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Instruction Manual Instruction Manual User and maintenance manual for ZenergiZe Energy Storage Systems (ESS) English ZBP45 - ZBE45 ESF...
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ZBP45 and ZBE45 User and maintenance manual for ZenergiZe Energy Storage Systems (ESS) User and maintenance manual .............. 5 Circuit diagrams ..................77 Original instructions Printed matter N° 2960 5810 01 ATLAS COPCO - POWER AND FLOW DIVISION www.atlascopco.com 10/2020...
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While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors. Copyright 2020, Grupos Electrógenos Europa, S.A.U., Zaragoza, Spain. Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings.
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While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors. Atlas Copco reserves the right to make changes without prior notice.
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Error #48 - DVCC with incompatible firmware ..........56 9.4.2 Trailer ..........67 MPPT Solar Charger Error Codes ..56 Technical specifications of 6.3.1 Error Codes........56 the ESS ........68 Storage of the ESS ....60 10.1 Technical specifications of the ZBP45 unit ........68 Storage..........60 - 6 -...
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The policy of Atlas Copco is to provide the users of their Atlas Copco equipment. It is the responsibility of unsafe operating conditions. Take necessary steps to equipment with safe, reliable and efficient products.
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ESS. Atlas Copco reserves tampered with. 12 In the event the safety labels are damaged or...
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During operation, hazardous voltages can be present at Never leave a load hanging on a hoist. Safety during transport and the ESS surroundings. A hoist has to be installed in such a way that the installation Work on or in the vicinity of the device is only allowed object will be lifted perpendicular.
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- above 85 dB(A): room to be classified as a noise- 11 If there is a risk of inhaling hazardous gases, fumes Safety during use and hazardous area and an obvious warning shall be or dust, the respiratory organs must be protected and operation placed permanently at each entrance to alert depending on the nature of the hazard, so must the...
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If any sound- ual voltage on the power circuit. Parts shall only be replaced by genuine Atlas Copco damping material is damaged, replace it to prevent 20 When operating the ESS in Remote or Auto mode, replacement parts.
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16 When using cartridge type breathing filter equip- Tool applications safety Battery safety precautions ment, ascertain that the correct type of cartridge is Apply the proper tool for each job. With the knowledge While working on the Li-ion Battery wear protective used and that its useful service life is not surpassed.
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Li-ion Batteries are heavy. If involved in an accident they can become a projectile! Ensure adequate and secure mounting and always use suitable handling equipment for transportation. Handle with care because Li-ion Batteries are sensitive to mechanical shock. If charged after the Li-ion battery was discharged below the Discharge cut-off voltage, or when the Li-ion battery is damaged or overcharged, the Li- ion battery can release a harmful mixture of gasses...
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Main parts General description ZenergiZe modular ESS design to meet the requirements of applications such as rental, events and telecom. Ideal for any metropolitan job or event. Based in lithium ion batteries, this portable product is ready to supply power in the most demanding situation, working in island mode or a hybrid solution together with a diesel generator. Giving flexibility to the final product with a list of options such as solar panel connection to increase its sustainability or cold weather kit for the most critical environments.
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Markings Indicates that the unit may Markings provide instructions and information. They start automatically and Indicates that the unit contains a also warn of hazards. For convenience and safety, that the instruction book chargeable battery. has to be consulted prior keep all markings in legible condition, replacing them to use.
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Mechanical features 2.3.4 Data plate and serial number Electrical features The ESS is furnished with a data plate showing the The mechanical features described in this chapter are The electrical features described in this chapter are product code, the unit number, the energy stored and standard provided on this energy storage pack.
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2.4.2 Inverter / battery charger Q23 ..Breaker 32A 4P 30mA Power electronics that combines inverter and charger. Q22 ..Breaker 63A 4P It is needed to transform the energy supply from batteries (DC) to the loads (AC) with or without Q21 ..Breaker 125A 4P additional sources as diesel generators or grid.
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K4 ..Relay 230V 1C 2.4.4 Emergency stop button Push the button to stop the ESS in case of an K3 ..Relay 48V 1C K102 F400 emergency. When the button is pressed, it must be K103 unlocked by rotating it clockwise, before the ESS can K2 ..
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This connector includes dry contact to remote start and stop the genset connected to the ESS. The intelligence of the hybridization is controlled by the ESS. - 20 -...
