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ANA EBOSS 220kvA Operation Manual

Hybrid energy system
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Operation Manual
V1 - 12.10.24
PN: 3000000213

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  • Page 1 Operation Manual V1 - 12.10.24 PN: 3000000213...
  • Page 2 Page Intentionally Left Blank...
  • Page 3 Thank you for purchasing the EBOSS™. The ANA EBOSS™ is a hybrid energy system that integrates a very efficient diesel generator with our ultra-high cycle life lithium battery storage system optimized to reduce noise, emissions, maintenance, and fuel consumption. The EBOSS™ Human Machine Interface (HMI) is the central control...

  • Page 4: Table Of Contents

    Table of Contents About ANA Fueling & Grounding Information about ANA, Inc. Safe fueling and grounding procedures. About EBOSS™ Setup for Operation Features, benefits, and How to setup the EBOSS™ for overview of the EBOSS™. operation. Specifications Start Up / Shut Down EBOSS™...

  • Page 5: Battery Information

    Cold Weather Remote Monitoring Operating the EBOSS™ in cold Information about EBOSS™ weather. telematics. Parallel Mode Maintenance Operating the EBOSS™ in Maintenance procedures of parallel mode. the EBOSS™. HMI Display Storage Operation of the Human Information about proper Machine Interface (HMI). storage of the EBOSS™.

  • Page 6: About Ana

    About ANA Founded in 2017, ANA, Inc is a customer focused, rapidly growing company specializing in the construction, industrial, utilities, telecom, and rental equipment sectors. ANA is the exclusive North American supplier of AIRMAN mobile generators and air compressors. ANA also designs and manufactures the EBOSS™, a hybrid energy system revolutionizing the mobile power generation industry.

  • Page 7: About Eboss

    About EBOSS™ The EBOSS™ hybrid energy system provides an energy efficient power generation solution that provides clean power, long battery life, reduced emissions, lower maintenance costs, with an improved ROI over just running a generator alone. Using a generator to charge battery packs that provide outgoing electrical power, the EBOSS™...

  • Page 8: Specifications

    EBOSS™ Specifications EBOSS™ 220kVA specifications. Specifications EBOSS™ 220kVA Hybrid Energy System ANA EBOSS™ Prime Output Three - Phase 220 kVA / 176 kW Frequency 60 Hz Voltage (Three - Phase), Simultaneous 208 / 480 Voltage Regulation Adjustable Output Panel Single - Phase (120V)
  • Page 9 EBOSS™ Specifications (Cont) EBOSS™ 220kVA specifications. Battery Life* EBOSS™ 220kVA Battery Type Lithium Titanate Oxide (LTO) Battery Size 75 kWh Est. Life Cycle @ 770F Laboratory Cond. 90k Cycles at 90% DOD Est. Life Cycle @ 1000F Enclosure Temps. 80k Cycles at 90% DOD Battery Life (1000F) @ 3 kW Average Load 41 Years Operating Temperatures...
  • Page 10 EBOSS™ Components EBOSS™ 220kVA hybrid component information. EBOSS™ HMI Access Panel EBOSS™ Emergency Stop EBOSS™ Generator Engine Access Door Generator Generator Control Access Panel Generator Controller Generator Emergency Stop EBOSS™ Breaker Panel EBOSS™ Power Outlet Connections Trailer Jack EBOSS™ Trailer Operation Manual EBOSS 220 kVA...
  • Page 11 EBOSS™ Components EBOSS™ 220kVA hybrid component information. Generator Engine Access Door Overhead Lift Point Generator DEF Access Door EBOSS™ Rear Access Doors Trailer Fender Wheel & Tire Overhead EBOSS™ Lift Point Battery Pack EBOSS™ Rear Access Panel EBOSS 220 kVA Operation Manual...
  • Page 12 EBOSS™ Dimensions EBOSS™ 220kVA hybrid specifications. 255.44in 202.09in 113.35in 82.11in Operation Manual EBOSS 220 kVA...
  • Page 13 EBOSS™ Dimensions EBOSS™ 220kVA hybrid specifications. 82.44in 108.79in 57.17in 82.29in 10.8in EBOSS 220 kVA Operation Manual...
  • Page 14 EBOSS™ Decals EBOSS™ 220kVA hybrid decal locations. (inside door) TES. IN MINU This rs CAN KILL n mono xide. indoo carbo a gener ator st conta t see or smell Using rator n you exhau canno Gene a poiso OUTS windo Only away...
  • Page 15 EBOSS™ Decals EBOSS™ 220kVA hybrid decal locations. er Exc follo thre g cha e pha ulta rt sho ilab le at sett t con ings . Valu Single ptio ptio n (ma m pow ulta Phase 120V- n from in term er ava GFCI I rec...
  • Page 16 Warning - Ball Hitch Lift Point Location NATM MFG Badge Caution - Do Not Open Rad Cap DEF Only ANA Charging System logo Ground Wire Location Airman logo Warning - Arc Flash - PPE Warning - Wheels & Lugnuts ANA Energy logo...
  • Page 17 EBOSS™ Decals EBOSS™ 220kVA hybrid decals. WARNING BEWARE OF EXHAUST GASES When you operate machine INDOORS or in TUNNEL, provide good ventilation. Poor ventilation can cause fatal accident. 39176 73300 ENGINE GENERATOR DANGER MODEL SDG125S - 8E1 Using a generator indoors CAN KILL YOU IN MINUTES. SER.
  • Page 18 EBOSS™ Decals EBOSS™ 220kVA hybrid decals. CAUTION WARNING OPERATOR RESPONSIBILITY NOT FOLLOWING THESE SAFE TRAILER GUIDELINES CAN LEAD TO SERIOUS INJURY SAFE TRAILER TOWING GUIDELINES : OR DEATH AND/OR PROPERTY DAMAGE. BEFORE TOWING CHECK COUPLING, SAFETY CHAIN, SAFETY BRAKE, TIRE INFLATION, WHEELS AND LIGHTS. DO NOT DRIVE SO FAST THAT THE TRAILER BEGINS TO SWAY DUE TO SPEED.

