Compact and High-performanceOffering Vast Possibilities for Energy Use.

Expanding the Future of Energy Utilization

Apr.2015GIGACELL® is a trademark of Kawasaki Heavy Industries, Ltd. in Japan and the U.S.A.

GIGACELL Battery Sales Section, Machinery & Parts Sales Dept.,Marketing & Sales Div., Rolling Stock Company

http://www.khi.co.jp/english/gigacell/

1-14-5, Kaigan, Minato-ku, Tokyo 105-8315, JapanPhone: +81-3-3435-2572 Fax: +81-3-3435-2157

Tokyo Head Of�ce

Building 4, 29 Wells Avenue, Yonkers, New York, 10701, U.S.A.Phone: +1-914-376-4700 Fax: +1-914-376-4717 http://www.kawasakirailcar.com/

KAWASAKI RAIL CAR, INC.

GIGACELL® is a next-generation Ni-MH battery.Designed to be eco-friendly, GIGACELL® commits to the ef�cient use of energyand carbon footprint reduction.

HighScalability

FEATURE

Low internal resistance enables fast charging and discharging.

No welding used, enabling easy disassembly for recycling.

Designed to withstand frequent cycles of short, rapid charging and discharging.

No lead, mercury, cadmium or other toxic materials are used.

Low operating temperature; water-based electrolyte eliminates risk of �re.

Rapid Chargeand

Discharge

FEATURE

Easy toRecycle

FEATURE

ExcellentCycle

Durability

FEATURE

EnvironmentallyFriendly

FEATURE

Simpleand Safe

FEATURE

Conventional Battery

Wind power generation

Lead

Solar power generation Railway Gas turbine

AA Type : 2Ah 1.2V 2.4Wh

GIGACELL®

500A-running

3000A-50s

GIGACELL® NICKELdismantling

assembly

Lead oxide Cadmium Mercury Sulfuric acid

organic solvent metallic oxide Lithium hexa�uorophosphate

Received the Grand Prizefor the 19 th Global Environment Award

(Hosted by the Fuji Sankei Communications Group)

Received 2009 Japan Minister of theEnvironment Award for Achievements

in Reducing Global Warming

01 02

150Ah × 36V = 5,400Wh

× 2,250

No No No No No

No No No

0 20 40 60 80 100

50

48

46

44

42

40

38

36

34

32

30

1.0C discharge

3.0C discharge

5.0C discharge

5.0C charge

3.0C charge

1.0C charge

Volt

age

(V)

Charge / discharge capacity ratio (%)

03 0404

Innovative Design

Conventional cylindrical Ni-MH batteries consisting of rolled electrodes

and separators heat up during rapid charges and discharges. These

batteries also have limited scalability due to the energy loss created in

their connections. In addition, their welded structure complicates

recycling procedures.

In the GIGACELL®, cooling fans that send air through the structure

prevent overheating. The bipolar structure minimizes energy loss

between cells and actualizes greater capacity. GIGACELL® is highly

recyclable because of its non-welded structure.

Cooling Fan Powerful and ef�cient cooling enables charging / discharging at high amperages.

Non-welded With no welding processes during its production, disassembly and recycling processes are facilitated.

Fully Sealed The GIGACELL® is fully sealed, needing no mainte-nance.

Comparison of Conventional Ni-MH Battery and GIGACELL®

GIGACELL®

Conventional Ni-MH Cylindrical Battery

Negative electrode

Separator

Positive electrode

Bipolar enables GIGACELL®’s high capacity and rapid charging

GIGACELL® modules are composed of individual cells that are connected in series by their cell walls, with the front and rear surfaces becoming positive and negative electrodes, forming the bipolar structure. The thin cell walls provide a large cross-sectional area that minimizes energy loss, which occurs when the cells are connected. Therefore, the large capacities of modules can be accomplished by increasing the number of cells connected in the bipolar structure.

