Redflow ZBM3 User manual

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ORIGINAL INSTRUCTIONS V1
ZBM3 Installation and
Operation Manual
MNL-ZBM-003.1

MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 2 of 58
© 2022. Redflow Limited. All rights reserved.
Any reproduction, modification, or electronic transmission of this publication requires the prior written
authorisation of Redflow Limited.

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Contents
1Introduction ...................................................................................................................................6
1.1 Purpose...................................................................................................................................6
1.2 About the ZBM ........................................................................................................................6
1.3 Abbreviations and Definitions..................................................................................................9
2ZBM Safety...................................................................................................................................10
2.1 Electrolyte Characteristics.....................................................................................................10
2.1.1 Gas Emissions ..............................................................................................................10
2.1.2 Electrolyte Leaks...........................................................................................................11
2.1.3 Personal Protective Equipment (PPE)..........................................................................11
2.2 ZBM Battery Voltage Hazard ................................................................................................11
2.3 ZBM Fire Safety Characteristics ...........................................................................................11
2.4 Safety Labels.........................................................................................................................12
3ZBM Handling..............................................................................................................................13
3.1 ZBM Weights & Dimensions .................................................................................................13
3.2 Lifting Straps .........................................................................................................................13
3.3 Dry ZBMs ..............................................................................................................................14
3.4 Transporting ZBMs................................................................................................................14
3.5 Storing ZBMs.........................................................................................................................14
4ZBM Components .......................................................................................................................15
4.1 Electrode Stack.....................................................................................................................15
4.2 Electrolyte and Tanks............................................................................................................15
4.3 Battery Control Module .........................................................................................................16
4.4 Pumps...................................................................................................................................16
4.5 Catch Can and Pressure Relief Valve ..................................................................................17
4.6 Fan........................................................................................................................................18
4.7 Cooling Tubes.......................................................................................................................18
4.8 Analog Loom.........................................................................................................................19
4.8.1 Leak Sensor..................................................................................................................20
4.8.2 Temperature Sensors ...................................................................................................20
4.9 Power Cables........................................................................................................................20
4.10 Lifting Straps .........................................................................................................................20
4.11 Battery Management System................................................................................................21
5ZBM Installation and Connection..............................................................................................22
5.1 Remove the Transport Crate.................................................................................................22
5.2 Perform Pre-installation Checks............................................................................................24
5.3 Lift the ZBM into Place..........................................................................................................26
5.4 Install and Connect the BMS.................................................................................................27
5.5 Connect the ZBM to the DC Bus...........................................................................................28
6Commission a Battery ................................................................................................................30
6.1 Configure the BMS Settings..................................................................................................30
6.1.1 Connect to the BMS......................................................................................................30
6.1.2 Set the BMS Settings....................................................................................................30
6.1.3 Update BMS Firmware..................................................................................................32
6.1.4 Check BMS Date and Time...........................................................................................33
6.2 Set Up a Battery....................................................................................................................33
6.3 Check Visibility of a Battery in the BMS................................................................................35
6.4 Upgrade Battery Firmware....................................................................................................36
7ZBM Operation.............................................................................................................................37
7.1 Operating “From Empty” .......................................................................................................37
7.2 ZBM Operating Modes..........................................................................................................37
7.3 Startup Procedure.................................................................................................................37
7.4 Shutdown Procedure.............................................................................................................38
7.5 Start Battery Discharge and Self-maintenance Cycle...........................................................40

