ZUCCHETTI AZZURRO ZZT-ZBT5K-ES5 User manual

BATTERY HV
ZZT-ZBT5K-ES5 ~ ES20

Identification: MD-AL-GI-00 Rev.
0.0 of 30/09/2022 - Application: GID
Zucchetti Centro Sistemi S.p.A.
- Green Innovation Division
Via Lungarno, 248
- 52028 Terranuova Bracciolini - Arezzo, Italy
tel. [phone]
- fax. [phone]
[e-mail]
- [e-mail] – www.zcsazzurro.com
Reg. Pile IT12110P00002965 - Share Capital € 100,000.00 fully paid up
AR Company Reg. no. 03225010481
- REA AR no. 94189
ISO 9001 Certified Company - Certificate no. 9151 - CNS0 - IT-17778
Battery
AZZURRO ZZT-ZBT5K-ES5 ~ ES20
User Manual

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User’s Manual AZZURRO ZZT-ZBT5K-ES5 ~ ES20
Rev. 0.0 30/09/2022
Table of Contents
General information ..............................................................................................................................................................................................5
1.1. Validity ...........................................................................................................................................................................................5
1.2. Intended Use................................................................................................................................................................................5
1.3. Identifying The Product..........................................................................................................................................................6
Preface.........................................................................................................................................................................................................................7
2.1. Notice..............................................................................................................................................................................................7
2.2. Save this Instruction.................................................................................................................................................................7
2.3. Outline............................................................................................................................................................................................7
2.4. Target Group................................................................................................................................................................................7
2.5. Symbols Used ..............................................................................................................................................................................8
Safety............................................................................................................................................................................................................................9
3.1. Requirement for Installation and Maintenance ...........................................................................................................9
3.2. Description of safety information symbols .................................................................................................................11
Product Overview................................................................................................................................................................................................13
4.1. Brief Introduction...................................................................................................................................................................13
4.2. The main features are as follows:....................................................................................................................................14
4.3. Product Model Description ................................................................................................................................................15
4.3.1.1. Battery module ..............................................................................................................................................................15
4.3.1.2. Battery module ..............................................................................................................................................................16
4.3.1.3. Battery distribution unit: ..........................................................................................................................................17
4.3.1.4. Battery module port:...................................................................................................................................................17
4.4. Product Model Description ................................................................................................................................................21
Product Installation............................................................................................................................................................................................22
5.1. Checking Before Installation..............................................................................................................................................22
5.2. Checking packing list ............................................................................................................................................................23
5.3. Checking packing list ............................................................................................................................................................25
5.4. Installation environment ....................................................................................................................................................26
5.5. Installation Space ...................................................................................................................................................................26
5.6. Battery system installation ................................................................................................................................................27

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Electrical Connection.........................................................................................................................................................................................31
6.1. Preparation of Connection Cables...................................................................................................................................32
6.2. Electrical Connection for Internal System ...................................................................................................................33
6.3. External electrical connection ..........................................................................................................................................37
6.4. External ground Connection of the PGND cable........................................................................................................38
6.5. BMS communication cable installation.........................................................................................................................39
6.6. Battery parallel installation ...............................................................................................................................................40
6.7. Fuse replacement ...................................................................................................................................................................40
6.8. Install the protective cover.................................................................................................................................................41
Commissioning .....................................................................................................................................................................................................42
7.1. Double Check............................................................................................................................................................................42
7.2. Electrify for the First Time（Important）..................................................................................................................42
7.3. Battery Parameter Settings................................................................................................................................................42
7.4. Software Update......................................................................................................................................................................43
7.5. Battery Powered Off..............................................................................................................................................................44
Trouble shooting and maintenance.............................................................................................................................................................45
8.1. Troubleshooting......................................................................................................................................................................45
8.2. Daily Maintenance..................................................................................................................................................................46
8.3. Battery Module Storage Requirements and Power Supply ..................................................................................47
Technical Parameters.........................................................................................................................................................................................48
Uninstalling............................................................................................................................................................................................................50
8.1. Uninstallation steps...............................................................................................................................................................50
8.2. Packaging...................................................................................................................................................................................50
8.3. Storage ........................................................................................................................................................................................50
8.4. Disposal ......................................................................................................................................................................................50
Warranty terms and conditions ....................................................................................................................................................................51

