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  9. Atlas Copco ZBP45 User manual

Atlas Copco ZBP45 User manual

User and maintenance manual
for ZenergiZe Energy Storage Systems (ESS)
English
ZBP45 - ZBE45 ESF
00_00_ZBP45_EN.book Page 1 Monday, October 19, 2020 9:52 AM
Instruction ManualInstruction Manual
00_00_ZBP45_EN.book Page 2 Monday, October 19, 2020 9:52 AM
ATLAS COPCO - POWER AND FLOW DIVISION
www.atlascopco.com
Printed matter N°
2960 5810 01
10/2020
ZBP45 and ZBE45
User and maintenance manual
for ZenergiZe Energy Storage Systems (ESS)
User and maintenance manual .............................................................. 5
Circuit diagrams .................................................................................... 77
Original instructions
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Warranty and Liability Limitation
Use only authorized parts.
Any damage or malfunction caused by the use of unauthorized parts is not covered by
Warranty or Product Liability.
The manufacturer does not accept any liability for any damage arising from modifications,
additions or conversions made without the manufacturer's approval in writing.
Neglecting maintenance or making changes to the setup of the machine can result in major
hazards, including fire risk.
While every effort has been made to ensure that the information in this manual is correct,
Atlas Copco does not assume responsibility for possible errors.
Copyright 2020, Grupos Electrógenos Europa, S.A.U., Zaragoza, Spain.
Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies
in particular to trademarks, model denominations, part numbers and drawings.
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Contents
1 Safety precautions......................7
1.1 Introduction ........................................7
1.2 General safety precautions...............8
1.3 Safety during transport and
installation ..........................................9
1.4 Safety during use and operation ....10
1.5 Safety during maintenance and
repair .................................................11
1.6 Tool applications safety ..................12
1.7 Battery safety precautions..............12
2 Main parts..................................14
2.1 General description .........................14
2.2 Markings ...........................................15
2.3 Mechanical features.........................16
2.3.1 Galvanized skid..................................16
2.3.2 Galvanized and painted canopy.........16
2.3.3 Lifting beam and sling guides ............16
2.3.4 Data plate and serial number.............16
2.4 Electrical features ............................16
2.4.1 Lithium ION batteries .........................16
2.4.2 Inverter / battery charger....................17
2.4.3 Control and power cubicle..................17
2.4.4 Emergency stop button ......................18
2.4.5 Sockets panel.....................................19
2.4.6 Earth leakage relay ............................19
2.4.7 Earth pin.............................................19
2.4.8 Remote start connector......................19
3 Installation and connection .....21
3.1 Lifting ................................................21
3.2 Positioning and transport ...............21
3.2.1 Positioning for operation ....................21
3.2.2 Transportation and positioning of the
ESS onto vehicles ..............................22
3.3 Installation ........................................23
3.3.1 Indoor installation...............................23
3.3.2 Outdoor installation ............................23
3.4 Connecting the ESS.........................23
3.4.1 Precautions for non-linear and
sensitive loads....................................23
3.4.2 Quality, minimum section and
maximum length of cables .................24
3.4.3 Connecting the power supply.............24
3.4.4 Connecting the load ...........................25
4 Operating instructions............. 26
4.1 Before starting..................................26
4.2 Operating the ESS............................26
4.2.1 Before the ESS is started...................27
4.2.2 Starting the ESS.................................27
4.2.3 During operation.................................27
4.2.4 Connecting appliances.......................27
4.2.5 Stopping the ESS...............................28
4.3 Operating the CCGX controller.......28
4.3.1 Push buttons and display ...................28
4.3.2 Menu overview ...................................29
4.3.3 Battery State of Charge (SOC) ..........33
4.3.4 VE.Bus Inverter/charger monitoring ...34
4.4 Setting the CCGX controller............37
4.4.1 Customize the logo on the Boat &
Motorhome page ................................37
Congratulations on the purchase of your ZenergiZe Energy Storage System, from now on ESS, based on batteries. It is a solid, safe and reliable machine, built according
to the latest technology. Follow the instructions in this booklet and we guarantee you years of trouble free operation. Please read the following instructions carefully
before starting to use your machine.
While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors. Atlas Copco
reserves the right to make changes without prior notice.