  • Page 19: High Voltage

    EBOSS™ Decals EBOSS™ 220kVA hybrid decals. WARNING Tire, wheel or lugnut failure can cause loss of control. Before towing, you must CHECK: Lug Nuts Tire pressure and tread. TIGHT? 2. Tires and wheels for damage. 3. Lug nuts for tightness. For new and remounted wheels, re-tighten lug nuts at the first 10, 25 and 50 miles of driving.
  • Page 20 EBOSS™ Decals EBOSS™ 220kVA hybrid decals. WARNING CAUTION! Do not touch live electrical parts. Power distribution and cable route to main Always wear dry insulating gloves. Do not operate the unit in the rain, around standing water or when wet. terminal connections located under panel.

  • Page 21: Ground Wire

    EBOSS™ Decals EBOSS™ 220kVA hybrid decals. WARNING WARNING WARNING WARNING ALWAYS use safety chains. Uncoupling will cause trailer to come Trailer can roll if it comes loose. Lights can prevent trailer from being Chains hold trailer if connection fails. loose from tow vehicle. You must: Safety brake applies when hit by other vehicles.
  • Page 22 Safety - Explanations and Symbols Read this manual thoroughly and make sure you understand the procedures before you attempt to install, set up, or operate the ANA EBOSS™. Operating and servicing any part of the EBOSS™ requires Personal Protective Equipment (PPE) such as High Voltage gloves rated up to 1000V, Protective Eyewear, and Non Conductive Shoes.
  • Page 23 Caution - Equipment Damage Any electrical or mechanical modification to this equipment without prior written consent of ANA will void all warranties and may result in a safety hazard and voiding of the UL listing. EBOSS 220 kVA...
  • Page 24 Caution - Equipment Damage Inside the EBOSS™ enclosure, BEFORE CONNECTING POWER, ensure that all DC power connections, communication cables, and control wires are connected. Connecting any of these cables or wires while the system is powered may result in an electrostatic discharge or an initial over current which can result in damage of electrical components.
  • Page 25 Caution - Equipment Damage Do not touch any components on the circuit boards. Static voltage discharge may damage the components. Caution - Equipment Damage Prevent foreign material such as wire clippings or metal shavings from entering the drive or controller enclosure, as this may cause arcing damage and fire.

  • Page 26: Definitions And Acronyms

    Definitions and Acronyms The following terms and acronyms are used throughout this manual to describe the functions and operation of the EBOSS™. Please reference this page if you need any clarification as you read through this operation manual. SOC - State of Charge. DC - Direct Current.

