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ANA EBOSS 70kVA Operation Manual

Hybrid energy system
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Operation Manual
V1 - 11.26.24
PN: 3000000211

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  • Page 1 Operation Manual V1 - 11.26.24 PN: 3000000211...
  • 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™ 70kVA specifications. Specifications EBOSS™ 70kVA Hybrid Energy System ANA EBOSS™ Prime Output Three - Phase 70 kVA / 56 kW Single - Phase 47 kVA / 37 kW Frequency 60 Hz Voltage (Three - Phase), Simultaneous 208 / 480...
  • Page 9 EBOSS™ Specifications (Cont) EBOSS™ 70kVA specifications. Battery Life* EBOSS™ 70kVA Battery Type Lithium Titanate Oxide (LTO) Battery Size 25 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™ 70kVA hybrid component information. Generator Generator Engine Access Door EBOSS™ EBOSS™ Front Access Panel Wheel & Tire EBOSS™ Power Outlet EBOSS™ Connections Trailer EBOSS™ EBOSS™ Breaker Panel Emergency Stop EBOSS™ EBOSS™ Side Access Door HMI Access Panel Operation Manual EBOSS 70 kVA...
  • Page 11 EBOSS™ Components EBOSS™ 70kVA hybrid component information. Overhead Lift Point Trailer Jack Generator Engine Access Door Overhead Lift Point Generator Control Access Panel Generator Controller EBOSS™ Generator Battery Pack Emergency Stop Trailer Fender EBOSS™ Side Access Panel EBOSS 70 kVA Operation Manual...
  • Page 12 EBOSS™ Dimensions EBOSS™ 70kVA hybrid specifications. 167.06in 77.25in 42.5in Operation Manual EBOSS 70 kVA...
  • Page 13 EBOSS™ Dimensions EBOSS™ 70kVA hybrid specifications. 71in 75.55in 52.26in 58in 9.25in EBOSS 70 kVA Operation Manual...
  • Page 14 EBOSS™ Decals EBOSS™ 70kVA hybrid decal locations. foll ilab rt sho le at t con d Sim Sing an eou le Phas 120V -20A m the in the er ava s Po I Rcep Thre left ilab r Co e Phas in ter le fro 240/...
  • Page 15 EBOSS™ Decals EBOSS™ 70kVA hybrid decal locations. R E N S T I R E A N D E I G N E M E N TIRE T h e L O A D I N G I N T S S U SIZE of carg F O R M...
  • Page 16 Warning - Do Not Touch Generator Data Plate Caution - Power Distribution Warning - Diesel Exhaust Do Not Use Warning - Exhaust Fumes SDG45 logo Danger - Carbon Monoxide ANA Charging System logo ANA logo (small) Lift Point Location Operation Manual EBOSS 70 kVA...
  • Page 17 EBOSS™ Decals EBOSS™ 70kVA hybrid decals. WARNING MAXIMUM LOADED (GVWR) = EQUALS TRAILER WEIGHT OVERLOAD HAZARD RISK OF DEATH DUE TO LOSS OF CONTROL NEVER EXCEED THE GROSS VEHICLE WEIGHT RATING (GVWR) BEFORE LOADING THE TRAILER FOR THE FIRST TIME, YOU MUST VERIFY ITS CARGO CAPACITY. + PLUS You MUST WEIGH the EMPTY TRAILER.