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Installation and connection 7. In the case of permanent use on vehicles, Lifting Positioning and transport additional measures must be taken to prevent The lifting eye, to lift the ESS by means of a hoist, is The operator is expected to apply all vibrations (for example decoupling via vibration integrated in the bodywork and easily accessible from relevant safety precautions, includ-...
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3.2.2 Transportation and positioning Schematic overview: of the ESS onto vehicles Due to its compact and optimized design, the ESS Transport of one single unit: offers a great transport efficiency. The ESS can be easily lifted and moved to difficult areas thanks to its central lifting eye and double forklift pockets in its frame.
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– Leave enough space for operation, inspection and ray equipment, audio amplifiers and elevators. maintenance (at least 1 meter at each side). Consult Atlas Copco for measures against the adverse – Check that the inner earthing system is in influence of non-linear loads.
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The lowest acceptable wire section and the 3.4.2 Quality, minimum section and 3.4.3 Connecting the power supply corresponding maximum cable or conductor length maximum length of cables In order to recharge the ESS or use it as an hybrid for multiple core cable or H07 RN-F, at rated current solution, it is necessary to connect the ESS to a The cable connected to the sockets or powerlocks of (20 A), for a voltage drop lower than 5% and at a...
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3.4.4 Connecting the load 3.4.4.1 Protection For safety reasons, it is necessary to provide an isolating switch or circuit breaker in each load circuit. Local legislation may impose the use of isolating devices which can be locked. – Check whether frequency, voltage and current comply with the ratings of the ESS.
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Operating instructions Before starting Operating the ESS – Perform all daily checks and maintenance as Carefully read follow In your own interest, always strictly specified in the “Maintenance schedule” on page sequence all the operating instruc- observe all relevant safety instruc- tions in this manual! tions.
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4.2.1 Before the ESS is started 4.2.2 Starting the ESS 4.2.4 Connecting appliances 1. Before starting the system, check that all the 1. Put starter switch S20 in position GENSET or Keep in mind that this machine is a automatic switches (general ELCB, sockets MAINS to power the CCGX module.
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4.2.5 Stopping the ESS Operating the CCGX 4.3.1 Push buttons and display controller Follow the instructions below to switch the ESS off correctly: 1. Place all the automatic switches in their OFF position. 2. Turn the selector mode switch to OFF position. Should an emergency arise, it is also possible to stop the machine by pressing the EMERGENCY 'STOP'...
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1. Go one step further down into another submenu (right) or back into the respective higher-level menu (left). 2. Moves the cursor to the right or left. AC loads total power and splitted by phase. Information of PV charger (if connected). Menu button.
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Item Default Description General Remote support Enable this to allow Victron engineers to access your system in case there is a problem. User and Access level Set this to 'User' to prevent accidental and unwanted changes to the configuration. installer Audible alarm When there is an alarm on the CCGX or a connected product, the CCGX will beep - unless this setting is set to 'Off'.
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Item Default Description Enabling will allow direct connection to the CCGX by typing its IP address or in VictronConnect when connected to the same network. Enable on LAN Only Enable this function on trusted networks. Disable password check, or set password first. System setup AC input 1 Generator...
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(bulk → absorption) to the VRM Portal. These events initiate an immediate transmission of all parameters. Rest of parameters Please contact Atlas Copco for more details. Wireless AC Sensors Select the position for each AC sensor (PV Inverter on AC-input 1, 2 or on AC-output).
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CCGX (and make it beep): SOC, it only retrieves it from the connected devices. – Disabled: The CCGX will never beep or show a In the ZBP45 and ZBE45, we use the Multi and notification. Quattro inverter/chargers. – Alarm only: The CCGX will only beep and show a notification when the VE.Bus system switched...
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4.3.4 VE.Bus Inverter/charger monitoring 4.3.4.1 Input current-limiter setting This chapter explains the implications of the input current-limiter setting, as seen here in the menu: It specifies the maximum allowable input current for inlet connections. The limit must be set by the user through the potentiometer R10.
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ZBE45 highest value is 32 or 63 A depending on the is a minimum input current limit. The actual limit inlet socket configuration. differs for each model. It is 14,5 A for ZBP45 and Note that it is still possible to set the input current 3,9 A for ZBE45.
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Also, it is visible in the menus: Parallel and three phase systems 4.3.4.3 Grid failure monitoring The configured AC input current limit is the total When this feature is enabled, an alarm is raised when limit per phase. the system hasn't been connected to the AC input configured to be Grid or Shore for more than 5 4.3.4.2 Phase rotation warning...