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4.4.2 Enabling the start/stop function..........37
4.4.3 Ethernet LAN port ..............................42
5 Periodic maintenance...............43
5.1 Maintenance schedule.....................43
5.1.1 Precautions ........................................45
5.1.2 Use of maintenance schedule............45
5.1.3 Use of service packs..........................45
5.1.4 Best practices ....................................45
5.2 Adjustments and service
procedures .......................................46
5.2.1 Battery care........................................46
5.2.2 Cooling system ..................................47
6 Checks and trouble shooting . 49
6.1 VE.Bus Error Codes.........................50
6.1.1 General ..............................................50
6.1.2 VE.Bus Error Codes...........................50
6.2 GX error codes .................................55
6.2.1 Different origins of errors ...................55
6.2.2 Error #42 - Storage corrupt ................55
6.2.3 Error #47 - Data partition issue ..........55
6.2.4 Error #48 - DVCC with incompatible
firmware .............................................56
6.3 MPPT Solar Charger Error Codes ..56
6.3.1 Error Codes........................................56
7 Storage of the ESS ...................60
7.1 Storage..............................................60
7.2 Preparing for operation after
storage ..............................................60
8 Disposal .....................................61
8.1 General..............................................61
8.2 Disposal of materials .......................61
8.3 Disposal of Li-ion batteries .............62
9 Options ......................................63
9.1 Overview of the electrical options..63
9.2 Electrical options .............................63
9.2.1 Modem GSM 3G - GPS .....................63
9.2.2 WIFI USB stick...................................63
9.2.3 MPPT Solar charger + MC4 PV
connectors..........................................64
9.2.4 Sockets configuration.........................64
9.2.5 PowerLock connectors.......................65
9.2.6 ELP sockets .......................................65
9.2.7 Cold weather ......................................66
9.3 Overview of the mechanical
options ..............................................67
9.4 Mechanical options..........................67
9.4.1 Special colour canopy ........................67
9.4.2 Trailer.................................................67
10 Technical specifications of
the ESS ......................................68
10.1 Technical specifications of the
ZBP45 unit ........................................68
10.2 Technical specifications of the
ZBE45 unit ........................................70
10.3 Critical bolt connections .................72
10.4 Dimension drawing ..........................73
10.5 Conversion list of SI units into
British units ......................................75
10.6 Data plate ..........................................75
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1 Safety precautions
To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the ESS.
1.1 Introduction
The policy of Atlas Copco is to provide the users of their
equipment with safe, reliable and efficient products.
Factors taken into account are among others:
- the intended and predictable future use of the
products, and the environments in which they are
expected to operate,
- applicable rules, codes and regulations,
- the expected useful product life, assuming proper
service and maintenance,
- providing the manual with up-to-date information.
Before handling any product, take time to read the
relevant instruction manual. Besides giving detailed
operating instructions, it also gives specific information
about safety, preventive maintenance, etc.
Keep the manual always at the unit location, easy
accessible to the operating personnel.
See also the safety precautions of the engine and
possible other equipment, which are separately sent
along or are mentioned on the equipment or parts of the
unit.
These safety precautions are general and some
statements will therefore not always apply to a particular
unit.
Only people that have the right skills should be allowed
to operate, adjust, perform maintenance or repair on
Atlas Copco equipment. It is the responsibility of
management to appoint operators with the appropriate
training and skill for each category of job.
Skill level 1: Operator
An operator is trained in all aspects of operating the unit
with the push-buttons, and is trained to know the safety
aspects.
Skill level 2: Mechanical technician
A mechanical technician is trained to operate the unit the
same as the operator. In addition, the mechanical
technician is also trained to perform maintenance and
repair, as described in the instruction manual, and is
allowed to change settings of the control and safety
system. A mechanical technician does not work on live
electrical components.
Skill level 3: Electrical technician
An electrical technician is trained and has the same
qualifications as both the operator and the mechanical
technician. In addition, the electrical technician may
carry out electrical repairs within the various enclosures
of the unit. This includes work on live electrical
components.
Skill level 4: Specialist from the manufacturer
This is a skilled specialist sent by the manufacturer or its
agent to perform complex repairs or modifications to the
equipment.
In general it is recommended that not more than two
people operate the unit, more operators could lead to
unsafe operating conditions. Take necessary steps to
keep unauthorized persons away from the unit and
eliminate all possible sources of danger at the unit.
