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.

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2.1.2 Electrolyte Leaks
The presence of liquid electrolyte in the ZBM means that there is potential for a spill to occur. Any
electrolyte leak or spill must be cleaned up in accordance with Appendix A.
The ZBM is packaged in a bund to contain a minor leak. To prevent electrolyte spillage during major
leaks, secondary containment should be used.
2.1.3 Personal Protective Equipment (PPE)
The following, or equivalent, PPE must be worn when handling electrolyte or cleaning up an
electrolyte leak.
Respirator: Moldex half-face pre-assembled respirator with multi-gas/vapour cartridges
(available from Protector Alsafe (www.protectoralsafe.com.au), product code
8602A, part number 0109 0268)
Goggles: Bollé Blast Duo goggles (available from Protector Alsafe, product code
1669211, part number 0708 2904)
Gloves: Prosafe Premium 806 Blue PVC Gauntlets (available from Protector Alsafe,
part number 0784 1563)
Spill kits should be kept on hand at all times, e.g. 62 litre Hazchem spill kits can be sourced from
Global Spill Control at: http://www.globalspill.com.au/?gclid=CMTvvobp-64CFYJLpgodSBzjwQ.
There is approximately 100L (26.5 US Gal) of electrolyte in each ZBM, and while any leak would be
unlikely to result in more than a few millilitres of electrolyte escaping, there is potential for a leak of up
to 100L to occur.
Redflow’s contracted global emergency contact can also provide additional details on how to clean up
an electrolyte leak. Contact details are provided in the Safety Data Sheet (SDS).
2.2 ZBM Battery Voltage Hazard
A single ZBM can have between 0V and 58V DC on any battery terminals during operation. See
Figure 5 to identify the battery terminals. While the ZBM should be fully discharged (terminal voltage
at 0V) during transportation or storage, care must be taken in case the terminals are live.
2.3 ZBM Fire Safety Characteristics
The ZBM is an inherently low fire risk battery as its electrolyte is non-flammable and has many
characteristics of a fire retardant (see Section 5 of the SDS).
As a failsafe measure, the ZBM’s BCM automatically turns off the electrolyte pumps if it detects a
leak. This prevents further electrolyte from being introduced into the battery’s stack so the battery
cannot self-sustain an energy discharge. While there will be a slight increase in temperature, these
measures help prevent stack overheating.
Spills and leaks of ZBM electrolyte must be cleaned up as soon as
possible by trained personnel. Until trained personnel are present, the
area around the spill or leak should be quarantined.

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2.4 Safety Labels
The ZBM label is located on top of the electrode stack and on the tank below the BCM. Figure 2
shows an example of the ZBM label and the information it conveys.
Figure 2: Example ZBM label

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3 ZBM Handling
3.1 ZBM Weights & Dimensions
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)
The ZBM is delivered in a wooden crate. The crate can be moved using an appropriately rated forklift
or pallet jack.
3.2 Lifting Straps
Lifting requirements:
•Lifting of the ZBM must not be done manually.
•Any handling of the ZBM must involve the use of the 2 lifting straps supplied with the ZBM
under the guidance of two persons.
•Lifting straps must not be removed from the ZBM when installed as they will be required for
use in removal of the ZBM.
•The ZBM must always be operated, handled, stored, and transported
in the upright position.
•Transportation and lifting devices must be appropriately rated.
•The ZBM must always be discharged before transportation.
•The ZBM must never be lifted or manhandled via the battery stack.
Always lift and handle the ZBM through the tanks.
•Strapping that loops around the stack and tank and around the tanks
must not to be removed.
The ZBM is supplied with two lifting straps to enable safe handling of a
ZBM when it is not in an enclosure. The straps are rated to handle
lifting of a ZBM filled with electrolyte and must be used to move a ZBM
in an upright orientation using only a suitably rated lifting device for the
ZBM’s weight.

