Summary of Contents for Redflow ZBM3
- Page 1 ZBM3 Installation and ORIGINAL INSTRUCTIONS V1 Operation Manual MNL-ZBM-003.1 redflow.com...
- Page 2 © 2022. Redflow Limited. All rights reserved. Any reproduction, modification, or electronic transmission of this publication requires the prior written authorisation of Redflow Limited. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 2 of 58...
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Page 3: Table Of Contents
Upgrade Battery Firmware ....................36 ZBM Operation..........................37 Operating “From Empty” ....................... 37 ZBM Operating Modes ......................37 Startup Procedure ......................... 37 Shutdown Procedure ......................38 Start Battery Discharge and Self-maintenance Cycle ............40 MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 3 of 58... - Page 4 System Design Guidelines – Communications ..............52 10.5 Addressing ZBM Electrolyte Spills/Leaks ..............53 Maintenance Checklist ....................55 Standard Test Cycle ....................56 Example Setup: Inverter and Load ................57 MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 4 of 58...
- Page 5 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 MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 5 of 58...
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Page 6: Introduction
Introduction 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. -
Page 7: Table 1: Zbm Electrical Operating Envelope
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... -
Page 8: Table 2: Zbm Physical And Communications Characteristics
Positive: 8mm (approx. 5/16 inch) eyelet ZBM Bus Terminal Connection Negative: 8mm (approx. 5/16 inch) eyelet ZBM Bus Terminal 10 Nm (7.4 lb-ft) (applies to bolts fitting cables to BCM) Torque Communications RS-485 MODBUS RTU MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 8 of 58... -
Page 9: Abbreviations And Definitions
The following acronyms, abbreviations and terms are defined here within the context of this manual. Term Definition Battery Control Module Battery Management System Extra-Low Voltage Energy Storage System Personal Protective Equipment Safety Data Sheet State of Charge Zinc-Bromine Module MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 9 of 58... -
Page 10: Zbm Safety
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. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 10 of 58... -
Page 11: Electrolyte Leaks
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). -
Page 12: 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 MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 12 of 58... -
Page 13: Zbm Handling
• Lifting straps must not be removed from the ZBM when installed as they will be required for use in removal of the ZBM. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 13 of 58... -
Page 14: Dry Zbms
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. -
Page 15: Zbm Components
The amount of electrolyte is sized to allow the delivery of 10kWh of energy when fully charged. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 15 of 58... -
Page 16: Battery Control Module
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. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 16 of 58... -
Page 17: 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). MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 17 of 58... -
Page 18: Fan
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. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 18 of 58... -
Page 19: 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. LEAK BATTERY TEMPERATURE SENSOR SENSOR Figure 9: Leak sensor and battery temperature sensor locations MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 19 of 58... -
Page 20: Leak Sensor
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 MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 20 of 58... -
Page 21: Battery Management System
4.11 Battery Management System Redflow offers an additional accessory for use with the ZBM called the Battery Management System (BMS, see Figure 10). When powered and provided with an internet connection, a single BMS allows the user to monitor, log, and control operation of up to 12 ZBMs via an online interface. A minimum of one BMS is required for every site installation. -
Page 22: Zbm Installation And Connection
Note: For an example installation setup, refer to Appendix D. This section lists the steps to perform to install and connect a ZBM into an energy storage system. Installation in compliance with these instructions by suitably qualified and Redflow trained personnel is a condition for a valid warranty. -
Page 23: Figure 12: Lifting Crate Lid
4. Undo the plastic bag and remove. Ensure the two lifting straps are fitted through the locating holes of the tank. LIFTING STRAPS Figure 13: Plastic bag removed, lifting straps in place MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 23 of 58... -