When handling, operating, overhauling and/or
performing maintenance or repair on Atlas Copco
equipment, the mechanics are expected to use safe
engineering practices and to observe all relevant local
safety requirements and ordinances. The following list is
a reminder of special safety directives and precautions
mainly applicable to Atlas Copco equipment.
Neglecting the safety precautions may endanger people
as well as environment and machinery:
- endanger people due to electrical, mechanical or
chemical influences,
- endanger the environment due to leakage of
solvents or other substances,
- endanger the machinery due to function failures.
All responsibility for any damage or injury resulting
from neglecting these precautions or by non-observance
of ordinary caution and due care required in handling,
operating, maintenance or repair, also if not expressly
mentioned in this instruction manual, is disclaimed by
Atlas Copco.
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The manufacturer does not accept any liability for any
damage arising from the use of non-original parts and for
modifications, additions or conversions made without
the manufacturer’s approval in writing.
If any statement in this manual does not comply with
local legislation, the stricter of the two shall be applied.
Statements in these safety precautions should not be
interpreted as suggestions, recommendations or
inducements that it should be used in violation of any
applicable laws or regulations.
Atlas Copco is also not responsible for patent
infringement or violation of any rights of third parties
arising out of the use of the ESS. Atlas Copco reserves
the right to make changes regarding the technical
specifications of this product without prior notice.
1.2 General safety precautions
1 The owner is responsible for maintaining the unit in
a safe operating condition. Unit parts and accesso-
ries must be replaced if missing or unsuitable for
safe operation.
2 The supervisor, or the responsible person, shall at
all times make sure that all instructions regarding
machinery and equipment operation and
maintenance are strictly followed and that the
machines with all accessories and safety devices, as
well as the consuming devices, are in good repair,
free of abnormal wear or abuse, and are not
tampered with.
3 Whenever there is an indication or any suspicion
that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers
shall be opened before sufficient cooling time has
elapsed.
4 Normal ratings (pressures, temperatures, speeds,
etc.) shall be durably marked.
5 Operate the unit only for the intended purpose and
within its rated limits (pressure, temperature,
speeds, etc.).
6 The machinery and equipment shall be kept clean,
i.e. as free as possible from dust or other deposits.
7 To prevent an increase in working temperature,
inspect and clean heat transfer surfaces (cooler fins,
intercoolers, water jackets, etc.) regularly. See the
maintenance schedule.
8 All regulating and safety devices shall be
maintained with due care to ensure that they
function properly. They may not be put out of
action.
9 Pressure and temperature gauges shall be checked
regularly with regard to their accuracy. They shall
be replaced whenever outside acceptable tolerances.
10 Safety devices shall be tested as described in the
maintenance schedule of the instruction manual to
determine that they are in good operating condition.
11 Mind the markings and information labels on the
unit.
12 In the event the safety labels are damaged or
destroyed, they must be replaced to ensure operator
safety.
13 Keep the work area neat. Lack of order will increase
the risk of accidents.
14 When working on the unit, wear safety clothing.
Depending on the kind of activities these are: safety
glasses, ear protection, safety helmet (including
visor), safety gloves, protective clothing, safety
shoes. Do not wear the hair long and loose (protect
long hair with a hairnet), or wear loose clothing or
jewellery.
15 Take precautions against fire. Keep a fire-extin-
guisher in the vicinity.
16 ESS (with earthing pin):
Earth the pack of batteries as well as the load
properly.
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During operation, hazardous voltages can be present at
the ESS surroundings.
Work on or in the vicinity of the device is only allowed
to be performed by qualified electricians. Before each
job (maintenance and repair) of the ESS, the device must
be taken out of service by pressing the emergency off
switch! All consumers and voltage sources (generator,
network or similar) must be removed from the ESS
surroundings. Otherwise, the ESS or a connected
generator could automatically start (under certain
circumstances). Even routine maintenance may only be
carried out by qualified electricians. It must therefore be
ensured that, during the work on the electrical system,
the device is stress-free, i.e. separated from the generator
or mains (AC voltage). Even if the ESS has been
separated from its voltage source (generator or grid),
there may still be a dangerous voltage present at the
outputs. To avoid this, the emergency off switch must be
pressed. Inputs and outputs are separated by all Poles.
