Free BESS inspection checklist

• The MapTrack BESS inspection checklist contains 29 checks across 5 sections. Sections covered: Isolation & lockout, Battery racks & cells, Power conversion system, Transformer & switchgear, Fire & gas detection.
• Site identification: project name PCS make and model BESS capacity (MWh) container count BMS firmware version commissioning date and inspector electrical licence number.
• Permit isolation and PPE: lockout-tagout of PCS and HVAC arc-flash PPE category insulating gloves rated for the DC bus voltage and gas-detector calibration.
• Battery modules and racks: visual inspection of cell venting bus-bar torque rack interconnect cables module humidity sensors and any electrolyte residue or swelling.

Learn more about maintenance and work orders in MapTrack.

• Thermal runaway prevention: walk-down of BMS thermal data HVAC airflow gas detection and suppression nozzles is the engineered barrier that catches a single-cell anomaly before it propagates across a rack.
• NFPA 855 compliance: the signed inspection record is the evidence the authority having jurisdiction requires for stationary energy storage permits including suppression spacing and clearance verification.
• Grid availability protection: PCS firmware protection settings harmonic filters and AS 4777.2 grid-connection verification keep the site dispatchable and prevent loss-of-mains tripping that erodes revenue.
• Capacity health visibility: capturing state-of-health and state-of-charge data at each inspection feeds the degradation model that predicts when modules need rebalancing or replacement.
• Insurance and warranty defence: insurers and OEM warranty providers expect documented quarterly inspections aligned to IEC 62619 and AS/NZS 5139 as a precondition for coverage on multi-million dollar assets.
• Fire authority readiness: confirming the suppression system gas detection emergency stop and operator training matches the building permit means the fire brigade and local authority can review evidence on demand.

• Site identification: project name PCS make and model BESS capacity (MWh) container count BMS firmware version commissioning date and inspector electrical licence number.
• Permit isolation and PPE: lockout-tagout of PCS and HVAC arc-flash PPE category insulating gloves rated for the DC bus voltage and gas-detector calibration.
• Battery modules and racks: visual inspection of cell venting bus-bar torque rack interconnect cables module humidity sensors and any electrolyte residue or swelling.
• Battery management system: BMS communication health cell voltage spread state-of-health state-of-charge balance fault history and protection setpoint verification.
• Power conversion system (PCS): IGBT cooling DC link capacitor health firmware version protection setpoints AC contactor inspection and harmonic filter capacitor venting.
• Transformer and switchgear: MV transformer oil sample bushing condition tap-changer position switchgear interlocks earth fault relay and surge arrester counter.
• HVAC and thermal management: chiller refrigerant level fan airflow filter condition humidity setpoint and coolant pump operation.
• Fire detection gas and suppression: VESDA aspirating smoke head photoelectric detector hydrogen and electrolyte off-gas detector suppression cylinder pressure and nozzle clearance.
• SCADA and operator interface: SCADA fault log review remote stop test alarm escalation matrix communication channel health and operator training records.
• Sign-off: defect list severity escalation path owner target close-out date inspector signature and licence number.

1. Plan the visit and review SCADA and BMS data before site access

   pull the last quarter of BMS cell voltage spread state-of-charge and state-of-health trends pull the PCS fault history and the HVAC and gas-detector event log agree the inspection scope with the asset owner and pre-stage arc-flash PPE insulating gloves and a calibrated gas detector.

2. Isolate the system and verify zero energy

   stop the PCS from SCADA isolate the AC and DC sides apply lockout-tagout to the PCS HVAC and switchgear verify zero potential at the DC bus and AC terminals with a rated multimeter and post the permit at the entry point before entering any battery enclosure.

3. Inspect the battery modules racks and BMS

   walk each rack visually checking for cell venting electrolyte residue bus-bar torque and rack interconnect cable condition open the BMS interface and confirm cell voltage spread balance state-of-health protection setpoints and fault history download the BMS log and oil sample any liquid-cooled coolant where fitted.

4. Inspect the PCS transformer switchgear and HVAC

   open the PCS cabinet check IGBT cooling DC link capacitor venting AC contactor wear and harmonic filter capacitor condition verify firmware version and protection setpoints inspect the MV transformer bushings tap position oil sample and surge arrester switchgear interlocks and HVAC chiller refrigerant fan airflow filter condition and humidity setpoint.

5. Verify fire gas detection and suppression then close out

   visually inspect VESDA aspirating heads photoelectric smoke detectors hydrogen and electrolyte off-gas detector calibration suppression cylinder pressure and nozzle clearance test the remote emergency stop and SCADA alarm escalation release lockout-tagout return the site to service and submit the signed checklist defect register and BMS PCS and HVAC log references.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

• IEC 62619 (Industrial lithium-ion batteries safety)
• IEEE 1547-2018 (Grid interconnection of distributed energy resources)
• NFPA 855-2023 (Stationary energy storage systems)
• AS/NZS 5139:2019 (Battery systems for power conversion)
• AS 4777.2:2020 (Grid connection via inverters)

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

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