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8ZBM Wear and Failure Processes .............................................................................................41
8.1 Leaks.....................................................................................................................................41
8.2 Stack Degradation.................................................................................................................41
8.3 Incorrect Operation ...............................................................................................................41
8.4 Electrolyte Contamination.....................................................................................................41
8.5 Pump Failures.......................................................................................................................41
8.6 Electronics and Electrical......................................................................................................41
8.7 Over Temperature.................................................................................................................42
9ZBM Maintenance........................................................................................................................43
9.1 Ongoing Maintenance...........................................................................................................43
9.2 Periodic Maintenance............................................................................................................44
9.3 Cleaning................................................................................................................................45
10 ZBM System Integration.............................................................................................................46
10.1 System Design Guidelines –Safety......................................................................................46
10.1.1 Shutdown Systems........................................................................................................46
10.1.2 Spillage Management System ......................................................................................46
10.1.3 Hydrogen & Bromine Gas Management/Detection System..........................................46
10.1.4 Fire Control System.......................................................................................................47
10.1.5 Noise .............................................................................................................................47
10.2 System Design Guidelines –Mechanical..............................................................................47
10.2.1 Separation of ZBMs and ESS Electronics ....................................................................48
10.2.2 Corrosion Protection .....................................................................................................48
10.2.3 Ventilation Requirements..............................................................................................48
10.2.4 Securing ZBMs..............................................................................................................48
10.3 System Design Guidelines –Thermal Management ............................................................48
10.3.1 Temperature Considerations.........................................................................................49
10.4 System Design Guidelines –Electrical .................................................................................49
10.4.1 Voltages ........................................................................................................................50
10.4.2 Currents.........................................................................................................................50
10.4.3 Power Output ................................................................................................................50
10.4.4 Energy Output...............................................................................................................51
10.4.5 Response Time.............................................................................................................51
10.4.6 Efficiency.......................................................................................................................51
10.4.7 Self-Maintenance ..........................................................................................................51
10.4.8 Parallel Arrangements of ZBMs ....................................................................................52
10.5 System Design Guidelines –Communications.....................................................................52
Addressing ZBM Electrolyte Spills/Leaks ................................................................53
Maintenance Checklist ...............................................................................................55
Standard Test Cycle....................................................................................................56
Example Setup: Inverter and Load............................................................................57

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Figures
Figure 1: The ZBM..................................................................................................................................6
Figure 2: Example ZBM label................................................................................................................12
Figure 3: ZBM key components............................................................................................................15
Figure 4: Location of ZBM terminals.....................................................................................................16
Figure 5: BCM connections (viewed from underneath) ........................................................................16
Figure 6: Catch Can and Pressure Relief Valve ...................................................................................17
Figure 7: Fan, ambient temperature sensor, and direction of airflow ...................................................18
Figure 8: Sensor analog loom...............................................................................................................19
Figure 9: Leak sensor and battery temperature sensor locations.........................................................19
Figure 10: Redflow BMS.......................................................................................................................21
Figure 11: Crate with strapping removed..............................................................................................22
Figure 12: Lifting crate lid......................................................................................................................23
Figure 13: Plastic bag removed, lifting straps in place .........................................................................23
Figure 14: Positive and negative ZBM terminals ..................................................................................24
Figure 15: Example capillary tubes.......................................................................................................24
Figure 16: Leak Sensor and Temperature Sensors locations ..............................................................25
Figure 17: BCM connections.................................................................................................................25
Figure 18: Lifting the ZBM.....................................................................................................................26
Figure 19: BMS connections.................................................................................................................27
Figure 20: Cat6 cable assembly ...........................................................................................................27
Figure 21: BCM connection ports for the BMS .....................................................................................28
Figure 22: Bus cable connections.........................................................................................................28
Figure 23: Bolt, cable, and washer arrangement for bus terminal........................................................29
Figure 24: BMS interface showing warning and failure alarms on the Status page .............................43
Figure 25: BMS interface showing details, warnings, and failures on the Battery Status page ...........44
Figure 26: Excerpt from Figure 27 showing ZBM voltage profile..........................................................50
Figure 27: ZBM Standard Test Cycle....................................................................................................56
Figure 28: Example connections ZBM..................................................................................................57
Tables
Table 1: ZBM Electrical Operating Envelope..........................................................................................7
Table 2: ZBM Physical and Communications Characteristics ................................................................8