All electrical components are discharged after 20
seconds and the respective work can then be carried out
safely.
If a thunderstorm occurs in the immediate vicinity of the
ESS, disconnect all electrical devices from the ESS and
press the emergency off switch or the main switch!
Overvoltage hazard!
Warning: The ESS is suitable for use in outdoor areas.
Protection against moisture is equivalent to the class
IP54 (splash water protection).
Cleaning with steam radiators, high pressure cleaners,
hard water jet or similar devices is not allowed.
1.3 Safety during transport and
installation
To lift a unit, all loose or pivoting parts, e.g. doors, shall
first be securely fastened.
Do not attach cables, chains or ropes directly to the
lifting eye; apply a crane hook or lifting shackle meeting
local safety regulations. Never allow sharp bends in
lifting cables, chains or ropes.
Helicopter lifting is not allowed.
It is strictly forbidden to dwell or stay in the risk zone
under a lifted load. Never lift the unit over people or
residential areas. Lifting acceleration and deceleration
shall be kept within safe limits.
1 In case of transporting a non-trailer unit on a truck,
fasten it to the truck by attaching straps mainly via
the marked roof guides and additionally via the fork
lift holes, via the holes in the frame at the front and
back or via the lifting beam. To prevent damage,
never put straps on the roof surface of the unit.
2 To lift heavy parts, a hoist of ample capacity, tested
and approved according to local safety regulations,
shall be used.
3 Lifting hooks, eyes, shackles, etc., shall never be
bent and shall only have stress in line with their
design load axis. The capacity of a lifting device
diminishes when the lifting force is applied at an
angle to its load axis.
4 Lifting eye of the unit can only be used when the
environment temperature is between -20°C and
80°C.
5 For maximum safety and efficiency of the lifting
apparatus all lifting members shall be applied as
near to perpendicular as possible. If required, a
lifting beam shall be applied between hoist and
load.
6 Never leave a load hanging on a hoist.
7 A hoist has to be installed in such a way that the
object will be lifted perpendicular. If that is not
possible, the necessary precautions must be taken to
prevent load-swinging, e.g. by using two hoists,
each at approximately the same angle not exceeding
30° from the vertical.
8 ESSs shall be stalled on an even, solid floor, in a
clean location with sufficient ventilation. If the floor
is not level or can vary in inclination, consult Atlas
Copco.
9 The electrical connections shall correspond to local
codes. The machines shall be earthed and protected
against short circuits by fuses or circuit breakers.
10 Never connect the ESS outlets to an installation
which is also connected to a public mains.
11 Before connecting a load, switch off the corre-
sponding circuit breaker, and check whether fre-
quency, voltage, current and power factor comply
with the ratings of the pack of batteries.
12 Before transportation of the unit, switch off all the
circuit breakers.
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1.4 Safety during use and
operation
1 When operating in a dust-laden atmosphere, place
the unit so that dust is not carried towards it by the
wind. Operation in clean surroundings considerably
extends the intervals for cleaning the air intake
filters and the cores of the coolers.
2 All doors shall be shut during operation so as not to
disturb the cooling air flow inside the bodywork
and/or render the silencing less effective. A door
should be kept open for a short period only e.g. for
inspection or adjustment.
3 Periodically carry out maintenance works according
to the maintenance schedule.
4 Stationary housing guards are provided on all
rotating or reciprocating parts not otherwise
protected and which may be hazardous to
personnel. Machinery shall never be put into
operation, when such guards have been removed,
before the guards are securely reinstalled.
5 Noise, even at reasonable levels, can cause irritation
and disturbance which, over a long period of time,
may cause severe injuries to the nervous system of
human beings.
When the sound pressure level, at any point where
personnel normally has to attend, is:
- below 70 dB(A): no action needs to be taken,
- above 70 dB(A): noise-protective devices should
be provided for people continuously being
present in the room,
- below 85 dB(A): no action needs to be taken for
occasional visitors staying a limited time only,
- above 85 dB(A): room to be classified as a noise-
hazardous area and an obvious warning shall be
placed permanently at each entrance to alert
people entering the room, for even relatively
short times, about the need to wear ear
protectors,
- above 95 dB(A): the warning(s) at the
entrance(s) shall be completed with the recom-
mendation that also occasional visitors shall
wear ear protectors,
- above 105 dB(A): special ear protectors that are
adequate for this noise level and the spectral
composition of the noise shall be provided and a
special warning to that effect shall be placed at
each entrance.