  • Page 27: Loading And Unloading

    EBOSS™ must be loaded or unloaded using the correct equipment operated by trained personnel. ANA offers no direct support for untrained individuals carrying out any action on the unit. The unit must remain upright at all times. Contact ANA Support to request training. Warning - Equipment Damage The EBOSS™...
  • Page 28 Overhead Lifting - Anchor Points The EBOSS™ may be lifted using an appropriately rated crane and rigging connected to the anchor point on the generator and the 2 rigging points located at the rear. Initially, apply partial load and check for proper rotation and alignment. Never use an anchor or rigging point that shows signs of corrosion, wear or damage.
  • Page 29 Unloading 1) Remove tiedowns or chains securing the EBOSS™ to the flatbed trailer. Carefully approach the EBOSS™ with a properly rated forklift with a pintle hitch attachment. 2) Position the pintle hitch attachment to connect to the EBOSS™ trailer. Slowly raise the forks to level out the EBOSS™. Carefully begin backing the EBOSS™...
  • Page 30 Unloading (cont) 3) Slowly back the EBOSS™ off of the flatbed trailer, being careful to keep the load centered on the trailer and ramps. Be aware of your surroundings and use a spotter if available to assist you. 4) Back the EBOSS™ completely away from the flatbed trailer. Engage the trailer jacks into an upright position and lower the forks to set the EBOSS™...
  • Page 31 Loading 1) Disconnect the tow rig from the trailer (depending on your truck and trailer configuration). Position boards or low rise ramps as needed for the EBOSS™ to load onto the flatbed trailer. 2) Position the pintle hitch attachment to connect to the EBOSS™ trailer.
  • Page 32 Loading (cont) 3) Slowly load the EBOSS™ onto the flatbed trailer, being careful to keep the load centered on the trailer and ramps. Be aware of your surroundings and use a spotter if available to assist you. 4) Carefully lower the forks, positioning the EBOSS™ onto the flatbed trailer.
  • Page 33 Securing to a Flatbed Once the EBOSS™ has been loaded on a flat bed, utilize the 4 tie downs on the underside of the trailer frame to secure the EBOSS™ to the flat bed trailer. Tie down locations are located in front of the front axles (2) and behind the rear axles (2).

  • Page 34: Tie Down Locations

    Tie Down Locations There are 4 tie down locations on the EBOSS™. These tie down locations are designed to secure the EBOSS™ to a flatbed trailer for transport only. Do not use these tie down locations to lift, tow, reposition, or otherwise move the EBOSS™.
  • Page 35 Towing the EBOSS™ The EBOSS™ can be towed using a properly rated tow vehicle. With the EBOSS™ weighing more than 16,000 lbs, the driver of the tow vehicle should be familiar with towing heavy loads. Warning - Equipment Damage The EBOSS™ can be transported using a vehicle with adequate available towing capacity.
  • Page 36 Attaching the Hitch The EBOSS™ can be towed with a properly rated vehicle that has a correctly installed pintle hitch and lunette ring connections. Attach the Pintle Hitch 1) Using the trailer jack, raise the lunette ring coupler high enough to clear the pintle hitch on the tow vehicle.
  • Page 37 Inspecting the Trailer and Tow Vehicle The EBOSS™ trailer and tow vehicle should be thoroughly inspected before every trip. Pre-Trip Inspection Checklist 1) Check the trailer has been attached correctly and the running and brake lights are operating properly and visible. 2) Ensure the trailer tires are properly inflated and have sufficient tread depth, and the trailer wheels are torqued to the correct values.

  • Page 38: Fueling & Grounding

    Fueling and Grounding Fill the fuel tank on the generator before initial start-up. Ensure the generator is properly grounded per the manufacturer’s operation manual instructions. Ensure that the generator is grounded to specifications outlined in the generator’s user manual. Failure to properly ground the generator may result in damage to the EBOSS™...

  • Page 39: Setup For Operation

    Setup for Operation The EBOSS™ is a Hybrid Energy System that combines a Generator with an Energy Storage system that maximizes the use of fuel and reduces generator run time. The system only runs the generator at full load when charging the EBOSS™, which is the most efficient use of the generator in terms of gallons per kW.

  • Page 40: Start-Up Procedure

    Start Up Procedure 1) Before starting the EBOSS™, ground the generator. 2) On generator, turn control power switch to “ON.” 3) Press “AUTO” button to place generator in auto mode. 4) Adjust voltage selector to 480V if needed. 5) Switch main generator breaker to “ON.” 6) On EBOSS™, push and hold down black button under control screen until screen fully turns on (up to 30 seconds).

  • Page 41: Power Sources

    Power Sources The EBOSS™ has the following power connection options: 3-Phase 480V (2 - connections, Cam Loks) 3-Phase 208V (2 - connections, Cam Loks) Single Phase 120V (1 - outlet connection) The combined output of each leg at 480V is 58kW. Thus, ensure legs are balanced as much as possible to ensure reliable operation.