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1 Introduction
1.1 Purpose
This manual is for Redflow’s DC flowing electrolyte battery product, the Zinc-Bromine Module (ZBM).
It provides information on the battery’s installation, operation, and maintenance for nominal 48 Vdc
systems. Installation of the ZBM must only be performed by trained installers.
1.2 About the ZBM
The ZBM is a DC flow battery with in-built electronic management. The ZBM is ideally suited to daily
cycling of its full capacity and offers long cycle life energy storage in such applications. With
appropriate ancillary circuitry, multiple ZBMs can be connected in parallel for increased capacity.
Figure 1: The ZBM
Note: When supplied, the ZBM is fitted with a bund but it is not shown in all images.
The ZBM’s main components are:
•Electrode Stack
•Battery Control Module (BCM)
•Electrolyte and Tanks
•Analog Loom
•Pumps
•Cooling Fan
•Cooling Tubes
•Pressure Relief Valve
•Catch Can
Battery operation is controlled by the BCM. Operation of ZBMs must be kept within the boundaries of
the operating envelope set out in Table 1 to ensure correct operation and to comply with warranty
conditions; failure to keep within the boundaries will void the warranty. In applications where one ZBM
would not be able to remain within the operating envelope, adding another ZBM may bring the
performance of each ZBM back within the envelope.

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Table 1: ZBM Electrical Operating Envelope
Power Rating *
Continuous charge power: 2.5kW
Continuous discharge Power: 3kW
Peak discharge Power: 5kW
Note: Refer to Section 10.4.3 for more information about peak
power.
Usable Capacity/Energy *
200Ah / 10kWh
Minimum Ah Output (end of
life)
200Ah (standard cycle)
Note: Standard test cycle is defined in Appendix C and is used
for warranty claims.
DC Voltage Operating Range
40 to 58V DC
Absolute Voltage Range
0 to 70V DC
Note: ZBM have a terminal voltage = 0V on initial start-up and
after maintenance cycles
Auxiliary Power
180W maximum @ 40V DC minimum
Circuit Protection Maximum
Rating
125A
Note: Each ZBM must have a fuse or circuit breaker between
the ZBM and the Power Control System DC bus.
Short Circuit Fault Current
Rating
600A
Battery Operating
Temperature Range
0-1000m above sea level**
Charging: 10 to 50 °C (50 to 122 °F)
Discharging: 15 to 50 °C (59 to 122 °F)
The battery temperature is the electrolyte temperature.
Allowable Ambient
Temperature Range
Operation: 5 to 45 °C (41 to 113 °F)
Storage and Transportation: -5 to 45°C (14 to 113 °F)
Contact Redflow for advice if outside this range.
Self-Maintenance Cycle
Frequency
Optimally every full discharge.
A minimum of once every 72 hours of zinc pump operation.
For warranty to be valid and battery performance to be
maintained users must not override ZBM internal automatic self-
maintenance procedures.
Stack Energy Efficiency*
80% DC-DC maximum
EMC Compliance
Emissions: EN61000-6-3:2007; Immunity: EN61000-4-2, 3, 4, 5,
6:2007
Approvals
CE
RCM
* At beginning of life
** For altitudes between 1000m and 2000m upper temperature limit is 45.5°C (113.9 °F)
For altitudes between 2000m and 3000m upper temperature limit is 42°C (107.6 °F)
Contact Redflow to adjust the ZBM temperature limit to the correct setting if above 1000m
Any voltage exceeding the absolute maximum voltage specified in Table 1 will damage the electronics
in the BCM if connected to the ZBM. Devices connected to the battery that produce voltages outside
the allowable range and damage the ZBM will void battery warranty e.g. voltage spikes. For
connected component compatibility contact Redflow.