6 Never operate the unit in surroundings where there
is a possibility of taking in flammable or toxic
fumes.
7 If the working process produces fumes, dust or
vibration hazards, etc., take the necessary steps to
eliminate the risk of personnel injury.
8 When using compressed air or inert gas to clean
down equipment, do so with caution and use the
appropriate protection, at least safety glasses, for
the operator as well as for any bystander. Do not
apply compressed air or inert gas to your skin or
direct an air or gas stream at people. Never use it to
clean dirt from your clothes.
9 When washing parts in or with a cleaning solvent,
provide the required ventilation and use appropriate
protection such as a breathing filter, safety glasses,
rubber apron and gloves, etc.
10 Safety shoes should be compulsory in any work-
shop and if there is a risk, however small, of falling
objects, wearing of a safety helmet should be
included.
11 If there is a risk of inhaling hazardous gases, fumes
or dust, the respiratory organs must be protected and
depending on the nature of the hazard, so must the
eyes and skin.
12 Remember that where there is visible dust, the finer,
invisible particles will almost certainly be present
too; but the fact that no dust can be seen is not a
reliable indication that dangerous, invisible dust is
not present in the air.
13 Never operate the ESS in excess of its limits as
indicated in the technical specifications.
14 Do not open electrical cabinets, cubicles or other
equipment while voltage is supplied. If such cannot
be avoided, e.g. for measurements, tests or
adjustments, have the action carried out by a
qualified electrician only, with appropriate tools,
and ascertain that the required bodily protection
against electrical hazards is applied.
15 Never touch the power terminals during operation
of the machine.
16 Whenever an abnormal condition arises, e.g.
excessive vibration, noise, odour, etc., switch the
circuit breakers to OFF and stop the ESS. Correct
the faulty condition before restarting.
17 Check the electric cables regularly. Damaged cables
and insufficient tightening of connections may
cause electric shocks. Whenever damaged wires or
dangerous conditions are observed, switch the
circuit breakers to OFF. Replace the damaged wires
or correct the dangerous condition before restarting.
Make sure that all electric connections are securely
tightened.
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18 Avoid overloading the ESS, it is provided with
circuit breakers for overload protection. When a
breaker has tripped, reduce the concerned load
before restarting.
19 Never remove the cover of the output terminals dur-
ing operation. Before connecting or disconnecting
wires, switch off the load and the circuit breakers,
stop the machine and make sure that the machine
cannot be started inadvertently or there is any resid-
ual voltage on the power circuit.
20 When operating the ESS in Remote or Auto mode,
observe all relevant local legislation.
1.5 Safety during maintenance
and repair
Maintenance, overhaul and repair work shall only be
carried out by adequately trained personnel; if required,
under supervision of someone qualified for the job.
1 Use only the correct tools for maintenance and
repair work, and only tools which are in good
condition.
2 Parts shall only be replaced by genuine Atlas Copco
replacement parts.
3 All maintenance work, other than routine attention,
shall only be undertaken when the unit is stopped.
Steps shall be taken to prevent inadvertent starting.
In addition, a warning sign bearing a legend such as
“work in progress; do not start” shall be attached to
the starting equipment.
On engine-driven units the battery shall be
disconnected and removed or the terminals covered
by insulating caps.
On electrically driven units the main switch shall be
locked in open position and the fuses shall be taken
out. A warning sign bearing a legend such as “work
in progress; do not supply voltage” shall be attached
to the fuse box or main switch.
4 Prior to stripping an engine or other machine or
undertaking major overhaul on it, prevent all
movable parts from rolling over or moving.
5 Make sure that no tools, loose parts or rags are left
in or on the machine. Never leave rags or loose
clothing near the engine air intake.
6 Never use flammable solvents for cleaning (fire-
risk).
7 Take safety precautions against toxic vapours of
cleaning liquids.
8 Never use machine parts as a climbing aid.
9 Observe scrupulous cleanliness during maintenance
and repair. Keep away dirt, cover the parts and
exposed openings with a clean cloth, paper or tape.
