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.: +49 (0)2482 –12 200
Fax: +49 (0)2482 –12 222
email: info@goelz.de
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.

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3.6.1 Risks through mechanical hazards
Movable parts
3.6.2 Risks through electrical hazards
Electric current
3.6.3 Risks through thermal hazards
Hot surfaces
3.6.4 Risks due to work environment conditions
CAUTION!
Risk of injury by pinching in movable parts!
Failure to follow the instructions can result in serious injury.
- Apply the brake on the swivel castors
DANGER!
Danger to life from electric current!
Touching live parts leads to death. Damaged insulation or individual components can be life-
threatening.
- Switch off power supply before maintenance, cleaning and repair operations and secure
the machine against being restarted.
- If the power supply insulation is damaged, switch off immediately and arrange for repairs.
- Never bypass or disable fuses.
- Keep moisture away from live parts.
- The battery must not be opened under any circumstances!
CAUTION!
Risk of burns on hot surfaces.
Contact with hot parts may cause burns.
- Do not touch the surface.
- Before every work, make sure that the parts have cooled down to the ambient
temperature.
CAUTION!
Risk of injury due to inadequate lighting.
Work in inadequate lighting conditions may lead to heavy injuries.
- Provide for adequate lighting at the workplace.

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3.6.5 Risks posed by special physical effects
Physical effects
3.6.6 Risks due to hazardous substances
3.7 Safety
3.7.1 General safety instructions
Use the product and accessories only in perfect technical condition
Never tamper with or change the product or accessories. The product must not be opened.
Do not touch the electrical contacts with your fingers, tools, jewelry, or other electrically
conductive objects.
Do not short-circuit the outputs of the product.
CAUTION!
Danger of injuries caused by special physical effects!
Failure to wear appropriate protective equipment may lead to heavy injuries.
- Wear protective gloves
- Take adequate breaks
- Regular medical examinations ‘G20‘
CAUTION!
Risk of injury due to improper handling of lithium-ion batteries!
Failure to wear appropriate protective equipment can result in serious injury.
- Use personal protective equipment
- Store lithium-ion batteries according to regulations
- Avoid short circuits
CAUTION!
Risk of injury Hazardous substances, such as escaping chemicals or chemical vapors!
- Failure to wear suitable protective equipment can lead to damage to health.
- Use personal protective equipment
- Never touch chemicals
- In case of escaping chemicals or chemical vapors, leave the danger zone immediately!
If the battery cells are damaged, switch off the battery immediately and get help if chemicals are
leaking. Never continue to use the battery with a damaged battery cell.
CAUTION!
Observe the following safety instructions for the safe handling and use of Li-ion batteries.
Failure to comply may lead to
- Irritation
- severe corrosive injuries,
- chemical burns,
- -Fire and/or lead to explosions.

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Close the protective caps of the connectors when not in use.
The product must not be disassembled, crushed, heated above 60°C or burned.
Never expose the product to direct sunlight, increased temperature, sparking or open flame.
This can lead to explosions.
Keep the product away from moisture and liquids. Moisture ingress can cause short circuits,
electric shocks, burns, fire, and explosions.
Do not use or store the product in potentially explosive environments.
Use the product only within the defined limits of use.
Handle the product carefully to avoid damage and prevent the leakage of liquids that are
highly harmful to health!
Make sure that the product stands securely when using it. Place the product only on a non-
slip surface. Avoid protruding the product over an edge.
Make sure that the cable length of the connected consumer is sufficient, the connecting
cable must not be under tension.
Do not use or charge the product if it has received a blow or is otherwise damaged.
Periodically inspect the product for signs of damage.
Do not use the product as a conductor replacement.
Do not transport the product on a crane or with lifting equipment.
Comply with your local regulations for the safe operation of electrical consumers.
Do not connect defective consumers to the product.
Do not connect generators to the outputs of the product.
Charge the product only with the supplied charging cable.
Make sure the consumer is turned off before connecting the consumer. Always switch off the
consumer after use.
Do not use the product to operate life-sustaining medical consumers.
If the product is too hot to touch, it may be defective. Place the product in a visible, non-
flammable place at a sufficient distance from combustible materials. Let it cool. If the product
is still too hot to touch after an hour, then it is defective. Please contact the GÖLZ® service..
3.7.2 Safety devices
WARNING:
Danger to life due to defective or bypassed safety devices!
Inoperable, bypassed or disabled safety devices do not protect from hazards and may lead to
heavy or fatal injuries.
- Before commencement of works, always make sure that all safety devices are properly
installed and functional.
- Never disable safety devices.
- Ensure that the safety devices are always freely accessible.
NOTE!
See safety devices in "Design and function".

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Emergency switch off
By pressing the emergency stop switch, the connected devices are de-energized.
Eliminate the error that has occurred before switching on again after pressing the emergency stop.
3.8 Spare parts
Original spare parts can be obtained via an authorised dealer or directly from the manufacturer.
3.9 Actions in emergency and in case of accidents
Necessary actions
Always be prepared for accidents or fire.
First aid facilities (first aid box, cloth, etc.) and fire extinguisher must be close at hand.
Personnel must familiarise themselves with accident signalling equipment, first aid and rescue
facilities.
Access roads for rescue vehicles must be always kept free.
If the need arises, act properly
Activate emergency stop immediately
Initiate first aid measures
Remove persons affected from the danger area.
Inform persons responsible at the operation site.
Alert doctor and/or fire brigade in case of heavy injuries.
Keep access roads for rescue vehicles free.
Emergency switch off
WARNING:
Risk of injury due to wrong spare parts.
Wrong spare parts can seriously compromise safety and cause damage and malfunction up to
total failure.
- As a matter of principle, only original spare parts must be used.

