GÖLZ Battpak Xpansion 9600 Installation instructions

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Translation of the Original Operating Manual
Energy storage system –Battpak Xpansion 9600
Read operating manual before starting any work!
Keep the operating manual for future use!

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Revision
Date
Chapter
Reason for change
Person responsible
08-23
New creation
R&D
Revision status: 08-2023
Serial number:
© Gölz GmbH
Dommersbach 51
D- 53940 Hellenthal
Tel.: [phone]
Fax: [phone]
email: [e-mail]
website: www.goelz.de

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1 Content
1Content...................................................................................................................................................3
2General...................................................................................................................................................5
2.1 Operating manual........................................................................................................................5
2.2 Symbols, acronyms, terminology .................................................................................................5
2.3 Explanation of symbols................................................................................................................5
2.4 Liability limitation.........................................................................................................................6
2.5 Customer service.........................................................................................................................7
2.6 Copyright.....................................................................................................................................7
3Safety .....................................................................................................................................................8
3.1 Intended use ...............................................................................................................................8
3.2 Rationally foreseeable misuse .....................................................................................................8
3.3 Responsibilities of the operator....................................................................................................8
3.4 Responsibilities of the personnel..................................................................................................9
3.5Personnel requirements.............................................................................................................10
3.6 Dangers ....................................................................................................................................10
3.6.1 Risks through mechanical hazards................................................................................11
3.6.2 Risks through electrical hazards....................................................................................11
3.6.3 Risks through thermal hazards......................................................................................11
3.6.4 Risks due to work environment conditions.....................................................................11
3.6.5 Risks posed by special physical effects.........................................................................12
3.6.6 Risks due to hazardous substances ..............................................................................12
3.7 Safety........................................................................................................................................12
3.7.1 General safety instructions............................................................................................12
3.7.2 Safety devices...............................................................................................................13
3.8 Spare parts................................................................................................................................14
3.9 Actions in emergency and in case of accidents..........................................................................14
3.10 Signage.....................................................................................................................................15
4Technical data......................................................................................................................................16
4.1 Dimensions ...............................................................................................................................16
4.2 Generel information...................................................................................................................16
4.4 Charging operation....................................................................................................................16
4.5 Information of battery cells and battery ......................................................................................16
4.6 Connections..............................................................................................................................16
4.7 Operating conditions..................................................................................................................17
4.8 Type plate .................................................................................................................................17
4.9 Installation site requirements .....................................................................................................17
4.10 Storage requirements................................................................................................................17
5Design and function.............................................................................................................................19
5.1 Scope of delivery and responsibility...........................................................................................19
5.2 BattPak Xpansion 9600.............................................................................................................19
5.2.1 Functional description ...................................................................................................20
6Transport & packaging........................................................................................................................21
6.1 Transport safety information ......................................................................................................21
6.2 Transport inspection..................................................................................................................21
6.3 Transport symbols.....................................................................................................................21
6.4 Transport and storage ...............................................................................................................22
7Installation and first commissioning ..................................................................................................24
7.1 Location ....................................................................................................................................24
7.2 First commissioning and acceptance, general............................................................................24
8Operation .............................................................................................................................................25

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8.1 Operation safety information......................................................................................................25
8.2 Start-up preparation...................................................................................................................25
8.3 Start-up.....................................................................................................................................25
8.4 Charging via 230V .....................................................................................................................26
8.5 Operation and LCD display........................................................................................................26
8.6 Ruhezustand.............................................................................................................................26
9Maintenance & cleaning......................................................................................................................26
9.1 Maintenance safety information.................................................................................................27
9.2 Maintenance plan......................................................................................................................27
9.3 Description of the maintenance works to be carried out by the operator.....................................28
9.4 Steps after completing maintenance..........................................................................................28
9.5 Parts susceptible to wear...........................................................................................................28
10 Errors ...................................................................................................................................................29
10.1 Troubleshooting safety information............................................................................................29
10.2 Actions in case of errors............................................................................................................29
10.3 Störungen..................................................................................................................................30
10.4 Steps after troubleshooting........................................................................................................30
11 Disposal ...............................................................................................................................................31
12 Index.....................................................................................................................................................32
EU conformity declaration........................................................................................................................34