  • Page 42: Batteries

    Batteries The ANA lithium battery system is a high power, ultra-high cycle life system built for a wide number of commercial and industrial applications. Operation of the battery is fully automated and it shouldn’t require any maintenance or servicing. EBOSS™ 220kVA Battery Specs...

  • Page 43: Operation Sequence

    Operation Sequence EBOSS™ Sequence of Operation 1) After starting up the generator (unit is fueled and properly grounded, voltage set to 480V, and load has been connected), the EBOSS™ is now ready to operate. 2) On the EBOSS™, push and hold down black button under control screen until screen fully turns on (up to 30 seconds).

  • Page 44: Cold Weather Operation

    EBOSS™ Sequence of Operation (cont) 11) Remember to also turn off the control switch on the generator and close the main breaker to prevent unnecessary battery drain on the generator. Cold Weather Operation Important Notes 1) The EBOSS™ can operate at temperatures as low as -220F (-300C) as long as it is powering a load and the generator is equipped with a cold weather package.
  • Page 45 Enclosure Heater Location Enclosure Heater EBOSS 220 kVA Operation Manual...

  • Page 46: Cold Start Procedure

    Cold Start Procedure 1) The three inverters in the EBOSS™ must be above 140F (-100C) to start up and begin operation. This could take several minutes or hours to heat up on its own so it is recommended plug in the optional enclosure heater or use an external heater to get the inverter and enclosure components warm enough to start.
  • Page 47 Parallel Mode Procedure To put the units in parallel mode, click on the grid inverter on the HMI, and click on the parallel mode button. A gray button indicates the mode is enabled. Allow all generators to fully charge batteries before attempting parallel connection to load.
  • Page 48 Parallel Mode Procedure (cont) Once all units to be paralleled have the parallel selection set, start one of the units and enable the output, then bring all other units online (there is no number or timing sequence). For head units, all A1 gen auto-start command connections are to be connected in parallel and tied to the X(A1) contact on the generator, and all head unit A2 wires are to be connected together and tied to the XX(A2) contact on the generator.
  • Page 49 HMI (Human Machine Interface) Display Overview of the HMI Display The Home screen of the HMI allows the user to operate the EBOSS™. The start button is red when the unit is off with the description “Press to Start”. When the start button is pressed the color turns green with the description “Press to Stop”.
  • Page 50 The top right above the battery shows general battery information such as state of charge (SOC) percentage and battery state. When the unit is operating the battery state will either say “charging” or “discharging.” Notice the flow of power between all the major devices: Generator to Generator Inverter (AC) Generator Inverter to Grid Converter (DC Bus) Grid Converter to Load (AC)
  • Page 51 Generator Supplying Power and Charging the Batteries The screen below shows power going through the generator inverter. The generator inverter is sending power to the output through the grid inverter AND sending power to the batteries for charge. The DC/ DC inverter is charging the batteries.
  • Page 52 Battery Storage System Supplying Power and Generator Supplying Power to Load (temporary power source) The screen below shows both the generator and the battery bank supplying power to the load. This is in a rare scenario that the load requirement is greater than the ability for either the generator or the battery but not too great for both of them to supply.
  • Page 53 Faults can be viewed and reset via the HMI screen. Possible fault causes should be investigated by the user in an effort to prevent future faults from occurring. Please contact ANA technical support if repeated faults are experienced with your EBOSS™.

  • Page 54: Remote Monitoring

    (HMI) software. From a single unit to an entire fleet, ANA’s telematics enables remote access, diagnostics, and monitoring of the EBOSS™. This enables our service technicians to provide an enhanced level of service to your EBOSS™...
  • Page 55 Completely turn off the EBOSS™ and generator and remove the service disconnects before performing any maintenance. Ensure the service disconnects are twisted off completely and placed away from the mating connector to avoid making any contact. Internal components of the EBOSS™ should be dusted every 6 months (every 2-3 months in severe conditions).
  • Page 56 Dusting Locations Compressed air should be used to remove dust and debris from the EBOSS™. Do not make contact between the air nozzle and the sensitive electronics of the EBOSS™, as damage can result. Storage The internal battery storage system should be stored with 50% to full-charge while the unit is not in use for long periods.

  • Page 57: Battery Disconnect

    This equipment should be serviced by qualified electrical maintenance personnel. Failure to observe this precaution could result in death or severe injury. Battery Disconnect Locations Battery Disconnect The EBOSS™ is designed to be used outdoors. However, it is recommended that the unit is stored undercover when possible to prevent unnecessary weathering.