Bipolar

Press bolt

Fix plate

Single cell

Cooling fan

Detailed Drawing

Separator

Negative electrode

Positive electrode

Heat sink

Positive electrode

Nickel hydroxide/Substrate

Separator

Polyole�n non-woven material

Negative electrode

Hydrogen storage alloy/Substrate

Battery Monitoring System

Safty Tests

Overcharge Test Vibration Test

JIS Z-0200JIS Z 0200UN38.3 TestT.3Vivration(38.3.4.3.2)2.5.7 Vibration Test based on Development of Energy Storage System for Grid-connection with Renewable Energy Resources Basic research for the fundamental study by NEDO

Battery for power storage system(JEAC 5006-2010) table 3-6-2 in Articles 3 to 62.5.3 Overcharge test based on Development of Energy Storage System for Grid-connection with Renewable Energy Resources Basic research for the fundamental study by NEDO

Drop Test Water Immersion Test (fresh water and salt water)

2.5.9 Immersion Test based on Development of Energy Storage System for Grid-connection with Renewable Energy Resources Basic research for the fundamental study by NEDO

JIS C 8714 (Safty Tests for Portable Lithium-Ion Secondary Cells and Batteries For Use In Portable Electronic Applications)

* SOC: State of Charge, is the level of the charge in the battery

The Battery Monitoring System (BMS) that is installed on each module calculates the SOC* and uses this to determine if there are any abnormalities. BMS enhances the safety of GIGACELL®

Functions

Power supply line

Rail

Monitor slave unit(Capable of withstanding 1500 V)

Monitor master unit

IO SystemVarious typesof controllers

CAN:Control Area Network RS485/RS232C

GIGACELL®

GIGACELL®

GIGACELL®

Calculates SOC, takes measurements of cell voltage, battery temperature and battery internal pressure, and outputs warnings as necessary.

Cooling air

05 06

A Combination of Safe,Reliable Rail Transport and Ef�cient Use of Energy

* HSCB= High Speed Circuit Breaker

System Image System Outline

BPS

BPS can provide all functions simultaneously

Energy SavingReducing overall energy consumption by encouraging regenerative braking and then ”recycling” it.

No Regeneration CancellationStabilized line voltage prevents regenerative braking failure.

Peak ShavingPower discharged from the BPS reduces power demand at all times, including rush hours.

Emergency RunsBatteries will power trains to the nearest station during a power outage.

Line Voltage StabilizationCharging and discharging stabilizes line voltage.

Alternative to SubstationsThe BPS can serve as an alternative where substations are difficult to install.

Power line

HSCB

SubstationⅠ SubstationⅡ

Rail

BPS

HSCB

HSCB

HSCB

Battery

Direct Connection to System

Low Costs

No power controllers needed

High Efficiency

No loss through controllers

No Delays and Losses

Max. use of regenerative energy

No EMI

No adverse effects to signal systems

A large effect can be obtained by continuous operation

Fuse

DCCT

Batterymain

monitor

Disconnectswitch

Battery mainmonitor cubicle

Disconnect switchcubicle

Batterycubicle

GIGACELL(2 banks)

DCL

DC reactorcubicle

P-side HSBCcubicle

N-side HSBCcubicle

Hight-speedcircuit breaker

Hight-speedcircuit breaker

BPS System Diagram

Direct Connection to Feeder Line

No DC-DC converters Full range voltagecharge / discharge

900

850

800

750

700

650

600-1500 -1000 -500 0 500 1000 1500

Vo

ltag

e (V

)

Amperage I (A)

Power Supply Line Voltage > Vo Charge

Charge

Vo > Power Supply Line Voltage Discharge

Discharge

NEW APPL ICATIONS

07 08

Energy Saving

No Regeneration Cancellation,Line Voltage Stabilization

Peak Shaving Alternative to SubstationsEmergency Runs

625 V DC Third Rail Voltage & Battery Power Waveforms

14,000

12,000

10,000

8,000

6,000

4,000

2,000

0

-2,000

-4,000

700

650

600

550

500

450

400

350

300

250

6000

5000

4000

3000

2000

1000

0

-1000

-2000

-3000

7:209:20 9:30 9:40 9:50 10:00 10:10 10:20

7:21 7:22 7:23 7:24 7:25

Po

wer

(kW

)