Page 24: Perform Pre-Installation Checks
Check for any electrolyte leaks both visually and by the presence of a chlorine-like smell. If a leak is present, do not operate the ZBM and contact Redflow. Contact details are provided on the rear cover of this manual. Leaks must be cleaned up in accordance with Appendix A. -
Page 25: Figure 16: Leak Sensor And Temperature Sensors Locations
The 5-pin connector of the bromine pump. • The 4-pin connector of the fan cable. • The 5-pin connector of the zinc pump. ANALOG BROMINE ZINC LOOM PUMP PUMP Figure 17: BCM connections MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 25 of 58... -
Page 26: Lift The Zbm Into Place
(refer to section 5.2) are repeated once the ZBM is in its required location. STEP 3 Tidy the ZBM’s lifting straps away neatly beside the ZBM (the straps remain on the ZBM). MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 26 of 58... -
Page 27: Install And Connect The Bms
(with reference to Figure 20): feed the Cat6 cable through the waterproof cap (A), followed by the rubber grommet (B) and the cable mount (C). Figure 20: Cat6 cable assembly MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 27 of 58... -
Page 28: Connect The Zbm To The Dc Bus
8mm eyelets. STEP 1 To connect the positive bus cable, remove the washer and bolt from the bus terminal (refer to Figure 22). -BUS +BUS Figure 22: Bus cable connections MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 28 of 58... -
Page 29: Figure 23: Bolt, Cable, And Washer Arrangement For Bus Terminal
Repeat above steps to fit the negative bus cable on the negative bus terminal (-BUS) with a negative boot (black). STEP 4 Connect the DC bus cables from the ZBM to the ZBM circuit breakers (ensure correct polarity). MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 29 of 58... -
Page 30: Commission A Battery
6. Select the [Login] button at the top right of the window and enter admin in the Username and Password fields. 6.1.2 Set the BMS Settings 1. From the Menu bar, select Configuration > Site. The Site Configuration window displays: 2. In the Site section, enter the details. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 30 of 58... - Page 31 Do not select the options for pre-release software. 5. Unless advised otherwise, do not select the options in the Master BMS and Slave BMS sections. 6. Select the Submit button at the bottom of the window. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 31 of 58...
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Page 32: Update Bms Firmware
3. When the download completes, select the Complete – Upgrade Now link to install the software. A progress window displays. Wait for the BMS to restart and display the Status page. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 32 of 58... -
Page 33: Check Bms Date And Time
1. Connect power to the battery from the DC bus. 2. Select Configuration > Battery Setup. Wait for the serial number to display to indicate that the battery has started and is communicating with the BMS. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 33 of 58... - Page 34 Wait for the serial number to display to indicate that the battery has started and is communicating with the BMS. c. Input the Description field, then select the Add Battery button. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 34 of 58...
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Page 35: Check Visibility Of A Battery In The Bms
1. Wait a few minutes for the battery settings to be activated in the BMS. 2. On the Menu bar, select the Status option. The BMS displays each battery that it can connect to. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 35 of 58... -
Page 36: Upgrade Battery Firmware
3. Select the Upgrade button. The upgrade parameters window displays. 4. Select the Upgrade button. A progress bar dialog displays; once the upgrade is indicated as complete, close the progress bar dialog. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 36 of 58... -
Page 37: Zbm Operation
After a ZBM has been installed and connected, the ZBM can be put into operation. Use the BMS online interface: 1. From the Menu bar, select Status. The batteries for the BMS display. 2. Select a battery row. The battery detail displays. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 37 of 58... -
Page 38: Shutdown Procedure
2. Use the BMS online interface to decommission the battery. a. From the Menu bar, select Status. The batteries for the BMS display. b. Select the battery row. The battery detail displays. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 38 of 58... - Page 39 3. Disconnect the ZBM by switching off the bus circuit breakers. 4. Use a multimeter to measure the voltage across the battery’s bus terminals to confirm that the ZBM’s voltage is approximately 0V. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 39 of 58...