10 Do not remove any of, or tamper with, the sound-
damping material. Keep the material free of dirt and
liquids such as cleansing agents. If any sound-
damping material is damaged, replace it to prevent
the sound pressure level from increasing.
11 When performing any operation involving heat,
flames or sparks on a machine, the surrounding
components shall first be screened with non-
flammable material.
12 Never use a light source with open flame for
inspecting the interior of a machine.
13 Check the direction of rotation of electric motors
when starting up the machine initially and after any
alteration to the electrical connection(s) or switch
gear, to check that the oil pump and the fan function
properly.
14 Maintenance and repair work should be recorded in
an operator’s logbook for all machinery. Frequency
and nature of repairs can reveal unsafe conditions.
15 When hot parts have to be handled, e.g. shrink
fitting, special heat-resistant gloves shall be used
and, if required, other body protection shall be
applied.
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16 When using cartridge type breathing filter equip-
ment, ascertain that the correct type of cartridge is
used and that its useful service life is not surpassed.
17 Make sure that solvents and other substances likely
to pollute the environment are properly disposed of.
18 Before clearing the ESS for use after maintenance
or overhaul, submit it to a test run, check that the
AC power performance is correct and that the
control and shutdown devices function correctly.
All precautions regarding batteries: see chapter 1.7.
1.6 Tool applications safety
Apply the proper tool for each job. With the knowledge
of correct tool use and knowing the limitations of tools,
along with some common sense, many accidents can be
prevented.
Special service tools are available for specific jobs and
should be used when recommended. The use of these
tools will save time and prevent damage to parts.
1.7 Battery safety precautions
While working on the Li-ion Battery wear protective
eyeglasses and clothing.
1 Observe these instructions and keep them located
near the Li-ion Battery for future reference.
Work on the Li-ion Battery should be carried out by
qualified personnel only.
2 Any uncovered battery material such as electrolyte
or powder on the skin or in the eyes must be flushed
with plenty of clean water immediately. Then seek
medical assistance. Spillages on clothing should be
rinsed out with water.
3 Explosion and fire hazard.
Terminals of the Li-ion Battery are always a live;
therefore do not place items or tools on the Li-ion
Battery. Avoid short circuits, too deep discharges
and too high charge currents. Use insulated tools.
Do not wear any metallic items such as watches,
bracelets, et cetera. In case of fire, you must use a
type D, foam or CO2 fire extinguisher.
4 Never try to open or dismantle the Li-ion Battery.
Electrolyte is very corrosive. In normal working
conditions contact with the electrolyte is impossi-
ble. If the battery casing is damaged do not touch
the exposed electrolyte or powder because it is cor-
rosive.
5 Too deep discharges damage the Li-ion battery
seriously and can even be dangerous. Therefore, use
of an external safety relay is obligatory.
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6 Li-ion Batteries are heavy. If involved in an
accident they can become a projectile! Ensure
adequate and secure mounting and always use
suitable handling equipment for transportation.
Handle with care because Li-ion Batteries are
sensitive to mechanical shock.
7 If charged after the Li-ion battery was discharged
below the Discharge cut-off voltage, or when the
Li-ion battery is damaged or overcharged, the Li-
ion battery can release a harmful mixture of gasses
such as phosphate.
8 Non-compliance with operating instructions, repairs
made with other than original parts, or repairs made
without authorization render the warranty void.
9 The Li-ion battery must be transported in its
original or equivalent package and in an upright
position.
If the battery is in its package, use soft slings to
avoid damage.
Do not stand below a Li-ion battery when it is
hoisted. Never lift the battery at the terminals, only
lift the battery at the handles.
10 Batteries are tested according to UN Handbook of
Tests and Criteria, part III, sub section 38.3 (ST/SG/
AC.10/11/Rev.5).
For transport the batteries belong to the category
UN3480, Class 9, Packaging Group II and have to
be transported according to this regulation. This
means that for land and sea transport (ADR, RID &
IMDG) they have to be packed according to
packaging instruction P903 and for air transport
(IATA) according to packaging instruction P965.
The original packaging satisfies these instructions.
