Single cell voltage difference equalization and replacement procedures
Applicable scenarios: Cloud alarm cell voltage difference (ΔV) >100mV, or the internal resistance of a certain string of cells is abnormal.
Battery replacement steps
Accurately locate backward battery cell numbers in the cloud
Use a professional suction cup to lift the battery core vertically upwards (314Ah cell is about 5.5kg). It is strictly prohibited to lift by the pole!
New batteries are put into the array, and a 1mm thick FR4 insulation board is inserted in the middle to prevent friction short circuit.
Connect the copper bar, and the torque is strictly set to 6N·m (M6 stud). After tightening, use a red marker to draw a "one-word anti-loosening line"
Deep equalization: CC-CV mode, 3.60V cut-off, 20A~50A current, charge until the current drops below 0.5A
Chapter 4 Extreme Scenarios and Disaster Emergency Plan (ERP)
4.1 Typhoon and severe flood disaster preparedness plan
4.1.1 48 hours before the typhoon makes landfall (triggered by PAGASA Signal No.2 and above)
Cloud action: Automatically issue a "forced full charge command" to the inverter to increase the SOC lower limit to 80%
On-site actions: Check whether the rainproof shutters of the outdoor cabinet are locked, and clean the drainage ditch within 2 meters around the cabinet.
4.1.2 When water is about to cover 10cm from the bottom of the cabinet - emergency fuse
⚠ Remotely forcibly shut down the inverter and BMS charging and discharging. Instruct customers to wear insulating boots and immediately pull down the DC main switch and AC main switch.
4.1.3 Restoring power supply after disaster (fatal red line)
⚠ Absolute prohibition: Customers are strictly prohibited from closing the switch and sending electricity by themselves after the water recedes! Warranty will be void if the machine explodes due to illegal startup!
The engineer came to the door with a 1000V megohmmeter. If there was water vapor inside, he used an industrial hot air blower to blow it dry.
Insulation resistance test: the positive and negative poles must be >2MΩ to ground. Power can be restored only after reaching the standard.
4.2 Battery thermal runaway emergency procedures (Thermal Runaway)
Trigger conditions: The unit temperature exceeds 75°C and continues to rise, or the cabinet makes a hissing pressure release sound and acrid white smoke.
Chapter 5 PCS (energy storage converter) operation and maintenance standards
5.1 PCS safety isolation and electrical inspection specifications
Turn off the AC grid circuit breaker, load circuit breaker, PV isolation switch and battery DC main gate in sequence
Forced to stand for ≥5 minutes (15 minutes for models above 100kW) to completely discharge the internal DC-Link large capacitor
Use a multimeter at DC 1000V range to measure BAT+ and BAT- to confirm that the internal residual voltage is <36V DC
5.2 PCS electrical connection and torque maintenance
5.3 PCS heat dissipation and dust-proof maintenance
External dust screen (monthly): Remove the air inlet dust screen, clean it with a high-pressure air gun (pressure <0.3MPa), dry it thoroughly and then reinstall it.
Cooling fan test (quarterly): The on-screen diagnostic menu forces the fan to run at 100%. If there is abnormal noise in the bearing, replace it.
Thermal conductive silicone grease inspection (annual): Check whether the silicone grease is dry, cracked and powdery, and reapply if there is any abnormality (thickness 0.1~0.2mm)
Chapter 6 Communication and Cloud Platform Operation and Maintenance Standards
6.1 Physical link layer check
Communication cable anti-interference: RS485 and CAN communication lines must use twisted pair shielded wires, and the shielding layer is grounded at one end at the inverter end.
Keep a distance of more than 15cm from AC and DC thick cables, and it is strictly prohibited to bundle them in parallel in the same cable trough.
Terminal matching resistor: If the bus distance exceeds 50 meters, a 120Ω terminal resistor must be connected in parallel at the end of the bus
6.2 Edge intelligent gateway operation and maintenance
Signal strength: RSSI>-85dBm, if it is lower than this value, the antenna must be moved to an unobstructed outdoor location
Watchdog test (quarterly): Unplug the 4G antenna to simulate a network disconnection, and observe whether the gateway can automatically restart and reconnect within 300 seconds.
6.3 Network security management
Default password modification: The factory default password (admin/admin) must be modified during the SAT stage, and a strong password of ≥12 digits must be set.
API key rotation: Third-party integration API keys such as Telegram Bot are rotated once a year
Operation log retention: All parameter modifications and remote control instructions are automatically recorded in the cloud and retained for ≥ 2 years
Chapter 7 Failure Response and RCA Investigation
7.1 SLA响应矩阵
7.2 Analysis of RCA root causes of major accidents
Evidence collection of illegal loads: Check the distribution box. If an oversized inductive load is found to be privately connected, take photos to collect evidence and characterize it as a violation by the customer.
Harsh environment evidence collection: If you find water leaking from the roof dripping into the cabinet or the anti-tamper warranty sticker is torn, immediately shut down the machine and take photos
Black box log extraction: Export the BMS bottom-level logs 5 minutes before the crash to analyze whether there is an ultra-high voltage surge in the power grid.