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Page 40: Start Battery Discharge And Self-Maintenance Cycle
The batteries for the BMS display. 2. Select a battery row. The battery detail displays. 3. Select the Operations button. The Battery Operations window displays. 4. Select the Force Maintenance button. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 40 of 58... -
Page 41: Zbm Wear And Failure Processes
Gradual reduction in electrode conductivity occurs as the ZBM is used. This is the normal life limiting process in the ZBM. Eventually, the electrode resistance increases to the point where the electrode stack needs to be replaced. If this occurs, contact Redflow for an approved part replacement and procedure. -
Page 42: Over Temperature
If the temperature of the electrolyte continues to significantly increase, this may result in high pressures inside the ZBM as gases are evolved (see Section 10.3 for related design considerations). MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 42 of 58... -
Page 43: Zbm Maintenance
ZBM warranty claim. If a part replacement is required, only Redflow-approved parts may be used; this is a requirement for any warranty claims. If replacements are necessary, contact the supplier of the ZBM. -
Page 44: Periodic Maintenance
• Check the pH and adjust if necessary. If any of the above checks identify defects, contact the supplier of the ZBM for Redflow-approved part replacement and procedures. Untrained maintenance on any of these parts voids the ZBM warranty. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual... -
Page 45: Cleaning
Ensure there are no kinks in the Catch Can and Pressure Relief Valve hoses. If any of the above checks identify defects, contact the supplier of the ZBM for Redflow-approved replacement parts and procedures. Untrained maintenance on any of these parts voids the ZBM warranty. -
Page 46: Zbm System Integration
Further, each ZBM is equipped with a Catch Can (see section 4.5) to capture gases generated during operation. The barb at the rear of the Catch Can provides a connection point for a hose to direct any MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 46 of 58... -
Page 47: Fire Control System
(see Section 9 for maintenance requirements). • System design must not restrict the flow of electrolyte in any piping or tubing included with the ZBM, this is a warranty condition. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 47 of 58... -
Page 48: Separation Of Zbms And Ess Electronics
Aluminium should be anodised (>20 micron). • Cables ties must be polypropylene not nylon. If building an enclosure, contact Redflow for further support. 10.2.3 Ventilation Requirements The ZBM is not intended for use in explosive environments. ZBMs must never be installed in airtight enclosures. -
Page 49: Temperature Considerations
ESS. • Grid-interconnection components as required by the application (e.g. transformers). It is a warranty requirement that operational electrical parameters specified in Table 1 must be adhered to. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 49 of 58... -
Page 50: Voltages
The ZBM’s power ratings are stated in Table 1. The duration of the ZBM’s peak discharge power depends on various parameters including the battery’s current state of charge, age, and temperature. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 50 of 58... -
Page 51: Energy Output
If there is no external power available to the ZBM when it begins the self-maintenance cycle or external power is lost during self-maintenance, the ZBM will power down. When external power is returned, the ZBM will continue where it stopped in the self-maintenance cycle. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 51 of 58... -
Page 52: Parallel Arrangements Of Zbms
It is important to note that 1 BMS can be used to communicate with up to 12 ZBMs in one system. If the system designed has more than 12 ZBMs contact Redflow for the best recommended solution. The BMS can also connect to other components in the larger energy system, including energy management systems and inverters, to enable control of the ZBMs from those components. -
Page 53: Addressing Zbm Electrolyte Spills/Leaks
Manage all clean up materials as hazardous waste by placing them in an acid debris waste accumulation container. Contact Redflow support for advice on how to proceed. Step 2.3 If the spill is not associated with a ZBM, for example, electrolyte is spilt from its container, use rags or disposable wipes to clean up the electrolyte. - Page 54 If possible, discharge the ZBM safely. Actively ventilate the affected area. Contact Redflow support for advice on how to proceed. Step 3.4 If the spill/leak is not associated with a ZBM, inspect for the cause or source of the spill and, if possible, prevent further spillage from occurring.
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Page 55: Maintenance Checklist
□ Done □ Done □ Done □ Done □ Done □ Done □ Done □ Done □ Done □ Done □ Done □ Done Check and remove any animal ingress MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 55 of 58... -
Page 56: Standard Test Cycle
Standard Test Cycle shows Redflow’s Standard ZBM test cycle that is run in the case of a warranty claim. The Figure 27 standard test cycle starts with a fully discharged ZBM. There are two operating modes that the ZBM goes through during this standard cycle at 25 °C... -
Page 57: Example Setup: Inverter And Load
• Control and monitoring of the performance of the ZBM is done using Redflow’s BMS product. MNL-ZBM-003.1 ZBM3 Installation and Operation Manual Page 57 of 58... - Page 58 Redflow Head Office Redflow Limited 27 Counihan Road Seventeen Mile Rocks Brisbane QLD 4073 Australia +61 7 3376 0008 sales@redflow.com SALES info@redflow.com GENERAL marketing@redflow.com MEDIA redflow.com...
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