Energy zeroCO2 XL User manual

zeroCO2XL
Large Storage Inverter System
Operation Manual
TM033 Rev.010
www.energyspa.com

This manual introduces the Energy zeroCO2XL.
zeroCO2XL is a large storage solution applicable to commercial, industrial and
utility scale plants, both new construction and as a retrofit for existing plants. It can
also manage entire energy communities.
The solution involves connecting an AC power source to 60 kW power converters
that can be scaled in a modular way to higher powers to manage the charging and
discharging phases of individual battery strings of
125 kWh, and parallelizable in turn obtaining storage of over 1 MWh, acting as a
diaphragm between the instantaneous load curve and the availability of the energy
source, two trends that for renewable sources are difficult to coincide.
Requiring an alternating current source as input, zeroCO2XL is compatible with
photovoltaic inverters, wind turbines and renewable or non-renewable electricity
generators.
The EMS on-board computer allows you to implement management logics
customized for the type of application: increase in self-consumption, peak shaving,
feeding energy into the grid in a controlled way following the daily energy price
curves in the electricity market.
Read this manual before installing your system and follow the instructions carefully
during the installation process.
If in doubt, contact the supplier immediately for advice and clarification.
Commissioning: the start-up of the system is to be carried out strictly by Energy
S.p.A. personnel and can take place on site or remotely, subject to commercial
agreements stipulated during the order.
Upon receipt of goods, contact Energy S.p.A. support. to agree on commissioning.

4
Table of Contents
1.0 Denitions........................................................................................................6
2.0 Safety ...............................................................................................................8
2.1 Skillsofqualiedpersonnel.......................................................................8
2.2 Symbols ....................................................................................................8
2.3 Referencestandards...............................................................................11
2.4 Beforeconnection ...................................................................................11
2.5 Duringtheuse.........................................................................................12
3.0 Introduction ...................................................................................................13
3.1 ProductPresentation...............................................................................13
3.1.1 Schematicdiagramsolution.........................................................14
3.1.2 Workinglogic ...............................................................................16
3.2 Systemarchitectureandoperation .........................................................17
3.2.1 zeroCO2-XLSystem...................................................................17
3.2.2 zeroCO2-XLcapabilitycurve ......................................................18
3.2.3 zeroCO2-XLSystemparameters................................................19
3.2.4 zeroCO2 - BESS 125K..................................................................22
3.2.5 ParametrizeroCO2- BESS 125K ................................................23
4.0 Receptionandhandling ...............................................................................24
4.1 Controloftheworkingenvironmentofthestoragesystem .....................24
4.1.1 Cleaning.......................................................................................24
4.1.2 Temperature.................................................................................24
4.1.3 Fire-ghtingsystem .....................................................................24
4.1.4 Installationplacechecking...........................................................25
4.1.5 Safetyarea ..................................................................................25
4.2 zeroCO2-XLSystem ..............................................................................25
4.2.1 Unpackingmode..........................................................................26
4.2.2 Packinglist...................................................................................32
4.3 zeroCO2- BESS 125K ............................................................................33
4.3.1 Unpackingmode..........................................................................34
4.3.2 Packinglist...................................................................................42
5.0 Installation .....................................................................................................44
5.1 Installationtools ......................................................................................44
5.2 Personalprotectiveequipment...............................................................45
5.3 zeroCO2-XLSysteminstallation ............................................................46
5.3.1 zeroCO2-XLSystemcableconnection.......................................46
5.3.2 MBMSADDSwitchsettings.........................................................50
5.4 BMScontrolmoduleandbatterybatterymoduleinstallation
inzeroCO2- BESS 125K.........................................................................52
5.4.1 Batterymoduleinterface..............................................................55
5.4.2 Controlmodule ...........................................................................56
5.4.3 zeroCO2-BESS125Kcablesconnection ...................................59
5.4.4 BMSADDSwitchsettings............................................................61