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General instructions
This manual contains important safety instructions that must be followed during installation and
maintenance of the equipment.
Please keep these instructions!
This manual must be considered an integral part of the equipment, and must be available at all times to
everyone who interacts with the equipment. The manual must always accompany the equipment, even when
it is transferred to another user or plant.
Copyright statement
Copyright of this manual belongs to Zucchetti Centro Sistemi S.p.A. No part of this manual (including the
software, etc.) may be copied, reproduced or distributed in any form or by any means without the permission
of Zucchetti Centro Sistemi S.p.A. All rights reserved. ZCS reserves the right to final interpretation. This manual
is subject to change based on feedback from users, installers or customers.
Please check our website at http://www.zcsazzurro.com for the latest version.
Technical support
ZCS offers a support and technical consultancy service accessible by sending a request directly from the
website https://www.zcsazzurro.com/it/support.
The following toll-free number is available for the Italian territory: 800 72 74 64.

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General information
This manual introduces AZZURRO ZZT-ZBT5K-ES5 ~ ES20 Battery. Please read this manual before you use
the battery.
Any confusion, please contact AZURRO technical support immediately for advice and clarification.
1.1. Validity
This user manual is applicable to AZZURRO ZZT-ZBT5K-ES5 ~ ES20 Battery.
This user manual contains AZZURRO ZZT-ZBT5K-ES5 ~ ES20 product information, usage guidance, safety
information, installation guide and details on common operating issues and subsequent corrective actions.
1.2. Intended Use
AZZURRO ZZT-ZBT5K-ES5 ~ ES20 is an energy storage unit that is designed to be used in residential on-grid
applications with the capability for short-term backup.
Notes regarding intended use:
AZZURRO ZZT-ZBT5K-ES5 ~ ES20 is not suitable for supporting life-sustaining medical devices.
This product is intended for use only in accordance with the information provided in the enclosed
documentation and with the locally applicable standards and regulations. Any other application may cause
personal injury or property damage.
The illustrations in this manual are meant only to help explain system configuration concepts, includes usage
guidance, safety precautions, and common operating issues and subsequent corrective actions.
Alterations to the product, e.g. changes or modifications, are only permitted with the express written
permission of ZCS Technical Support. Unauthorized alterations will void warranty claims. Zucchetti Centro
Sistemi S.p.A. shall not be held liable for any damage caused by such changes. Any use of the product other
than that described in the Intended Use section does not qualify as appropriate. The enclosed documentation
is an integral part of this product. Keep the documentation in a convenient place for future reference and
observe all instructions contained therein. The type label must remain attached to the product.
Please contact ZCS Technical Support or local after-service providers within 1 week once the user decides to
cease using their ZCS Battery products.

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1.3. Identifying The Product
The type labels were attached on the product, which contain the product identification information. For safe
usage, the user must be well-informed of the contents in the type labels.
The type labels include:
Figure 1a – Labels on the side of the system
Figure 2b – Labels on the side of the battery

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Preface
2.1. Notice
The purchased products, services and features are governed by the commercial contract made by the
Company. All or part of the products and features described in this document may not be within the
purchase scope. Except as otherwise agreed herein, no representations or warranties, express or implied,
are made as to the contents of this document.
2.2. Save this Instruction
This manual must be considered as an integral part of the equipment. Customer can print the electronic
version to hard copy and keeping properly for future reference. Anyone who operates the device at any
time must operate in accordance with the requirements of this manual.
2.3. Outline
It describes the assembly, installation, commissioning ,maintenance and failure of the product. Please
read it carefully before operating.
Scope of Validity
This product user manual describes the installation, electrical connection, debugging, maintenance and
troubleshooting of BTS series intelligent battery system. The series includes the following models：
ZZT-ZBT5K-ES5
ZZT-ZBT5K-ES10
ZZT-ZBT5K-ES15
ZZT-ZBT5K-ES20
2.4. Target Group
This document is intended for professional electrical engineers who are responsible for battery installation
and commissioning, including technical support engineers, system engineers, and electrical engineers