Th

ird

Rai

l V

olt

age[

V]

Bat

tery

Cu

rren

t[A

]

Time

Powered by the rectifier and the BPS

Powered by the rectifier

Powered by the BPS

Voltage Stabilization

3rd

Rai

l V

olt

age

(V)

Time

950

900

850

800

750

700

6504:00 8:00 12:00 16:00 20:00 0:00 4:00

Max. 939 V

Without BPS

Min. 703 V

Max. 854 V

Min. 718 V

Duration of BPS Connection

With BPS

Osaka Subway BPS Data

Location of BPS on Tokyo Monorail Line

Battery Current

3rd Rail Voltage (= Battery Voltage)

Rectifier Shutdown

9:38AM 10:08AMEmergency Power Supply

Transportable BPS

It is available as a temporary substation , in case of theconstruction, maintenance, or expansion of a substation.High tension electric work is not needed, and theconstruction period can be shortened.

All in two 20ft-containersContainer A : GIGACELL (forty modules) + Battery Monitering SystemContainer B : Circuit Braker Panel, Disconecting Switch Panel, etc

6,058 2,438

Tare weight : 2.2t Pay load : 21.8t Gross weight : 24t

2,8

96

(mm)

Disc

harg

e

Disc

harg

eCh

arge

Installed atShinagawa substation

in March 2013

Installed atTamagawa substation

in March 2014

Tokyo Monorail installedtwo BPS to allow strandedtrains on the entire 17.8 kmline to be moved to thenearest station during apower outage

0:00 2:00 4:00 6:00 8:00 10:00 12:00 14:00 16:00 18:00 20:00 22:00 24:00

700

650

600

550

500

450

400

350

300

250

3rd

Rai

l V

olt

age

(V)

(= B

atte

ry V

olt

age

(V))

2500

2000

1500

1000

500

0

-500

-1000

-1500

-2000

Time

3rd Rail Voltage (V)

Battery Power (kW)

NYCT-BPS at Central Substation 3rd Rail Voltage & Battery Power Waveforms

Bat

tery

Po

wer

(k

W)

Dis

char

geC

har

ge

Data taken in July 2010

Char

ge

09 10

Grid Stabilization

System Image

A four-year joint development was conducted to study the usage of GIGACELL® for supply/demand control when more renewable energy is implemented in the grid. GIGACELL® was installed at a substation near a 10-megawatt PV generation plant.

○Electrical Power Supply/ Demand System with GIGACELL®

Output signalCurrent output data

Charging and discharging will occur when frequency exceeds or becomes lower than the standard frequency of 60 Hz respectively. At high and low SOC levels, the system will prevent over-charging/discharging of the batteries.

Example of System Operation

GIGACELL® Bank

Ishizugawa Substation

Solar Sakai

Courtesy of KEPCO

Electrical Power Supply/Demand System

PV power

Wind power

GIGACELL®

Hydro-power

Fossil fuel power

Kansai Electric Power Co., Inc. (KEPCO)Nisshin Electric Co., Ltd.

JointDevelopment

Location KEPCO Ishizugawa Substation

GIGACELL® (12V-177Ah) × 48 modulesComposition

Rated Voltage 576 V

Rated Capacity 177 Ah

Battery Capacity 102 kWh

Battery Capacity 122 kWh

Start of Operation March 2013

Output 250 kW (System output with inverter connected.)

Freq

uen

cy (

Hz)

Inv

erte

r o

utp

ut (

kW)

Bias

con

trol

(kW

)

Dis

char

geC

har

geDi

scha

rge

Char

ge

Frequency increase Charge

Frequency decrease Discharge

Continuous lowfrequency

Continuousdischarge

Low SOC

Charge bias lowers output by 50 kWat SOC below 40% and preventsover-discharge.