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2 Main parts
2.1 General description
ZenergiZe modular ESS design to meet the requirements of applications such as rental, events and telecom. Ideal for any metropolitan job or event. Based in lithium ion
batteries, this portable product is ready to supply power in the most demanding situation, working in island mode or a hybrid solution together with a diesel generator.
Giving flexibility to the final product with a list of options such as solar panel connection to increase its sustainability or cold weather kit for the most critical environments.
A greener solution for a more efficient performance.
AI Air inlets
BAH Batteries access hatch
DP Data plate
EP Earthing point
ES Emergency stop
FFans
FS Forklift slots
LE Lifting eye
PS Pallet slot
SG Sling guides
ES
DP
LE
F
AI
FS FS
AI
PS
EP
SG
BAH
00_00_ZBP45_EN.book Page 14 Monday, October 19, 2020 9:52 AM
- 15 -
2.2 Markings
Markings provide instructions and information. They
also warn of hazards. For convenience and safety,
keep all markings in legible condition, replacing them
when damaged or missing. Replacement markings are
available from the factory.
A brief description of all markings provided on the
ESS is given hereafter. The precise location of all
markings can be found in the parts manual of this
ESS.
Indicates that an electric voltage,
dangerous to life, is present. Never
touch the electric terminals during
operation.
Indicates that these parts can become
very hot during operation (e.g.
engine, cooler, etc.). Always make
sure that these parts are cooled down
before touching them.
Indicates the forklift slots.
Indicates that the machine should not
be cleaned with high pressurised
water.
Indicates that the unit may
start automatically and
that the instruction book
has to be consulted prior
to use.
Read the instruction
manual before using the
lifting eye.
Indicates the location of the battery.
Avoid water ingress as this could
cause short circuits.
Indicates the earthing connections on
the ESS.
Indicates the roof guides.
Warning!
Indicates that the unit contains a
chargeable battery.
Indicates that the unit contains
lithium cells or batteries.
Indicates that the unit may start
automatically and that the instruction
book has to be consulter prior to use.
Indicates Arc flash and shock
hazard. Follow all requirements
in NFPA 70E for safe work
practices and for Personal
Protective Equipment.
Warning and information label
on Arc flash hazard and
appropriate PPE requirement.
00_00_ZBP45_EN.book Page 15 Monday, October 19, 2020 9:52 AM
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2.3 Mechanical features
The mechanical features described in this chapter are
standard provided on this energy storage pack.
2.3.1 Galvanized skid
To be able to lift the ESS by means of a forklift, a
galvanized skid with rectangular slots is provided.
2.3.2 Galvanized and painted canopy
The unit is equipped with a galvanized steel canopy to
avoid corrosion. This process means, there is a
considerable barrier between the steel plate and air
ensuring that the painted surface is not compromised.
The pieces are also cut with a Nitrogen high-pressure
laser (prevents from rust while its production). And
they are all finished and protected with a powder
coating paint.
Also rain caps are placed in the most sensitive parts of
the machine to protect from water ingress.
2.3.3 Lifting beam and sling guides
A lifting beam is attached to the unit base frame. This
single lifting point will allow to lift easily the ESS.
In order to secure the position while transport, use the
guides placed in the roof to avoid any canopy damage
with the proper slings.
This is not a lifting system alternative.
2.3.4 Data plate and serial number
The ESS is furnished with a data plate showing the
product code, the unit number, the energy stored and
the power output (see “Data plate” on page 75).
The serial number is located on the front side of the
canopy.
2.4 Electrical features
The electrical features described in this chapter are
standard provided on this ESS.
2.4.1 Lithium ION batteries
Lithium-iron-phosphate (LiFePO4 or LFP) is the
safest of its family. It also does not need to be fully
charged to perform correctly as other chemistries
need. Service life even slightly improves in case of
partial charge instead of a full charge. This is a major
advantage in addition, its wide operating temperature
range, excellent cycling performance, low internal
resistance and high efficiency.
LFP is therefore the chemistry of choice for very
demanding applications.
Each battery is connected and controlled by the BMS
(Battery Management System) that makes possible
the communication between components and learn
from each performance, as for example, get
automatically their cells balanced.
00_00_ZBP45_EN.book Page 16 Monday, October 19, 2020 9:52 AM
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2.4.2 Inverter / battery charger
Power electronics that combines inverter and charger.