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2.5. Symbols Used
In order to ensure the personal and property safety of users when using BTS series intelligent battery system,
as well as the efficient use of this product, the manual provides relevant safe operation information and
highlights it with corresponding symbols. These stressed messages must be fully understood and absolutely
adhered to avoid personal injury and property damage. The symbols used in this manual are listed below.
“Danger”indicates
a hazardous situation which, if not
avoided, will result in death or serious injury.
Danger
“Warning”indicates a hazardous situation which, if not
avoided, could result in death or serious injury
Warning
“Caution”indicates
a hazardous situation which, if not
avoided, could result in minor or moderate injury
Caution
“Attention”indicates there are potential risks, if fail to
prevent, may lead to equipment cannot normally or
property damage.
Attention
“Note”provides additional information and tips that are
valuable for the optimal operation of the product, will
help you to solve a problem or save your time.

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Safety
Please read the instruction carefully. Faulty operation may cause serious injury or death .
3.1. Requirement for Installation and Maintenance
The installation of battery series intelligent battery system must be in full compliance with national and local
laws and regulations.
Read and understand all instructions contained in this manual and familiarize yourself with safety symbols
before installing and commissioning the device.
For any maintenance or repair, please contact the nearest authorized repair center. For information about the
nearest authorization center, contact your reseller. Do not repair by yourself, which may cause personal injury
or property injury.
Before installing and maintaining the device, disconnect the device from the external device using the DC
switch. Otherwise, the high voltage may cause serious injury.
AZZURRO ZCS will not be responsible for any personal injury or property injury caused by improper use.
Installation and maintenance personnel requirements
The personnel responsible for installation and maintenance of the equipment for the first voyage must first
receive strict training, understand various safety precautions and master correct operation methods.
Only qualified professionals or trained personnel are allowed to install, operate, and maintain the device.
Only qualified professionals are allowed to remove safety facilities and repair devices.
The personnel, including the operators, trained personnel, and professional personnel, who operate the
equipment should have the special operation qualification required by the local state, such as the
qualification of high voltage operation, height climbing, and special equipment operation.
Only professional or authorized personnel can replace equipment or components (including software).
Note：
Professional personnel: those who have the training or operation experience of equipment and are able to
understand the potential sources and magnitude of hazards in the process of equipment installation,
operation and maintenance.
Trained personnel: personnel who have received the appropriate technical training and have the necessary
experience are aware of the risks that may be posed to them in performing a certain operation and can take
measures to minimize the risks to themselves or other personnel.
Operators: operators who may have access to the equipment except trained and professional personnel.
If you have any question or problem when you read the
following information, please contact Shenzhen
AZZURRO ZCS Ltd.
Note

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Assembly Condition
Assemble the BTS intelligent battery system as detailed in the following sections of this manual. Place the
battery in a position that can be fixed on the edge and ensure that it is placed vertically. A suitable place for
installation of electrical equipment should be selected to ensure sufficient space for fire escape for
maintenance in case of failure. Maintain proper ventilation to ensure adequate air circulation for cooling, and
air humidity is recommended to be less than <90% during assembly.
Transportation Requirement
The Batteries are in the good electrical and physical condition when it ship out from factory. During transport,
battery module must be placed in its original package or other proper package. Transportation company
should responsible for any damage during transport period. Please check the battery thoroughly when taking
delivery. If you find any packing problems that may cause the damage of inverter or any visible damage, please
notice the responsible transportation company immediately. You can ask your installer or AZZURRO ZCS for
help is necessary.
This product contains battery module through UN38.3, belongs to the ninth category of dangerous goods.
Therefore, loading and unloading must comply with local laws and regulations and industry standards during
transportation. Rough loading and unloading may cause short circuit or damage to batteries in containers,
which may result in battery leakage, breakage, explosion, or fire.
Requirement During the Transportation
Shipping complies with the IMDG CODE and the International Maritime Dangerous Goods CODE.
For land transportation, comply with ADR or JT T617 shipping requirements
Meet the regulatory requirements of the transport regulatory authorities of the country of origin, route and
destination.
Comply with international regulations for the transport of dangerous goods and the supervision
requirements of the corresponding national transport regulatory authorities.