  • Page 18: Ground Wire

    EBOSS™ Decals EBOSS™ 70kVA hybrid decals. WARNING DANGER Arc Flash and Shock Hazard. Appropriate PPE Required. Hazardous Voltage Can Cause Severe Injury or Death. Disconnect Incoming Power HIGH VOLTAGE Before Servicing Control or Motor. Refer to NFPA 70E for minimum PPE requirements WARNING GROUND WIRE Tire, wheel or lugnut failure can cause loss of...
  • Page 19 EBOSS™ Decals EBOSS™ 70kVA hybrid decals. LIFTING BAIL 39176 69300 CAUTION PREVENT BURNING ACCIDENT Do not open radiator cap while it is still hot. 39176 69600 ENG. OIL RADIATOR FUEL RETURN FUEL INLET DRAIN DRAIN 39189 21500 39178 01640 39189 21400 EBOSS 70 kVA Operation Manual...
  • Page 20 EBOSS™ Decals EBOSS™ 70kVA hybrid decals. TIRE AND LOADING INFORMATION RENSEIGNEMENTS SUR LES PNEUS ET LE CHARGEMENT The weight of cargo should never exceed 2,790 kg or 6,150 lbs. SEE OWNER’S TIRE SIZE COLD TIRE PRESS. MANUAL FOR ADDITIONAL FRONT ST205/75R-15D 448 KPA (65 PSI) INFORMATION...
  • Page 21 EBOSS™ Decals EBOSS™ 70kVA hybrid decals. DANGER CAUTION WARNING BEFORE TOWING THIS TRAILER CHECK THAT: COUPLER HITCH AND TRAILER BALL ARE THE SAME SIZE. COUPLER IS LATCHED. SERIOUS INJURY AND/OR YOU ARE REQUIRED TO COMPLY WITH PROPERTY DAMAGE CAN SAFETY CHAINS ARE CRISSCROSSED UNDER TONGUE AND ATTACHED TO TOWING LOCAL AND STATE REQUIREMENTS RESULT IF THIS VEHICLE VEHICLE.
  • 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 70 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 a spreader bar connected to the anchor points or lifting bails on the EBOSS™ and the generator. Initially, apply partial load and check proper rotation and alignment. There should be no interference between the load (EBOSS™) and the anchor point bail.
  • Page 29 Unloading 1) Remove tiedowns or chains securing the EBOSS™ to the trailer. Carefully approach the EBOSS™ with a properly rated forklift. 2) Position forks to lift behind the rear axle and forward of the front axle to balance the load. Slowly raise the forks until making contact with the EBOSS™.
  • Page 30 Unloading (cont) 3) Once raised, carefully back away from the trailer to allow sufficient clearance to lower the EBOSS™. Be aware of your surroundings and use a spotter if available to assist you. 4) Slowly lower the forks, placing the EBOSS™ on the ground. Lower the forks a few more inches, so they fully clear the EBOSS™.
  • Page 31 Loading 1) Carefully approach the EBOSS™ with a properly rated forklift. Fork lift locations are located behind the rear axle and in front of the front axle for balanced lifting. 2) Slowly raise the forks until making contact with the EBOSS™. Carefully lift the EBOSS™...
  • Page 32 Loading (cont) 3) Raise the EBOSS™ up high enough to clear the trailer. Slowly approach the trailer, using a spotter to assist you if available. Position the EBOSS™ in the middle of the trailer. 4) Carefully lower the EBOSS™ onto the flatbed trailer. Lower the forks slowly to ensure the load is stable on the 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 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 6,000 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 brakes 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 (1 - connection, Cam Loks) 3-Phase 208V (1 - connection, Cam Loks) 1-Phase 240V (4 - connections, 3 Twist Locks and 1 Cam Lok) Single Phase 120V (2 - outlet connections) The combined output of each leg at 480V is 18.5kW.

  • 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™ 70kVA 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 Ventilation Cover Enclosure Heater When temperatures are expected to be lower than -220F (-300C), it is recommended to keep the unit on and running with ventilation cover closed and enclosure heater plugged in. With these cold weather accessories installed, the EBOSS™ is rated for operation as low as -500F (-450C).

  • Page 46: Cold Start Procedure

    Cold Start Procedure 1) The three inverters in the EBOSS™ are located in the front panel. They 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 disconnect before performing any maintenance. Ensure the service disconnect is twisted off completely and placed away from the mating connector to avoid making any contact. There are five fans in the EBOSS™ that should be dusted every 6 months (every 2-3 months in severe conditions).
  • Page 56 Inverter Fans Compressed air should be used to remove dust and debris from the fans. Do not make contact between the can nozzles and the sensitive internal 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 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 70 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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