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The physical and communications characteristics of the ZBM can be found in Table 2.
Table 2: ZBM Physical and Communications Characteristics
Dimensions (ZBM)
LxWxH: 861 x 400 x 747 mm
(34 x 16 x 30 in)
Mass (ZBM)
With electrolyte: 237 kg (523 lb)
Without electrolyte: 80 kg (177 lb)
Dimensions (crated)
LxWxH: 1030 x 570 x 940 mm
(40.6 x 22.5 x 37 in)
Mass (crated)
With electrolyte: 278 kg (613 lb)
Without electrolyte: 121 kg (267 lb)
Orientation
The ZBM must be kept in an upright position (orientation shown in
Figure 3) at all times of operation, storage, handling, and
transportation. This is a warranty condition.
Electrolyte Volume
100 L (26 US Gal)
Module Geometry
One stack of 30 cells
Dangerous Goods Class
DG Class 8 for electrolyte or ZBMs containing any trace of electrolyte
Weather Protection
The ZBM must be installed indoors (out of weather) or in a weather-
proof enclosure. This is a warranty condition.
Installation
Requirements
ZBMs must be installed for stationary applications only on flat, level
and fully-supported base surfaces. This is a warranty condition.
Transportation
Requirements
ZBM must be transported in an original supplied crate/enclosure. This
is a warranty condition.
Ventilation
During operation the ZBM must be adequately ventilated with
minimum airflow of 50l/s (180 m3/h) per ZBM not opposing the
direction of ZBM cooling fan airflow. This is a warranty condition.
During storage the storage area must be dry and appropriately
ventilated.
This is a warranty condition.
Humidity Conditions
5%-95% humidity, non-condensing. This is a warranty condition.
Explosive Environments
The ZBM is not intended for use in explosive environments. This is a
warranty condition.
ZBM Bus Terminal
Connection
Positive: 8mm (approx. 5/16 inch) eyelet
Negative: 8mm (approx. 5/16 inch) eyelet
ZBM Bus Terminal
Torque
10 Nm (7.4 lb-ft) (applies to bolts fitting cables to BCM)
Communications
RS-485 MODBUS RTU

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1.3 Abbreviations and Definitions
The following acronyms, abbreviations and terms are defined here within the context of this manual.
Term
Definition
BCM
Battery Control Module
BMS
Battery Management System
ELV
Extra-Low Voltage
ESS
Energy Storage System
PPE
Personal Protective Equipment
SDS
Safety Data Sheet
SOC
State of Charge
ZBM
Zinc-Bromine Module

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2 ZBM Safety
The following safety rules apply for any operation of the ZBM batteries.
•Use tools with suitably rated insulated handles to make connections.
•No smoking near ZBMs.
•Check that cable connections between the ZBM and the rest of the Energy Storage System
are tightened to the recommended torque value in Table 2 (10Nm), and torqued nuts and
BCM are marked.
•Check DC cabling polarity to the ZBM is correct prior to powering the system up. Defects
caused by reversed polarity void the warranty.
•Even when disconnected, a ZBM battery can remain charged and have voltage on any
battery terminals (refer to Figure 4). Always check voltage before proceeding.
There are also four main areas of safety specifically relevant to the ZBM battery.
•Electrolyte characteristics
•ZBM battery voltage
•ZBM fire safety characteristics
•ZBM safety labelling
These are explained in detail in the following sections.
2.1 Electrolyte Characteristics
The ZBM is a flowing electrolyte battery containing approximately 100 litres (26.5 US gal) of a
water-based zinc-bromide electrolyte that includes additional supporting salts and complexing agents.
The electrochemical process of charging a ZBM battery alters the electrolyte. Zinc ions are plated out
as metallic zinc, and bromide ions become linked with the complexing agents in the electrolyte to form
a separate dense Bromine Complex phase.
2.1.1 Gas Emissions
Low levels of gas may be generated during operation of the ZBM. The gas is managed by the
pressure relief valve. If the pressure exceeds the relief valve’s limit, gas is directed into the Catch
Can, which uses activated carbon to capture gases thus reducing the concentration of any emissions
that exit the ZBM. Regardless, energy storage systems containing ZBMs must be located in areas
designed to ensure adequate ventilation. Refer to Section 10.2.3 for more information about
ventilation requirements. Standards such as AS4086.2 (Section 2.7) also provide guidelines about
battery room ventilation. Failure to provide adequate ventilation during both operation and storage will
void the warranty.
All low voltage (LV) wiring must be performed by licensed electrical
personnel who are responsible for ensuring that all local and
government regulations and applicable standards are complied with.
This is a warranty condition and failure to comply will void the warranty.
Ensure local government regulations and applicable standards are
complied with when working with ZBM electrolyte.