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3.2. Description of safety information symbols
High voltage of battery may be harmful to health!
Only
certified engineer can operate the product;
Juveniles, Disable, should not use this product;
Keep this product out of the reach of children;
Danger
Caution of burn injuries due to hot enclosure!
Only touch the screen and pressing key of the product
while it is working
Caution
Batteries should be grounded in accordance to the
requirements of the local electrical grid company
Attention
To ensure that the battery is used in the equipment system
authorized by AZZURRO ZCS, and the battery is
damaged or other losses caused by illegal use or
unauthorized use of the equipment by ZCS AZZURRO.
AZZURRO ZCS has the right not to do warranty, not to
bear joint liability.
Sings on the battery module
The battery module carries a number of safety related labels. Make sure to read and understand the labels
carefully before installing the device.
Symbols
Name
Explanation
This is a
residual voltage
in the battery
module!
There is a high voltage,when the
battery is powered on. After the
battery is powered off, the internal
capacitor is still charged ，
operator should wait for 5 minutes
to ensure the capacitor is
completely discharged.
Caution of high
voltage and
electric shock
The battery module operates at
high voltages. Prior to performing
any work on the product,
disconnect the product from
voltage sources. All work on the
product must be carried out by
qualified persons only.
C
aution of hot
surface
The battery module can get hot
during operation. Avoid contact
during operation.
Grounding
Terminal
Connect the battery module to the
ground bar for grounding
protection
Observe the
documentation
Read all documentation supplied
with the product before install

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Sings on the battery distribution unit
The battery distribution unit carries a number of safety related labels. Make sure to read and understand the
labels carefully before installing the device.
Symbols
Name
Explanation
This is a
residual
voltage in the
battery
module!
There is a high voltage,when the
battery is powered on. After the
battery is powered off, the internal
capacitor is still charged，operator
should wait for 5 minutes to ensure
the
capacitor is completely
discharged.
Caution of high
voltage and
electric shock
The battery module operates at high
voltages. Prior to performing any
work on the product, disconnect the
product from voltage sources. All
work on the product must be carried
out by qualified persons only.
Caution of hot
surface
The battery module can get hot
du
ring operation. Avoid contact
during operation.
Grounding
Terminal
Connect the battery module to the
ground bar for grounding protection
Observe the
documentation
Read all documentation supplied
with the product before install

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Product Overview
4.1. Brief Introduction
Figure 2 – Product overview
AZZURRO ZZT-ZBT5K-ES5 ~ ES20 is a battery system with an operating voltage range between 45.6~56.16V.
It is utilized in household energy storage applications and works together with a hig-voltage to realize the
goal of energy storage for the home.
AZZURRO ZZT-ZBT5K-ES5 ~ ES20 series intelligent battery system is mainly composed of battery module
and battery distribution unit. The input and output voltages are high DC voltage. The system adopts modular
design and stacked installation method. The capacity can be flexibly configured based on actual requirements.
The capacity ranges is 5kWh ~ 40kWh.

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4.2. The main features are as follows:
Full modular design, easy to install and transport；
Current balance between battery modules, higher battery available capacity；
Capacity Expansion by Stages；
Low power consumption of battery；
One key activate/shutdown.
Figure 3 – AZZURRO ZZT-ZBT5K-ES5 ~ ES20 series application principle diagram

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4.3. Product Model Description
4.3.1.1. Battery module
Identifiers
Meaning
Specification
①
Product series name
AZZURRO ZCS series battery module name
②
Battery module energy grade
5K: Battery module energy is 5kWh
Identifiers
Meaning
Specification
①
Product series name
AZZURRO ZCS series battery module name
②
Battery module energy grade
5K: Battery module energy is 5kWh
③
System Unit
BDU: Battery distribution unit
Identifiers
Meaning
Specification
①
Product series name
AZZURRO ZCS series battery module name
②Battery module energy grade
ES5: Battery total energy is 5kWh
ES10: Battery total energy is 10kWh
ES15: Battery total energy is 15kWh
ES20: Battery total energy is 20kWh
③
System Unit
BDU: Battery distribution unit