zeroCO2XL 5
6.0 TurningthesystemONandOFF .................................................................62
6.1 SystemturnON.......................................................................................62
6.2 SystemturnOFF.....................................................................................64
7.0 Maintenance ..................................................................................................66
7.1 zeroCO2-BESS125KBMSreplacement...............................................66
7.2 zeroCO2-BESS125Kbatterymodulereplacement...............................68
7.3 zeroCO2-XLSystemEMSmodulereplacement....................................70
7.4 zeroCO2-XLSystemMBMSmodulereplacement.................................72
7.5 zeroCO2-XLSystemSwitchmodulereplacement.................................74
7.6 zeroCO2-XLSystemUPSmodulereplacement ....................................76
7.7 zeroCO2-XLSystemPCSmodulereplacement ....................................78
8.0 Worklogicandcloudmonitoring ................................................................80
8.1 Worklogic ...............................................................................................80
8.2 Cloudplatformmonitoring .......................................................................81
9.0 Periodicmaintenanceofthesystem...........................................................94
9.1 VoltageInspection...................................................................................94
9.2 SOCInspection .......................................................................................94
9.3 CableInspection .....................................................................................94
9.4 Balance ...................................................................................................94
9.5 OutputRelayInspection..........................................................................94
9.6 Historyinspection....................................................................................94
9.7 Shutdownandmaintenance....................................................................94
9.8 Recycling.................................................................................................94
10.0 Remarks.........................................................................................................95
10.1Storagetips .............................................................................................95
10.2Capacityexpansion.................................................................................95
11.0 Expedition......................................................................................................95
Systeminstallationandpower-onprogresslist .................................................96
SystemShutdownprogresslist ...........................................................................97
CommonfailuresinEMSCloud............................................................................98
Accessory ...............................................................................................................99

6 - Definitions
1.0 DEFINITIONS
BESS: “Battery Energy Storage system”. Electrical energy storage system based
on electrochemical Li-ion batteries (LFP). Given the capacity of the individual
battery, the total number of modules used defines the capacity of the system.
BMS: “Battery Management System”. System for monitoring and managing the
charge /discharge of a Li-ion battery (LFP); allows entire strings of batteries to
charge and discharge in a balanced way, avoiding imbalances, in favor of the
efficiency of the system and the expected life for the modules themselves.
SOH: “State of health”. It is the percentage health status of a battery compared to
the condition of early life. SOH of a battery is physiologically reduced over its useful
life. SOH may suffer degradation over time in relation to non-optimal, prolonged and
/ or repeated conditions of use.
SOC: “State of charge”. The percentage of charge of a battery. The operating range
of the battery is delimited by a minimum SOC below which the discharge is not
forced , and by a maximum SOC beyond which the charge is not forced. SOC of
a battery can undergo a momentary reversible variation dictated by instantaneous
operating conditions such as operating temperature and working speed.
PCS: “Power Conversion System”. AC/DC conversion module for electrical power.
With an AC input/output and a DC output/input, the conversion can have a dual
direction, allowing, depending on the phase, to charge (to accumulate electricity )
or discharge the batteries (to self-consume by covering the loads and / or feeding
electricity into the network).
EMS: “Energy Management System”. Intelligent system for energy management in
the plant that monitors, collects instantaneous operating data downto the voltage
levels and temperature values of each cell, communicates with the devices and
coordinates their operation to make the entire system effective and efficient, allows
remote supervision and control through a web interface on a Cloud platform.
RACK: Standardized system for the physical installation of hardware, computer,
electronic or electrical components that make up the zeroCO2XL System.
The zeroCO2XL family racks are available in two distinct configurations for easy
installation, access, maintenance and security:
◦zeroCO2- XL System: for the containment Of Modules PCS Of Devices electrical
and functional organs to the system logic as well as to the management of
power.
◦zeroCO2- BESS 125K: for the housing of storage batteries.