Charge bias stops whenSOC recovers to 45%.

The charge bias lowers output by 50 kW in pink

compared to when there is no bias in blue .

20-ft container

20-ft containerNEDO project scope

Grid Stabilization

Installing renewable energy on remote islands with relatively small grid capacity can potentially increase frequency �uctuations. The GIGACELL® system can control these �uctuations, reducing the need for diesel generators to adjust their output.

○Remote Island Frequency Regulation

System Configuration

Wind turbine(OEPC)

Battery bank

20-ft containers for system (front: battery container)

6.6kV, 60Hz

Hzdata

Regulationsignal

Batterystatus

Monitoringsystem

Battery bank122 kWh

Batterystatus

Gridstatus

245kW×2

3640kW

Monitor slave unit

WT DE

TD

PLC

Transformer

Inverter300kVA

BMSLogger

Development of a Large-scale Energy StorageSystem with High-safety and Cost Competitiveness

NEDO*Subsidized Project

LocationMinamidaito, Okinawa PrefectureThe Okinawa Electric Power Co., Inc. (OEPC)Minamidaito C.S. & Internal-combustion Power Station

30-K5 GIGACELL® × 12 modules × 2 banksComposition

* New Energy and Industrial Technology Development Organization

SOC

(%)

2011/09/12 14:00-17:30

Frequency change &inverter output

Demonstration Data & Benefits

DE2 output

One out of twowind turbines

stopped

Battery output

Wind power output

14:30

600

500

400

300

200

100

0

-100

-200

-300

-400

0.30.20.1

0-0.1-0.2-0.3

14:40 14:50 15:00

Ou

tpu

t(k

W)

Fre

qu

en

cyd

evia

tio

n(H

z)

Operation ON Operation OFF

DE1 output

Reduce grid frequency�uctuations due tounstable wind power

Prevent frequency declinein the event of wind powerdrop

Provide alternative to dieselengine power (DE1 & DE2)governor adjustment

Dis

char

geC

har

ge

NEW APPL ICATIONS

11 12

Wind Power Generation

GIGACELL® can be applied for wind integration on the grid. Its smoothing and ramp control functions will reduce the adverse effects of unstable generation output. This leads to further implementation of renewable energy.

○Wind Power Smoothing

Example of Smoothing Wind Power Generation Output

Time

0:00 6:00 12:00 18:00 0:00 6:00 12:00 18:00 0:00

2011/1/10 2011/1/11

Bat

tery

po

wer

(kW

)

SOC

(%

)

Wind turbine output

Gen

erat

ion

ou

tpu

t (k

W)

Dis

char

geC

har

ge

Output after smoothing Actual GIGACELL® output × 8 SOC

GIGACELL®

Power converter

Location Yurihonjo City, Akita Prefecture (Fuji Green Power Co., Ltd.)

Smoothing and ramp control

Components GIGACELL® (12V-177Ah)× 48 modules

Battery Capacity 102 kWh

Start of Operation Above speci�cation completed in April 2010

Application

Fuji Green Power Co., Ltd.Joint Development ○PV + GIGACELL®

GIGACELL® connected to PV panels can store surplus energy for use during peak demand time. It can reduce peak demand, as well as provide power to essential loads during power outages.

Solar Power Generation

Location Yachiyo Shoin Gakuen

CompositionGIGACELL® (12V-182Ah) × 24 modules x 3 banks

Battery Capacity 148 kWh

Start of Operation August 2006

Peak shavingApplication Solar panels(100 kW)

Charge/discharge controller GIGACELL®Load

Mainload

DC-AC converter

Because the GIGACELL® offers stable battery voltage when charging and discharging, it can share the same DC-AC converter as the solar panels, and can be directly connected to the DC section, therefore reducing installation costs.