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4.3.1.2. Battery module
Figure 4 – System appearance
1
Indicator light
5
Base
2
DC switch
6
Black startup switch
3
Battery distribution unit
7
Heat sink
4
Battery module

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4.3.1.3. Battery distribution unit:
Figure 5 –Schematic diagram of battery power distribution unit ports
1
Battery distribution unit
7
DC switch
2
Black startup switch
8
BDU communication output
（
COM-OUT
）
3
Battery input
（
BAT IN
）
9
Fuse
4
BDU cascading communication port (Link)
10
Battery output
（
BAT Out
）
5
BDU communication input
（
COM-IN
）
11
Grounding hole
6
Grounding hole
4.3.1.4. Battery module port:
Figure 6 –Battery module port diagram
1
Battery distribution unit
5
Grounding hole
2
Left side handle
6
Communication output
（
Link Port Out
）
3
Output terminal B+
7
Communication input
（
Link Port In
）
4
Output terminal B-
8
Right side handle

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4.3.1.5. Indicator lights description
Figure 7 –Indicator diagram
Normal status indicator light:
Status light
Alarm light
SOC light
L1
L2
L3
L4
L5
Shutdown
Off
Off
Off
Off
Off
Off
Off
Standby
Green light flashing
Off
Display according to the battery SOC value
Updating
Blue light flashing
Off
Charge
Blue light ON
Off
Discharge
Green light ON
Off
SOC indicator light definition while charging
SOC value
SOC light
L1
L2
L3
L4
L5
0%~5%
Off
Off
Off
Off
Off
6%~25%
Flashing
Off
Off
Off
Off
26%~50%
ON
Flashing
Off
Off
Off
52%~75%
ON
ON
Flashing
Off
Off
76%~95%
ON
ON
ON
Flashing
Off
96%~100%
ON
ON
ON
ON
Flashing
SOC indicator light definition while discharging
SOC Value
SOC light
L1
L2
L3
L4
L5
0%~5%
Off
Off
Off
Off
Off
6%~25%
ON
Off
Off
Off
Off
26%~50%
ON
ON
Off
Off
Off
52%~75%
ON
ON
ON
Off
Off
76%~95%
ON
ON
ON
ON
Off
96%~100%
ON
ON
ON
ON
ON

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Alarm status indicator:
Alarm status
Status
light
Alarm light
SOC light
L1
L2
L3
L4
L5
High
temperature
alarm
Off
Flashing
ON
Off
Off
Off
Off
Low
temperature
alarm
Off
Flashing
Off
ON
Off
Off
Off
Over voltage
alarm
Off
Flashing
Off
Off
ON
Off
Off
Under
voltage
alarm
Off
Flashing
Off
Off
Off
ON
Off
Over current
alarm
Off
Flashing
Off
Off
Off
Off
ON
Battery cell
temperature
differential
abnormal
Off
Flashing
ON
ON
Off
Off
Off
Monomer
differential
pressure is
too large
Off
Flashing
Off
ON
ON
Off
Off
Abnormal
ambient
temperature
Off
Flashing
Off
Off
ON
ON
Off
Other
Off
Flashing
ON
ON
ON
ON
ON
Fault status indicator light:
Alarm status
Status
light
Alarm light
SOC light
L1
L2
L3
L4
L5
High
temperature
fault
Off
ON
ON
Off
Off
Off
Off
Low
temperature
fault
Off
ON
Off
ON
Off
Off
Off
Battery over
voltage
Off
ON
Off
Off
ON
Off
Off
Battery low
voltage
Off
ON
Off
Off
Off
ON
Off
Battery over
current
Off
ON
Off
Off
Off
Off
ON
Battery cell
temperature
differential
protection
Off
ON
ON
ON
Off
Off
Off