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3.3 Dry ZBMs
The ZBM will in most cases be delivered filled with electrolyte (wet), but in some cases (via air
freight), the ZBM will be delivered without electrolyte. When delivered dry, the electrolyte will be
delivered in separate transport containers. This requires the ZBM to be filled with electrolyte prior to
use. Please contact Redflow or the appropriate Systems Integrator for an additional guide for this
procedure.
3.4 Transporting ZBMs
When transporting a ZBM, the following is required:
•ZBM must be transported in an upright position on a flat, fully-supported base surface.
•If not using the original Redflow crating, construct a crate to handle the weight of the ZBM
and securely hold down the ZBM with support packaging to match or better the original
crating.
•Transport of ZBMs must conform to local and/or international regulations including those
applicable to electrolyte leak and spill containment, while considering the bund fitted to the
ZBM as supplied.
•Storage temperature conditions, specified in Table 1, apply during transportation. Exposure
to temperatures outside the specified storage temperature range voids the ZBM’s warranty.
Failure to comply with transportation requirements will void the warranty.
3.5 Storing ZBMs
ZBMs can generally be stored for up to 12 months in their wet state but must always be fully
discharged. Wet ZBMs are classified as Dangerous Goods Class 8.
In all cases, ZBMs must be stored on a flat, stable and fully-supported base surface in an upright
position. The storage area must be dry and ventilated; closed cycle air-conditioned spaces are not
suitable. ZBMs must be stored in areas that do not receive direct sunlight, as ultraviolet rays can
break down ZBM components.
The ambient temperature should adhere to the storage temperature range specified in Table 1.
Storage for longer than 12 months or in conditions that do not conform to the above will void the ZBM
warranty.
The ZBM, as supplied, is fitted with a bund to help manage electrolyte leaks. Ensure that leak and
spill containment measures are in place and comply with all relevant regulations.
A ZBM filled with electrolyte, as well as a ZBM that once contained
electrolyte, must be handled, stored, and transported as an item with a
Dangerous Goods Classification of 8 (refer to the SDS).
ZBMs that have never contained electrolyte do not require a Dangerous
Goods rating or similar considerations during handling.

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4 ZBM Components
The key components of the ZBM are shown in the following figure.
Figure 3: ZBM key components
4.1 Electrode Stack
The Electrode Stack contains the electrochemical cells that convert electricity into chemical energy
and vice versa. Each cell contains an electrode with a positive (bromine) side and a negative (zinc)
side. The stack consists of multiple connected cells where the electrolyte is circulated to enable the
electrochemical reaction to occur on the electrode in each cell.
4.2 Electrolyte and Tanks
The ZBM uses a water-based zinc-bromide electrolyte that includes additional supporting agents The
electrolyte is stored in 2 tanks; the left-side tank is referred to as the bromine tank and the right-side
tank is referred to as the zinc tank. The tank name relates to the side of the electrode in a stack cell
that the electrolyte is pumped into. The amount of electrolyte is sized to allow the delivery of 10kWh of
energy when fully charged.
LIFTING
STRAPS
BCM
ELECTRODE
STACK
PUMPS
BROMINE
TANK
ZINC
TANK

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4.3 Battery Control Module
The Battery Control Module (BCM) provides the in-built intelligence to protect the battery and allows
the user to manage the ZBM’s operation. Communication with the BCM is most effectively done using
the Battery Management System (BMS, see Section 4.11). The BCM is mounted on to the stack
terminals (+BAT, -BAT), which are fitted with terminal caps. The BCM provides connection points for
the electrical bus (+BUS, -BUS), ZBM components, and external systems as shown in Figure 4 and
Figure 5.
Figure 4: Location of ZBM terminals
Figure 5: BCM connections (viewed from underneath)
4.4 Pumps
The ZBM has 2 pumps (one in each tank) that are used to pump the electrolyte into the stack. The
pumps are powered from the BCM via cables connected to the base of the BCM. The cables and
BCM are labelled to enable correct connection. The speed and operation of the pumps are controlled
by the BCM.
STACK -VE (-BAT)
STACK +VE (+BAT)
+BUS
-BUS
AUX
ANALOG
LOOM
FAN
COM PORTS:
COM1 & COM2
BROMINE
PUMP
ZINC
PUMP
I2C