Definitions - 7
zeroCO2XL

8 - Safety
2.0 SAFETY
zeroCO2XL is a system that works at dangerous voltage levels both on the AC
side and on the DC side, it must be installed exclusively by qualified personnel and
authorized. Read all safety instructions carefully before any operation and always
observe them when working with the system.
Improper operation or work can cause:
• injury or death of the operator or third parties;
• damage to system equipment and other property of the operator or third parties.
2.1 Skills of qualified personnel
The staff qualified must possess the following skills:
• training in the installation and commissioning of the electrical installation and in
hazard management;
• knowledge of this manual and other related documents;
• knowledge of local regulations and directives.
2.2 Symbols
DANGER
Dangerous or lethal tension!
WARNING
Risk of system damage or personal injury.
Only a qualified person can perform the wiring of the system.
Caution
Risk of battery system failure or life cycle reduces.
Only a qualified person can perform the wiring of the system.
Read the product and operation manual before operating the battery system!
Danger! Safety!
Warning electric shock!
Do not place near flammable material
Do not install the system in an outdoor area
Do not reverse connection the positive and negative.
Do not place near open flame.

Safety - 9
zeroCO2XL
Do not place at the children and pet touchable area.
Recycle label.
Label for Waste Electrical and Electronic Equipment (WEEE) Directive
(2012/19/EU)
CE Marking
The certificate label for Safety by TÜV SÜD.
The certificate label for Safety by TÜV Rheinland.
Danger. The batteries and components of the electrical panel provide electrical
energy, causing burns or fire risk if short-circuited or installed incorrectly. Only a
qualified person can perform the wiring of the system.
Danger. Battery strings produce high-voltage direct current and can cause
dangerous, if not lethal, electric shock. Only a qualified person can perform the
wiring of the system.
Danger. The energy stored in the batteries is electrochemical. Even when the
system is switched off or disconnected, the residual energy of the battery modules
cannot be avoided. Improper use or handling can cause dangerous if not lethal
electric shock.
Danger. The electrical panel works with temporarily with high voltage direct current
and alternating current at dangerous voltage levels and can cause dangerous if not
lethal electric shocks. Only a qualified person can perform the wiring of the system.
Warning. Do not pull out the connectors while the system is running!
Disconnect all multiple power sources and verify that there is no voltage.
Danger. There are lethal voltages in terminals and cables. If you touch cables and
terminals, you can experience serious injury or death.
Warning. Do not open or deform the battery modules and the electrical panel,
otherwise the product will be out of warranty.
Warning. Whenever working on the system, wear appropriate personal protective
equipment (PPE) such as rubber gloves, rubber boots and goggles.
Warning. For installation, qualified personnel must refer to this manual and the
safety rules provided in the official language and applied in the country where the
installation takes place.

10 - Safety
Attention. Improper settings or maintenance can permanently damage the system.
Attention. Incorrect inverter parameters will lead to battery or system failure/
damage.
Attention. It is very important and necessary to read the user manual (in
accessories) carefully before installing or using the system. Failure to follow these
instructions or the warnings in this document may result in electric shock, serious
injury or death, or may damage the battery, potentially rendering it unusable.
Attention. In the event of a prolonged period of inactivity, the batteries must be
recharged every six months to a charge level (SOC) of not less than 90%.
Attention. The battery must be recharged within 12 hours, when it has been
completely discharged.
Attention. Do not install the system directly outdoors, do not install the system in
places with ambient temperature and humidity levels outside the operating ranges
listed in this manual.
Attention. Do not expose system cables to the external environment.
Attention. Do not connect the power terminals (direct current or alternating current)
in reverse.
Attention. Disconnect all terminals before the maintenance phase.
Attention. It is forbidden to insert any foreign object into any part of the system.
Attention. Do not use solvents to clean the system.
Attention. Do not expose the system to flammable or aggressive chemicals or
vapors.
Attention. Do not paint any part of the system, including internal or external
components.
Attention. Do not connect the system or battery directly to photovoltaic panels.
Attention. Please contact the supplier within 24 hours if you notice anything
abnormal.
Attention. Warranty claims for direct or indirect damages due to behavior that does
not comply with the above are excluded.