Solar panels

DC-AC converter

LoadLoadLoadLoad

GIGACELL®

DC-DC converterunnecessary

50

0

-50

Consumed Power

Received grid power

DC Output fromGIGACELL®

Discharge(Peak Shaving)

Charging(disconnected from power grid)

Output of 100 kWPower Controller

Output of 70 kW Power Controller

Command tobreak speci�c loads

TargetedPower Demand

500

400

300

200

100

0

En

ergy

(kW

)

Time (Hours)

GIG

AC

ELL

®D

isch

arge

Ou

tpu

t (k

W)

4 6 8 10 12 14 16 18 20

Example of Peak Shaving

NEW APPL ICATIONS

13 14

Distributed Energy (Gas Turbines & Engines) + GIGACELL®

Distributed Generation/Micro-grid

The Hybrid Power System forms a micro-grid system composed of installed wind turbine generator, PV panel and GIGACELL® batteries. The system controller sends optimal charge/discharge signals to the GIGACELL® through the power conditioner based on the generation data of renewable energies and the building’s power

consumption data and the power conditioner charges/discharges GIGACELL®. Therefore, the system not only stabilizes renewable energies, but also can reduce peak demand, level off power loads and provide emergency power during a blackout.

Kawasaki’s Kobe Works Office

Location Kawasaki’s Kobe Works Of�ce

CompositionGIGACELL® (12V-188Ah)12 modules × 2 banks

Battery Capacity 54kWh

Start of Operation April 2012

ApplicationPeak demand reduction, emergency power,renewable energy smoothing

○Kawasaki’s Kobe Works Of�ce Building Hybrid Power System

Office building

Power consumptiondata

Power input/output

Charge/dischargesignal

Charge/discharge

Generationdata

Generationoutput

PurchasedpowerGeneration data

Generationoutput

System controller

GridWind turbineGIGACELL®PV panels

Kawasaki Hybrid Power Conditioner

Hybrid Power System

Load InsideFacility

Gas Engine90 kW

Gas Engine350 kW

Charge/DischargeController

Charge/DischargePower Controller

100 kW

GIGACELL®81.2 kWh

Capacitor100 kW×2 sec.

Power SupplyControl System

A network of multiple power sources within a given area forms a micro-grid. The GIGACELL® has the ability to quickly respond to �uctuations in demand loads and generated power. It can ensure safe and dependable power for micro-grids isolated from the power grid.

Composition of Micro-grid

Location Shimizu Co. Ltd., Technical Research Center

Stabilization control to fix the amount of powerpurchased from power grid

Application

Components GIGACELL® (36V-141Ah) × 16 modules

Battery Capacity 81.2 kWh

Start of Operation February 2011

GIGACELL® can be combined with standby generators to provide stable power to �uctuating loads. This can reduce the capacity, cost, and space for emergency standby generators.

System Outline Example System Operation (Example)

Gas turbines/engines

Renewable energy

Lights Buildings Factories Gantry cranes

Small, stable loads Large, temporary loadsRegenerative machines

Electricity use / Battery charge Electricity generation / Battery discharge

6000

0

(Gen

erat

or

cap

acit

y)

(kVA) Disch

argefrom

GIGACELL®

Ch

arge toG

IGA

CE

LL®

Generator sup

ply

with

GIG

ACELL®

assistance

Regenerative energy

Load fluctuation GIGACELL® discharge GIGACELL® charge Generator output

Converter

GIGACELL®

Distributed Energy System

Kawasaki continues to develop and disseminate solutions for utilizing renewable energies such as PV, wind, and biomass.

Small hydro plant

Solar heat plant

Binary plant

Gas engineWoody biomassgassification power plant

Energy demand

Electric energy

Electricity & heat energy

Energy supplyGIGACELL®

Biomass methane plant

PV panel

Wind turbine

Power plant

Commercialfacilities

GIGACELL®

Gas turbinecogeneration system

Incineration plant

Schools

Homes Factories

NEW APPL ICATIONS