Atlas Copco ZenergiZe ZBP15 User manual

Instruction book
ZenergiZe Energy Storage Systems (ESS)
ZBP15 - ZBP45 ESF

Atlas Copco
ZenergiZe Energy Storage Systems (ESS)
ZBP15 - ZBP45 ESF
Instruction book
Original instructions
COPYRIGHT NOTICE
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.
This instruction book is valid for CE, non-CE as well as UKCA labelled machines. It
meets the requirements for instructions specified by the applicable European directives
or UK statutory instruments as identified in the Declaration of Conformity.
April 2023
No. 2960 8500 00
www.atlascopco.com

Table of contents
1 Safety precautions..........................................................................................................5
1.1 Introduction............................................................................................................................... 5
1.2 General safety precautions.................................................................................................... 6
1.3 Safety during transport and installation............................................................................ 7
1.4 Safety during use and operation............................................................................................ 8
1.5 Safety during maintenance and repair...................................................................................9
1.6 Tool applications safety........................................................................................................ 10
1.7 Battery safety precautions...................................................................................................10
2 Main parts......................................................................................................................12
2.1 General description................................................................................................................ 12
2.2 Markings and labels................................................................................................................ 13
2.3 Mechanical features............................................................................................................... 13
2.4 Electrical features.................................................................................................................14
3 Installation and connection......................................................................................... 20
3.1 Lifting.........................................................................................................................................20
3.2 Positioning and transport..................................................................................................... 20
3.3 Installation...............................................................................................................................22
3.4 Connecting the ESS.................................................................................................................22
4 Operating instructions................................................................................................. 25
4.1 Before starting........................................................................................................................25
4.2 Operating the ESS................................................................................................................... 25
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5 Operating the ECO Controller..................................................................................... 32
5.1 General......................................................................................................................................32
5.2 Main side tabs............................................................................................................................33
5.3 Additional tabs......................................................................................................................... 60
5.4 Additional working modes......................................................................................................69
6 Maintenance..................................................................................................................75
6.1 Maintenance schedule.............................................................................................................75
6.2 Adjustments and service procedures..................................................................................76
7 Checks and troubleshooting....................................................................................... 85
8 Storage of the ESS....................................................................................................... 90
8.1 Storage..................................................................................................................................... 90
8.2 Preparing for operation after storage..............................................................................90
9 Disposal.........................................................................................................................91
9.1 General......................................................................................................................................91
9.2 Disposal of materials..............................................................................................................91
9.3 Disposal of Li-ion batteries....................................................................................................91
10 Available option............................................................................................................ 92
10.1 Overview of the electrical options......................................................................................92
10.2 Electrical options................................................................................................................... 92
10.3 Overview of the mechanical options.................................................................................... 95
10.4 Mechanical options..................................................................................................................95
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11 Technical specifications of the ESS........................................................................... 97
11.1 Technical specifications of the ZBP15-ZBP45 unit.............................................................97
11.2 Critical bolt connections.................................................................................................... 100
11.3 Dimension drawing................................................................................................................. 102
11.4 Conversion list of SI units into British units................................................................... 103
11.5 Data plate................................................................................................................................103
12 Circuit diagrams......................................................................................................... 105
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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 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.
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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.
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
• The owner is responsible for maintaining the unit in a safe operating condition. Unit parts and
accessories must be replaced if missing or unsuitable for safe operation.
• 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.
• 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.
• Normal ratings (pressures, temperatures, speeds, etc.) shall be durably marked.
• Operate the unit only for the intended purpose and within its rated limits (pressure, temperature,
speeds, etc.).
• The machinery and equipment shall be kept clean, i.e. as free as possible from dust or other
deposits.
• To prevent an increase in working temperature, inspect filters regularly. See the maintenance
schedule.
• 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.
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• Safety devices shall be tested as described in the maintenance schedule of the instruction
manual to determine that they are in good operating condition.
•Mind the markings and information labels on the unit.
• In the event the safety labels are damaged or destroyed, they must be replaced to ensure
operator safety.
• Keep the work area neat. Lack of order will increase the risk of accidents.
• 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.
• Take precautions against fire. Keep a fire-extinguisher in the vicinity.
•Warning: The ESS is suitable for use in outdoor areas. Protection against moisture is
equivalent to the class IP54 (splash water protection).
ESS (with earthing pin): Earth the pack of batteries as well as the load properly. 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 30 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!
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.
• 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.
• To lift heavy parts, a hoist of ample capacity, tested and approved according to local safety
regulations, shall be used.
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• 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.
•Lifting eye of the unit can only be used when the environment temperature is between -20°C
and 80°C.
• 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.
• Never leave a load hanging on a hoist.
• 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.
• 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.
• The electrical connections shall correspond to local codes. The machines shall be earthed and
protected against short circuits by fuses or circuit breakers.
• Never connect the ESS outlets to an installation which is also connected to a public mains.
• Before connecting a load, switch off the corresponding circuit breaker, and check whether
frequency, voltage, current and power factor comply with the ratings of the pack of batteries.
• Before transportation of the unit, switch off all the circuit breakers.
1.4 Safety during use and operation
• 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.
• 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.
• Periodically carry out maintenance works according to the maintenance schedule.
• 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.
• 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 noisehazardous 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
recommendation that also occasional visitors shall wear ear protectors,
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