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4.3.4.4 Advanced menu Setting the CCGX controller 4.4.2.1 Generator start/stop 4.4.1 Customize the logo on the Boat & Motorhome page It is possible to use a custom logo onto the Boat & Motorhome page. Type the following address into the web browser of a device connected to the same network.
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4.4.2.2 Settings 4.4.2.3 Conditions On loss of communication If ever there is a communication breakdown between the CCGX and the selected battery monitor, and/or VE. Bus inverter/charger; and parameters have been set which depend on this information - choose between the following actions: –...
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– Inverter overload Relays triggered by Battery Current Relays triggered by Battery Voltage – Periodic test run – Use Battery current value to start/stop: Toggle this feature on or off. (*) The value measured here will be the total AC –...
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Relays triggered by Inverter High temperature Automatic periodic ‘Test run’ This feature builds in a delay before stopping the generator after the 'stop' value has been – Start on high temperature warning: Toggle this This feature allows automatic generator starts, period- reached.
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Manual Start Feature Use the Manual start feature to remotely start the generator. You can also press Start when the generator is already running - doing so will ensure that the generator won't automatically stop when the condition which caused it to start has been satisfied. In other words, the Manual start feature will override the auto-stop parameters.
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4.4.2.4 Quiet hours Using “Quiet hours” as a tool to define two sets 4.4.3 Ethernet LAN port of user-preferences When you connect an ethernet cable between a router Alternatively, the “Quiet hours” feature can be used and CCGX, the Settings > Ethernet page of your to define how you wish your system to respond to CCGX will confirm connection.
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Periodic maintenance Maintenance schedule Before carrying out any maintenance activity, check that the battery switch is in position OFF and that no electrical power is present on the terminals. Category Maintenance schedule (running hrs) Daily Weekly Monthly Yearly Check/test emergency stop (3) General Check torque on critical bolt connections (2) General...
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Category Maintenance schedule (km) Every 500 km Yearly Check tyre pressure 2,5 bars Undercarriage Check tyres for uneven wear Undercarriage Check torque of wheel nuts 120 Nm Undercarriage Check torque of coupling head 82 Nm Undercarriage Check towbar handbrake lever spring actuator, reversing lever, linkage and all movable parts for ease of movement Undercarriage 83 Nm Grease coupling head, towbar bearings at the housing of the overrun brake...
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Be The order number of the Service Packs are listed in careful when working in DC cubicle the Atlas Copco Parts list (ASL). Order Service Packs and use insulated tools. at your local Atlas Copco dealer.
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How to connect: Adjustments and service While working on the Li-ion battery procedures wear protective eyeglasses and cloth- 1. Enable the Bluetooth on your phone, tablet or ing. laptop (device). 5.2.1 Battery care 2. Open VictronConnect, and scan. You can either The battery set is largely maintenance-free when used The Li-ion battery must be trans- pull down the screen or tap the refresh button to...
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status LEDs will flash in case of reverse polarity 5.2.1.2 Battery replacement 5.2.2 Cooling system connection or short-circuit. – Move switch S31 (1) to position I. 5.2.2.1 Air filters replacement – Select LI-ION by pressing Mode button in the – Remove DC cubicle cover (2). charger or using VictronConnect app.
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5.2.2.2 Checking the cooling fans The battery set contains 6 cooling fans to take the hot air from the inverters out of the unit. Fans are controlled by internal command of inverters and by thermostat TM1 located inside the control cubicle.
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Checks and trouble N° Disorder Comment Device The ESS attempts a reboot three shooting switches off times in the interval of a few seconds Never perform a test run with con- due to and then switches off if the overload nected power cables.
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6.1.1 General 6.1.2.1 Error 1 - Device is switched off This should never happen, contact Atlas Copco because one of the other phases in During first installation, and in case of problems, service. the system has switched off update all devices to the latest firmware.
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6.1.2.4 Error 4 - No other device found 6.1.2.7 Error 7 - VE.Bus BMS detected, but Note not configured The master device is configured to run in a parallel-, System restarts can also be triggered when using Remote VEConfigure. split- and/or three-phase system, but cannot find other A VE.Bus BMS device is connected but there is no devices on the bus.