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2 General
2.1 Operating manual
This operating manual provides guidance on safe and efficient operation and should form a basis of
any actions involving the machine. It is an integral part of the machine, which should be kept in the
immediate vicinity accessible for its operating personnel.
Prerequisite of safe operation is adherence to all safety and handling instructions.
Therefore, before starting any work, the personnel must read carefully and understand the
operating manual.
Moreover, the accident prevention regulations applicable at the site of the machine operation and
general safety regulations must be complied with.
2.2 Symbols, acronyms, terminology
Symbols, acronyms and specialist terminology used in this document have the following meaning:
See item
Enumeration
- Enumeration
1 Position number
1. Action step
Text in italics Explanation of facts
Refers to the document contained in the enclosed documentation. The source of
the document is specified in italics behind the symbol.
2.3 Explanation of symbols
Warnings and safety instructions
Warnings and safety instructions in the manual are identified with the pictograms and provided in
blocks highlighted in grey.
Warnings and safety instructions, which draw attention to fundamental dangers, are additionally
preluded by signal words, which specify the scope of damage. Their structure is as follows:
All warnings and safety instructions must be implicitly complied with!
During the works, always act with caution, to avoid accidents, personal and material damage!
Pictograms combined with signal words mean:
SIGNAL WORD!
Origin of the danger.
Consequences of ignoring the danger.
- Actions to avoid danger
DANGER!
... draws attention to an immediate danger that, if not avoided, may result in heavy or even fatal
injuries.

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Tips and recommendations
Special safety instructions
To make aware of special dangers, the following pictograms are used in combination with the safety
instructions:
2.4 Liability limitation
All data and instructions provided in this manual were compiled with consideration of applicable
standards and regulations, state of the art in this field and our long-standing insights and
experience.
The manufacturer accepts no liability for damages caused by:
Non-observance of the Operating manual
Unintended use
Employment of unskilled and uninstructed personnel
Unauthorised conversions
Technical changes
NOTE!
… highlights tips and recommendations as well as information on efficient and trouble-free
operation.
WARNING:
... draws attention to potentially dangerous situations that, if not avoided, may cause heavy or
even fatal injuries.
CAUTION!
... draws attention to potentially dangerous situations that, if not avoided, may result in slight
injuries.
ATTENTION!
... draws attention to potentially dangerous situations that, if not avoided, may result in material
damage.
… marks danger due to electric current.
Failure to observe the safety instructions leads to danger of heavy or fatal injuries.
… marks danger of crushing.
Failure to observe the safety instructions leads to danger of heavy injuries from moving parts.
… marks danger due to hot surface.
Failure to observethe safety instructions leads to danger of burns and heavy skin injuries caused
by heat.

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Use of non-approved spare parts
The responsibilities agreed in the delivery contract, the General Terms and Conditions as well as the
delivery conditions of the manufacturer and the statutory regulations valid at the time of the
conclusion of the contract shall apply.
Warranty
The manufacturer guarantees the functional capability of the applied process technology and
performance parameters identified.
The warranty period commences with the defect-free delivery.
Wear parts
Wear parts are all parts having direct contact with the processed or machined material during normal
operation.
These parts are excluded from warranty and defect claims, insofar as tear and wear resulting from
normal operation.
Service life warranty
Service life warranty is granted for wear parts for the period of 6 months from the acceptance of the
defect-free product.
Warranty conditions
12 months after delivery of mechanical and electrical components for one-shift operation, except for
the wear parts and tools.
The warranty claim expires, if the system was not installed and started up by our experts.
The warranty extends to the replacement parts.
Consequential damages are excluded.
Damage caused by natural wear, deficient of improper maintenance, failure to comply with the
operating regulations, excessive loads and use of inappropriate equipment shall be excluded from
the warranty.
2.5 Customer service
Our customer service department is available to provide technical information.
You can obtain tips via the regional competent contact person by phone or via fax, email or website
at any time.
Moreover, our employees are interested in new information and experience arising from use and
which can be valuable for the improvement of our products.
2.6 Copyright
This document is protected by copyright. An unauthorised transfer to third parties, duplication of any
kind, including in parts, as well as use and/or disclosure of the content without written permission of
the publisher is prohibited.
Non-compliance with this provision is subject to damages. The right for further claims remains
reserved.
Service hotline
02482 –12 200

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3 Safety
This section provides an overview of all safety aspects of protection of operators and users from
potential dangers, and safe and trouble-free operation.
Disregarding these handling instructions, warnings and safety instructions may pose serious risks.
3.1 Intended use
The Battpak Xpansion 9600 is designed exclusively for the following purposes:
Any claims for damages resulting from unintended use are excluded.
The operator alone is responsible for all damages due to unintended use.
3.2 Rationally foreseeable misuse
Any use of the machine going beyond the intended one, shall be deemed unintended and thus
prohibited.
3.3 Responsibilities of the operator
Operator
An operator is every natural or legal person, who uses the machine or delegates its use to others
and is responsible for the safety of the user, personnel or third parties in the course of such use.
Operator's duties
The machine is used in the commercial sector. Therefore, the operator of the machine is subject to
statutory obligations regarding occupational safety.
The Battpak Xpansion 9600
is a mobile energy system. It is designed to increase the capacity of the Battpak5048.
WARNING:
Risk of unintended use!
Any use beyond the intended use of the machine may result in dangerous situations.
- The machine must be basically used for the intended purpose according to data
contained in this document, in particular, within the application limits provided in the
technical data.
- Refrain from any use beyond this scope or different use of the machine.
- Refrain from remodelling, refitting or changing the design or separate parts of the
machine for the purpose of changing the field of application or applicability of the
machine.
WARNING:
Risk of injury caused by misuse!
When misused, the machine may create dangerous situations for persons and cause heavy
material damage.
- Refrain from any misuse of the machine.
-