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4.5 Catch Can and Pressure Relief Valve
The Catch Can is connected to the Pressure Relief Valve (PRV), which is connected to the bromine
tank. Any gas released from the pressure relief valve flows into the Catch Can, which captures gases
using activated carbon, to reduce the concentration of any emissions that exit the ZBM. The Catch
Can is located between the tanks.
Figure 6: Catch Can and Pressure Relief Valve
The barb at the rear of the Catch Can provides a connection point for a hose to direct any uncaptured
gas to an area safe to vent (e.g. outside in open air).
CATCH CAN
LOCATION
PRESSURE
RELIEF
VALVE
PRESSURE
RELIEF
VALVE
CATCH
CAN

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4.6 Fan
The fan draws air from the rear of the ZBM and blows it over the cooling tubes. The operation of the
fan is controlled by the BCM. It turns the fan on, and controls fan speed based on the battery and air
temperature measured by the Battery and Ambient Temperature Sensors.
Figure 7: Fan, ambient temperature sensor, and direction of airflow
The fan assembly includes an integrated IP2X-rated cover to guard against direct contact with the fan
blades, which can present a cutting hazard. The fan cover should never need to be removed from the
fan. The fan cover is shown in Figure 7.
4.7 Cooling Tubes
The ZBM uses the cooling tubes to cool the ZBM by pumping electrolyte through the tubes while the
fan is blowing air over them. The cooling tubes are in a cavity under the stack and between the tanks.
FAN
AMBIENT
TEMPERATURE
SENSOR
AIRFLOW
DIRECTION
The fan cover shall only be removed when a fan needs to be replaced. In
this case, the whole fan assembly must only be removed once the ZBM
has been de-energised as described in section 7.4. A new fan with fan
cover must always be correctly secured before re-energising the ZBM.

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4.8 Analog Loom
The Analog Loom has the following sensors: Leak Sensor, Ambient Temperature Sensor, and Battery
Temperature Sensor (see Figure 8). The Analog Loom 12-pin UT Connector connects to the Loom
terminal on the base of BCM.
Figure 8: Sensor analog loom
The sensor information provides inputs to the BCM to make decisions on the operation of the ZBM.
The locations of the sensors are described in Section 5.2.
Figure 9: Leak sensor and battery temperature sensor locations
LEAK SENSOR
TEMPERATURE
SENSORS
UT CONNECTOR
LEAK 1
LEAK 2
BATTERY TEMPERATURE
SENSOR
LEAK
SENSOR

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4.8.1 Leak Sensor
The leak sensor is used to determine if an electrolyte leak has occurred from the ZBM and is located
beside the zinc pump. The following should be noted about the leak sensor:
•The leak sensor uses two level sensors: Leak 1 and Leak 2 (shown in Figure 8). Leak 1
signifies a lower level of electrolyte, and therefore a less significant leak than detected by the
Leak 2 reading.
•The BCM reads the status of the sensor and if a leak has occurred, operation of the ZBM will
be shut down.
4.8.2 Temperature Sensors
The ZBM has a battery temperature sensor and an ambient temperature sensor. The battery
temperature sensor measures the temperature of the electrolyte and is fitted to the zinc tank (refer to
Figure 9). The ambient temperature sensor is fitted beside the fan to measure the temperature of the
air being blown over the cooling tubes (refer to Figure 7).
4.9 Power Cables
The ZBM includes three Power Cables with waterproof connectors that provide DC power from the
BCM to ZBM components:
•Cooling Fan (4-pin connector)
•Zinc Pump (5-pin connector)
•Bromine Pump (5-pin connector)
4.10 Lifting Straps
The ZBM’s lifting straps are provided with the ZBM to enable movement of the ZBM with appropriate
lifting devices (see Section 3.2 for more detail). They must not be removed.
LIFTING STRAPS