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Steps to take 1. Make sure that the units have been updated to the latest firmware version. There have been various VE.Bus error 11 related improvements in the firmware. This may correct the error, and if it does not, it will provide additional information to assist After configuration, always confirm that the system is troubleshooting.
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Common causes Unable to solve 6.1.2.13 Error 16 - VE.Bus dongle is missing – Failing step #8: check that line and neutral have When the error persists after the all above steps, or Update firmware to latest version. VE.Bus dongles not been swapped.
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3. DC fuse blown. In this case, all units can in some 6.1.2.15 Error 18 - AC Over-voltage on the Possible causes in order of probability situations seem fine and work well as long as output of a slave while switched off –...
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Codes. procedure to find out if its a relay issue, and then Contact Atlas Copco if the problem persists. which unit. 6.2.2 Error #42 - Storage corrupt Execute this procedure right after the error occurred;...
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6.2.4 Error #48 - DVCC with MPPT Solar Charger Error 6.3.1.4 Error 6, Error 7 - Remote battery voltage sense failure incompatible firmware Codes Check if the V-sense connector is properly connected This error is raised when the DVCC feature is enabled Solar Chargers indicate an error with their LEDs.
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6.3.1.8 Error 20 - Maximum Bulk-time 6.3.1.10 Error 26 - Terminal overheated 6.3.1.13 Error 34 - PV over-current exceeded Power terminals overheated, check wiring, including The current from the solar-panel array has exceeded the wiring type and type of strands, and/or fasten bolts 75A.
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– The battery is disconnected using a Lithium Information 66 - Incompatible device 6.3.1.17 Error 68 - Network misconfigured charge relay connected to the “allow-to-charge” The CCGX is being paralleled to another CCGX that The charger detects multiple conflicting network output of a BMS.
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6.3.1.18 Error 114 - CPU temperature too 6.3.1.20 Error 119 - Settings data lost high The charger cannot read its configuration and This error will reset after the CPU has cooled down. stopped. If the error persists, check the ambient temperature This error will not auto-reset.
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Storage of the ESS Storage Preparing for operation after storage The ESS has been developed for outdoor installation and operation. However, in order to avoid Before operating the ESS again, remove the unnecessary weathering and prolong the service life wrapping, VCI paper and silica gel bags and check the of the battery set, it is recommended that the device is ESS thoroughly (go through the checklist “Before stored in the interior, if possible.
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Recycling and disposal policy are part of the develop- according the applicable local disposal regulations. waste handling. ment of all Atlas Copco products. Atlas Copco com- Remove the batteries. Do not throw batteries into the Recycling and re-usage of material pany standards determine strict requirements.
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Disposal of Li-ion batteries Batteries marked with the recycling symbol must be processed via a recognized recycling agency. By agreement, they may be returned to the manufacturer. Batteries must not be mixed with domestic or industrial waste. - 62 -...
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Options Overview of the electrical Electrical options 9.2.2 WIFI USB stick options This WIFI USB stick can be connected to the display 9.2.1 Modem GSM 3G - GPS USB port. This allows internet connection via WIFI – Modem GSM 3G - GPS This modem GSM 3G-GPS is connected to the for remote monitoring and control through the VRM –...
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9.2.3 MPPT Solar charger + MC4 PV Notes Maximum efficiency connectors If more PV power is connected, the con- Self- Less than 35 mA @ 12 V / 20 mA @ The MPPT (Maximum Power Point Tracking) Solar troller will limit input power. consumption 48 V charger is necessary to connect to the ESS a PV power...
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General / 5P 125A 5P 63A 5P 32A 3P 16A PowerLock Standard Circuit Breaker - Curve ELP-Installation Relay RH99 Integrated ELP-TYPE ELP-Sensitivity Adjustable 30 mA Option ELP type A Circuit Breaker - Curve ELP-Installation Relay RH99 Integrated Integrated Integrated ELP-TYPE ELP-Sensitivity Adjustable 300 mA...
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– Trailer the whole external parts of the canopy. Contact your – Check the brake system twice a year. Atlas Copco dealer for available configurations. – Check the condition of the vibration dampers 9.4.2 Trailer twice a year.
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Technical specifications of the ESS 10.1 Technical specifications of the ZBP45 unit ZBP45 Absolute air inlet pressure 1 bar Reference conditions Relative air humidity Air inlet temperature 25°C Model name ZBP45 Performance data Rated frequency 50 Hz Rated voltage 400/230 VAC Operating temperature - discharge (min) -20°C...