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In addition to the warnings and safety instructions in this manual, the occupational safety, accident
prevention and environmental protection regulations applicable to the field of the machine operation
must be adhered to.
The operator, in particular, must:
be informed about current occupational safety regulations,
determine, through hazard evaluation, any potential additional dangers resulting
from specific usage conditions at the site of the machine operation,
put necessary behavioural requirements of the operating instructions into practice during the
machine tool operation at the operation site,
check regularly throughout the service life of the machine, whether the operating instructions
drawn up by the operator are in line with the current status of rules and regulations,
adjust the operating instructions, where necessary, to the new regulations, standards and
operating conditions,
exercise control of the competence for installation, operation, maintenance and cleaning of
the machine in a clear and unambiguous manner,
make sure that all personnel involved with the machine have read and understood the
operating instructions. Moreover, the personnel must undergo training in handling the
machine at regular intervals and be informed about potential dangers,
provide the persons appointed for operating the machine with the prescribed and
recommended protective devices.
Moreover, the operator is responsible for ensuring that the machine
is always in a technically perfect condition,
is maintained according to the specified maintenance intervals, and
that all safety mechanisms of the machine are regularly controlled for completeness and
functionality.
3.4 Responsibilities of the personnel
The machine is in the commercial use. Therefore, the personnel are subject to statutory obligations
regarding occupational safety.
In addition to the warnings and safety instructions in this manual, the occupational safety, accident
prevention and environmental protection regulations applicable to the field of operation must be
adhered to.
In particular, the personnel must:
be informed about current occupational safety regulations,
adhere to behavioural requirements set out in the operating instructions issued at the site of
the machine operation,
properly exercise the responsibilities entrusted to them as regards installation, operation,
maintenance and cleaning of the machine,
fully read and understand the operating manual before starting work,
use the prescribed and recommended protection equipment,
Moreover, scope of responsibility of every person operating the machine includes the duty of always
keeping it in a technically perfect condition,
performing maintenance, according to the intervals specified,
controlling all safety mechanisms for completeness and functionality on a regular basis.

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3.5 Personnel requirements
Fundamentals
Any operation with the machine may only be carried out by the persons, capable of performing their
work properly and reliably and meet every requirement mentioned.
No works can be carried out by the persons, whose response capability is affected, e.g., by
drugs, alcohol or medicines.
When deploying personnel at the site of operation, always adhere to the applicable
occupational and age-specific regulations.
Qualification
Instructed personnel
Instructed personnel are the persons, who have been instructed by the operator on the tasks to be
carried out and potential dangers in a detailed and verifiable way.
Specialist personnel
Specialist personnel are the persons, who, due to their professional training, knowledge and
experience, as well as knowledge of the relevant provisions, are capable of duly carrying out the
works assigned, recognise potential dangers independently and avoid personal and material
damage.
Qualified electricians
As a matter of principle, all works on the electrical installations must be carried out by qualified
electricians.
Qualified electricians are the persons, who, due to their specialist training, knowledge and
experience, as well as knowledge of the relevant provisions, are capable of duly carrying out the
works on electrical systems, recognising potential dangers independently and avoiding personal and
material damage caused by electric current.
Unauthorised persons
3.6 Dangers
The machine has undergone a risk review. Wherever possible, the identified dangers were
eliminated and risks reduced. Nevertheless, the machine poses residual risks described in the
following section.
Strictly observe warnings and safety instructions specified here and in the chapters about handling
to avoid potential damage to health and dangerous situations.
WARNING:
Risk of injury for unqualified personnel!
Improper operation can result in significant personal and material damage.
- Any operations must be only carried out by the persons having required training,
knowledge and experience.
-
WARNING:
Danger of injuries for unauthorised persons!
Those who have not been instructed are not aware of the dangers in the area of operation and
must be considered unauthorised persons.
- Keep unauthorised persons away from the area of operation; if in doubt, address the
persons met and banish them from the area of operation.
- Suspend operations until unauthorised persons leave the area of operation.