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3.10 Signage
Danger from electric current!
Illegible signs
DANGER!
Danger to life from electric current!
Touching live parts leads to death. Damage to the insulation or individual components can be
life-threatening.
-
The battery must not be opened under any circumstances!
-
If the insulation is damaged, switch off the battery immediately and arrange for repairs.
-
Keep moisture and moisture away from the live parts.
CAUTION!
Risk of injury due to illegible symbols!
Stickers and signs that got illegible, make danger zones insufficiently recognisable and may
become incapable of indicating potential injury risks.
- Always maintain legibility of pictograms, safety, warning and operating instructions.
- Immediately replace the pictograms, labels, signs or stickers that became illegible.

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4 Technical data
4.1 Dimensions
4.2 Generel information
4.4 Charging operation
4.5 Information of battery cells and battery
4.6 Connections
Specification
Value
Unit
Length
660
mm
Width
410
mm
Height (without rollers)
630
mm
Weight
96
kg
Specification
Value
Unit
Output voltage
48
V
Interrupting voltage battery
47,5
V
Operating life
Ca. 6000
Lade-
zyklen
Internal impedance
≤50
mΩ
Communication
RS485/RS232
-
Specification
Value
Unit
Battery voltage
48
V
Maximum charging current
80
A
max. AC-Ladestrom
32
A
Overcharge cut-off point
57,5
Vdc
Specification
Value
Unit
Cell type
Lithium-Ironphosphate
-
Cell form
Rectangular Aluminum cell
-
Cell voltage
3,2
V
Cell capacity
100
Ah
Battery voltage
48
V
Battery capacity
9600
Wh
Connections
Output
Input
1 x Extension connection
1 x 230V
1 x DC IN

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4.7 Operating conditions
Working zone
Specification
Value
Unit
Ambient temperature when working
-20…60
°C
Storage temperature
-10…60
°C
Battery temperature at the start of
charging
0…45
°C
Relative air humidity, maximum
5 - 95
(without condensing)
%
Conditions
Avoid direct impact of dampness, dust and frost.
Do not operate in strong electric and magnetic fields!
Do not operate the machine tool in explosive atmosphere!
4.8 Type plate
The type plate is placed on the housing of the battery.
4.9 Installation site requirements
The floor surface must:
have sufficient load bearing capacity,
be slip proof,
be level.
Installation conditions
Choose the installation site as per space requirements according to the technical data.
4.10 Storage requirements
Storage conditions
As a matter of principle, the machine, its components, assemblies or parts must be only stored in the
following conditions:
do not store outdoors
store in dry and dust-free place
do not expose to aggressive media
protect from solar radiation
avoid mechanical vibrations

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storage temperature range -15 to 60°C
relative air humidity, max. 95%
Store the product out of the reach of children and unauthorized persons.
Do not store the product in the discharged state for long periods of time. This could lead to
deep discharge. Charge the product at least once every three months.
If stored for more than 3 months, regularly check the general condition of all parts and packaging.
Also check the charge level of the Battpak. If necessary, refresh or renew the preservation and load
the Battpak.

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5 Design and function
The BattPak Xpansion 9600 is used to expand the capacity of the Battpak 5048 via the expansion
port and the supplied expansion cable. The product consists of a housing, the lithium-ion battery
with built-in technology and connections, as well as carrying handles and transport rollers.
5.1 Scope of delivery and responsibility
The machine was developed and manufactured under sole responsibility of Gölz GmbH.
Upon transfer to the operator, the responsibility for safe handling and instruction of the personnel
passes to the operator.
The manufacturer offers training on the machine.
The scope of delivery includes the following components:
Components
Quantity
BattPak Xpansion 9600
1
Technical documentation
1
Connection cable
1
Charging cable
1
Optional accessories
Quantity
Transport car
1
5.2 BattPak Xpansion 9600
1
Emergency switch off
2
On/Off switch
3
LED-Display
4
Fan
5
Extension connection
6
DC IN
7
230V charging connection

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Housing The housing (1) protects the electronics and the battery from physical and environmental influences.
Plugs The various battery connections are used to charge the battery and connect the battery extension to
a battery.
Transport rollers
The battery can be moved around by one person using the transport rollers. The rollers can rotate
freely and are equipped with a parking brake for safe parking of the battery.
Battery The battery cells are made of lithium iron phosphate and are enclosed in an impact-resistant
housing. They are used to increase the capacity of the Battpak 5048.
Display
The battery display shows all relevant info about the battery via LCD display.
5.2.1 Functional description
By connecting the battery via the extension connection and then switching it on, the power supply is
enabled up to the Battpak5048. The Battpak5048 can now be switched on and up to two devices
can be operated simultaneously. All relevant information about the BattXpansion 9600 is shown on
the LCD display on the front.
NOTE!
Due to the design, the emergency stop switch is located to the right of the battery indicator. A
blow on the emergency stop causes the immediate interruption of the power supply to the
connected Battpak5048.
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