  • Page 58: Faults / Alarms

    Faults / Alarms Please refer to your generator’s manual for more information and description of the following faults. Generator Faults Generator Emergency Stop Generator Over Speed Generator Under Speed Generator High Voltage Generator Low Voltage Generator Fail to Start Generator Charge Alternator Failure Generator Oil Pressure Sender Fault Generator Mains Fail to Close Generator Calibration Lost...
  • Page 59 Generator Faults (Cont.) Generator Battery Low Voltage Generator Over Frequency Generator Fail to Stop Generator Battery High Voltage Generator Loss of Magnetic Pick Up Generator Fail to Close Generator Magnetic Pick Up Generator Low Fuel Level Open Circuit Generator Low Oil Level Switch Generator CAN ECU Warning Generator KW Overload Alarm Generator High Temperature Switch...
  • Page 60 AFE Faults (cont) AFE F9 Undervoltage Fault AFE F56 PT100 Temperature Fault AFE F59 SB Heart Beat AFE F10 Line Synchronization Fault (SystemBus Com) AFE F11 Line Phase Supervision AFE F60 Cooling AFE F13 Drive Under Temperature Fault AFE F62 Run Disable AFE F14 Drive Over Temperature Fault AFE F63 Quick Stop AFE F22 EEPROM Checksum Fault...
  • Page 61 AFE Faults (cont) AFE F83 Generator Inverter Stop AFE F89 Leakage Fault AFE F84 Insulation AFE F92 Supply Voltage AFE F85 Earth Switch Fault AFE F94 E-Stop AFE F86 Arc Relay AFE F95 Line THD AFE F88 High Amb Temperature AFE F96 Line HF Voltage DC-DC Faults DC-DC F1 Over Current Fault...
  • Page 62 DC-DC Faults (cont) DC-DC F63 Quick Stop DC-DC F82 External Fault 2 DC-DC F65 PT100 Board 2 DC-DC F97 Signal Trip DC-DC F72 Enter License Code DC1 W29 Thermistor DC-DC F74 Follower Fault DC1 F53 FB Warning DC-DC F76 Synchronization Fault DC1 F14 Over Temperature DC-DC F80 Charging Fault DC1 W63 or F62 Quick Stop...
  • Page 63 Grid Inverter Faults (cont) Grid Inverter F56 PT100 Grid Inverter F1 Over Current Fault Temperature Fault Grid Inverter F59 SB Heart Beat Grid Inverter F3 Earth Fault (SystemBus Com) Grid Inverter F60 Cooling Grid Inverter F5 Charge Switch Grid Inverter F62 Run Disable Grid Inverter F7 Saturation Fault Grid Inverter F63 Quick Stop Grid Inverter F8 System Fault...
  • Page 64 Grid Inverter Faults (cont) Grid Inverter F44 Device Changed Grid Inverter F65 PT100 Board 2 (Default Param.) Grid Inverter F45 Device Added Grid Inverter F72 Enter License Code (Default Param.) Grid Inverter F50 4mA Supervision Grid Inverter F74 Follower Fault Grid Inverter F76 Grid Inverter F51 External Fault Synchronization Fault...

  • Page 65: Technical Support

    Any servicing, diagnostics, or repairs should only be performed by trained personnel equipped with the proper tools and safety equipment. Please contact our technical support team for further information or to assist with repairs. ANA Technical Support Phone: 1-562-450-3570 Opt 3 Email: support@anacorp.com anacorp.com...

  • Page 66: Troubleshooting

    Troubleshooting The following chart lists potential issues, their causes, and solutions. If you are unable to resolve your issue, please contact our service department and they can assist you. Warning - Hazardous High Voltage This equipment should be installed, adjusted, and serviced by qualified electrical maintenance personnel familiar with the construction and operation of this type of equipment and the hazards...

  • Page 67: Troubleshooting Chart

    Test or replace cables first phase (L1) diesel generator and and connectors. EBOSS™. If the distance between Contact ANA Technical Output voltage is lower the unit and the services to arrange than desired voltage over consumers is more than adjustment of system distance.
  • Page 68 Issue Possible Cause(s) Suggestion Remote start switching For details on changing mode incorrect the switching mode, (normally open / please contact ANA normally closed). Technical Support. Diesel generator is in Switch diesel generator manual mode. to automatic mode. Remote Generator Start not working.
  • Page 69 Notes EBOSS 220 kVA Operation Manual...
  • Page 70 USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN. In no event will ANA be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss...
  • Page 71 Page Intentionally Left Blank...
  • Page 72 Operation Manual Cypress, CA Henderson, NV Spartanburg, SC Executive Offices 1770 Raiders Way, Henderson, NV 89052 1 (562) 450-3570 sales@anacorp.com www.anacorp.com...

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