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Transport length 1300 mm Transport dimensions Transport width 1160 mm Transport height 1900 mm Derating table Altitude (m) Ambient T (ºC) 1000 1500 3000 6000 For use of the ESS outside these conditions, please contact Atlas Copco. - 69 -...
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10.2 Technical specifications of the ZBE45 unit ZBE45 Absolute air inlet pressure 1 bar Reference conditions Relative air humidity Air inlet temperature 25°C Model name ZBE45 Performance data Rated frequency 50 Hz Rated voltage 400/230 VAC Operating temperature - discharge (min) -20°C Operating temperature - discharge (max) 50°C...
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Transport length 1300 mm Transport dimensions Transport width 1160 mm Transport height 1900 mm Derating table Altitude (m) Ambient T (ºC) 1000 1500 3000 6000 For use of the ESS outside these conditions, please contact Atlas Copco. - 71 -...
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10.3 Critical bolt connections Allowed Assembly Parts to Torque Additional Applicable Parts to assembly A Dimension Utilization Quality deviation Remarks location assembly B (N/m) treatment standard (N/m) Canopy Frame 24,3 ± 5 AC - STD 4369 Lifting beam Frame 48,2 ±...
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With undercarriage option 1150 1308 1625 1682 3873 Maximum lenght (Adjustable drawbar) Machine with undercarriage weight Weight (Kg) Model zBP45 1644 zBE45 1524 2316 - 74 -...
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10.5 Conversion list of SI units 10.6 Data plate Weight of the machine into British units INPUT value Nominal voltage 1 bar 14.504 psi Nominal frequency 0.035 oz Maximum nominal intensity 1 kg 2.205 lbs OUTPUT ISLAND value 1 km/h 0.621 mile/h Nominal voltage 1 kW...
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DC POWER CUBICLE STANDARD CONNECTION BATTERY PACK AC CURRENT AC CURRENT AC CURRENT LIMIT LIMIT LIMIT -IN01 -IN02 -IN03 QUATTRO 48V / 15000 QUATTRO 48V / 15000 QUATTRO 48V / 15000 Tº+1 12.4V 12.4V 12.4V 03.D6 03.D6 Tº+1 12.4V 12.4V 12.4V 12.4V 12.4V...
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DC POWER CUBICLE STANDARD CONNECTION BATTERY PACK AC CURRENT AC CURRENT AC CURRENT LIMIT LIMIT LIMIT -IN01 -IN02 -IN03 QUATTRO 48V / 15000 QUATTRO 48V / 15000 QUATTRO 48V / 15000 Tº+1 12.4V 12.4V 12.4V 03.D6 03.D6 Tº+1 12.4V 12.4V 12.4V 12.4V 12.4V...
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DC POWER CUBICLE STANDARD CONNECTION BATTERY PACK AC CURRENT AC CURRENT AC CURRENT LIMIT LIMIT LIMIT -IN01 -IN02 -IN03 MULTIPLUS 48V / 5000 MULTIPLUS 48V / 5000 MULTIPLUS 48V / 5000 Tº+1 12.4V 12.4V 12.4V 03.D6 03.D6 Tº+1 12.4V 12.4V 12.4V 12.4V 12.4V...
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DC POWER CUBICLE STANDARD CONNECTION BATTERY PACK AC CURRENT AC CURRENT AC CURRENT LIMIT LIMIT LIMIT -IN01 -IN02 -IN03 MULTIPLUS 48V / 5000 MULTIPLUS 48V / 5000 MULTIPLUS 48V / 5000 Tº+1 12.4V 12.4V 12.4V 03.D6 03.D6 Tº+1 12.4V 12.4V 12.4V 12.4V 12.4V...
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A company within the Atlas Copco Group Postal address Phone: +34 902 110 316 V.A.T A50324680 Poligono Pitarco II, Parcela 20 Fax: +34 902 110 318 50450 Muel ZARAGOZA For info, please contact your local Atlas Copco representative Spain www.atlas copco.com p.1(6) - 103 -...
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A company within the Atlas Copco Group Postal address Phone: +34 902 110 316 V.A.T A50324680 Poligono Pitarco II, Parcela 20 Fax: +34 902 110 318 50450 Muel ZARAGOZA For info, please contact your local Atlas Copco representative Spain www.atlas copco.com p.2(6) - 104 -...
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