Issue an 8D standard RCA report within 48 hours to clarify the ownership of responsibilities
Chapter 8 Special Specifications for On-site Operation in the Philippines
8.1 Extreme moisture and salt spray corrosion protection
Contact sealing (quarterly): Use electronic cleaner to clean the oxide layer, apply industrial conductive paste after tightening, and spray conformal anti-paint
Anti-condensation management (every rainy season inspection): Check whether the anti-condensation heating plate at the bottom of the cabinet is working properly
8.2 Pest and rodent disaster investigation
Mandatory action: Every time you open the cabinet, the debris at the bottom must be cleaned, and the cable entry and exit holes must be tightly sealed with fireproof mud.
Industrial insect repellent/rodent repellent tablets are regularly placed in the corner of the electrical cabin (replaced quarterly)
8.3 Surge protection of old power grids
Lightning protection module (SPD) inspection: Check the status indicator window every quarter, green = normal, red = activated and needs to be replaced
Before the typhoon season (before June every year): Special SPD inspection of the entire station, and lightning protection modules that are nearing the end of their service life are replaced in advance
Chapter 9 Customer Service and Asset Management
9.1 SOH life tracking and asset health score
The cloud integrates SOC, SOH, maximum pressure difference, and historical overtemperature times to automatically generate a hundred-point "health score"
Monthly physical examination report: The system automatically generates a PDF report on the first day of each month and sends it to the customer.
Commercial conversion: If the score is lower than 80 points, customer service will proactively send an early warning and attach a "Deep Balance and Life Extension Maintenance Quotation"
9.2 SaaS service package grading
9.3 Reference price for paid maintenance
9.4 Spare parts warehouse management (One-in, One-out principle)
Bottom line of safety inventory: 4G gateway, DC circuit breaker, fuse tube, spare battery core, and BMS motherboard should be kept above the safe level
Trade-in and write-off: The engineer applies for a new motherboard for rush repair. When returning, he must hand back the burned old parts and enter them into the system for write-off.
Chapter 10 Annual Maintenance Calendar and KPI System
10.1 Overview of maintenance frequency
10.2 Philippine climate-adapted annual calendar
10.3 Operation and maintenance KPI system
Chapter 11 Firmware Upgrade and Network Security Management
11.1 BMS firmware upgrade procedures
⚠ Version locking principle: Firmware upgrades during the warranty period must be authorized in writing by CoreTect headquarters. Private upgrades will invalidate the warranty.
Backup: Export the complete parameter configuration file from BMS before upgrading, and backup one copy locally and in the cloud.
Version Compatibility Confirmation: Check the compatibility list of new firmware with current battery models
Switch to standby mode and confirm that the charge and discharge current is 0A
Connect the USB to RS485 cable to the laptop and open the corresponding brand PC software
Power outages are strictly prohibited during the upgrade! Monitor the progress bar throughout the process
After the upgrade is completed and the system is restarted, check that all protection parameters are consistent with the backup files one by one.
The cloud confirms that the device is back online, performs 5-minute charge and discharge verification, and files the work order.
11.2 Network security management
Chapter 12 Employee Training and Certification System
Detailed course content can be found in the separate document "CoreTect Engineer Training Course Manual CT-TRN-2026-V1.0"
12.1 Level 3 certification path
12.2 Certification maintenance regulations
L1/L2 certification is renewed every 2 years (retake the practical assessment)
If a safety violation occurs (if LOTO is not implemented), the on-site qualification will be immediately suspended and you must participate in retraining and re-assess.
Chapter 13 Environmental Compliance and Used Battery Disposal
13.1 Relevant regulatory framework in the Philippines
13.2 SOP for disposal of used batteries
⚠ It is strictly prohibited to discard, disassemble, short-circuit or burn used batteries with fire! LFP batteries are hazardous solid waste.
After the battery core is determined to be scrapped, a "hazardous waste" label is attached and the serial number and weight are recorded.
Stored in the dedicated hazardous waste isolation area of the Marikina warehouse (fireproof cabinet, independent area)
When a certain amount is accumulated (recommended once a quarter), contact a DENR-approved hazardous waste treatment provider
Issue a hazardous waste transport manifest (Waste Transport Manifest), and the processor issues a recycling certificate for archiving
13.3 Carbon emission reduction record (customer-oriented ESG report)
Annual power generation per device (kWh) → Carbon reduction (×0.71 kg CO₂/kWh, Philippine power grid emission coefficient)
Automatically generate a "Green Energy Contribution Report" every month as the data source for customers' ESG reports
Compare electricity bills before and after installation to calculate actual economic savings and strengthen motivation for renewal
Appendix A: Monthly inspection record form (printable)
Equipment number: ______________ Customer name: ______________ Address: ____________________________
Inspection date: ______________ Engineer name: ______________ Certification level: □L1 □L2
Weather conditions: □ Sunny □ Cloudy □ Rain Arrival time: ______ Departure time: ______
Comprehensive assessment of this inspection: □ All qualified □ There is a yellow warning (the work order has been registered) □ There is a red warning (the response has been initiated)
Signature of Customer Representative: ____________________ Date: ____________________
Engineer's signature: ____________________ Certificate number: ______________
Appendix B: Standard List of Spare Parts Safety Stock
CoreTect Global Technology | CT-SOP-OM-2026-V2.0 | Internal Top Secret Document