It is needed to transform the energy supply from
batteries (DC) to the loads (AC) with or without
additional sources as diesel generators or grid. They
can provide to the consumer double of their nominal
power during short period (seconds) thanks to its
overload capability, enabling the start of inductive
loads as electric motors.
2.4.3 Control and power cubicle
The control cubicle grouping the ESS controller
(from now on CCGX (Color Control GX)), fuses,
automatic switches sockets, etc., is accessible by
opening the door at the front.
Q23 .....Breaker 32A 4P 30mA
Q22 .....Breaker 63A 4P
Q21 .....Breaker 125A 4P
X30 .....Remote start connector
F23 ......Fuse 30A Gpv
F22 ......Fuse 30A Gpv
F21 ......Fuse 30A Gpv
X22 .....Female socket 63A 4P
X23 .....Female socket 32A 4P
X21 .....Female socket 125A 4P
A1 .......CCGX
R10......Potentiometer
Q24 .....Breaker 16A 2P 30mA
Q25 .....Breaker 16A 2P 30mA
Q2 .......Breaker 16A 2P
Q1 .......Breaker 100A 4P
X3 .......Socket 16A 1P+N male (optional in
ZBE)
X24 .....Female socket 16A 2P
X25 .....Female socket 16A 2P
X2 .......Socket 125A 3P+N male
X25
X24
X2
X3
X30
F23
F22
F21
X22
X23
X21
Q1
Q2
Q25
Q24
A1
R10
Q21
Q22
Q23
00_00_ZBP45_EN.book Page 17 Monday, October 19, 2020 9:52 AM
- 18 -
K4 .......Relay 230V 1C
K3 .......Relay 48V 1C
K2 .......Relay 48V 2C
K1 .......Relay 48V 1C
F400.... Fuse 6A
Q20 .....Breaker 160A 4P
N22 .....ELR 30/300mA
P20...... V mains sender
Q11 .....Breaker 2A
K102 ...Relay 230V
K103 ...Relay 230V FANS 3NO
TM1 ....Thermostat
R10 .....Potentiometer
S20 .....Telergon selector
KM1 ....Contactor 4P 230V 125A
KM2 ....Cont. 2NO+2NC 230V 80A
2.4.4 Emergency stop button
Push the button to stop the ESS in case of an
emergency. When the button is pressed, it must be
unlocked by rotating it clockwise, before the ESS can
be restarted.
Q20
F400
K1
K2
K3
K4
P20
Q11
K102
K103
TM1
R10
S20
N22
KM2
KM1
00_00_ZBP45_EN.book Page 18 Monday, October 19, 2020 9:52 AM
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2.4.5 Sockets panel X22 ..... Female socket 63A 4P
X23 ..... Female socket 32A 4P
X21 ..... Female socket 125A 4P
X3 ....... Socket 16A 1P+N male (optional in
ZBE)
X24 ..... Female socket 16A 2P
X25 ..... Female socket 16A 2P
X2 ....... Socket 125A 3P+N male
The ESS is provided with inlet and outlets sockets:
– One main inlet 3-phases socket X2 to connect to
the external power supply (genset or mains).
– Several 3-phases (X21-22-23) and 2 single phase
outlet sockets (X24-25) to connect the different
loads to the ESS.
– One single phase inlet socket X3 (optional in
ZBE) to connect the ESS to an external supply in
order to slowly recharge the ESS and maintain the
batteries voltage and charge during storage or
non-activity.
2.4.6 Earth leakage relay
An earth leakage relay provides protection in case of
an earth leak current. It detects and indicates an earth
fault current and activates the main circuit breaker.
The detection level is set at 30 mA with instantaneous
trip, but it is adjustable in intensity and in trip delay.
2.4.7 Earth pin
The earth pin, to be connected to the ESS’s earth
terminal is located at the bottom of the frame on the
outside.
2.4.8 Remote start connector
X30 .....Remote start connector
X25
X24
X2
X3
X22
X23
X21
X30
00_00_ZBP45_EN.book Page 19 Monday, October 19, 2020 9:52 AM
- 20 -
This connector includes dry contact to remote start
and stop the genset connected to the ESS. The
intelligence of the hybridization is controlled by the
ESS.
00_00_ZBP45_EN.book Page 20 Monday, October 19, 2020 9:52 AM

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