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ZOE P 5000 User Manual

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P5015L2H – A - EU Liquid Cooling Containerized ESS
P 5000
104 PACK
1

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  • Page 1 User Manual P5015L2H – A - EU Liquid Cooling Containerized ESS P 5000 104 PACK...
  • Page 2 The products, services, features, etc., that you purchase are subject to the commercial contracts and regulations of ZOE Energy Storage Technology Co., Ltd. All or part of the products, services, or features described in this specification may not fall within the scope of what you have purchased or are using, unless otherwise stipulated in the contract.

  • Page 3: About This Manual

    This manual is specifically applicable to the container-type liquid-cooling energy storage products developed by ZOE Energy Storage Technology Co., Ltd., with the product model: P 5000-2H. NOTE ： For any matters not covered in this user manual, please contact our after-sales support team.
  • Page 4 The following symbols may appear throughout this document, and their meanings are as follows: Symbol Symbol Meaning Warning Symbol Used to alert to emergency hazardous situations. Failure to avoid these situations may result in death or serious personal injury Caution Symbol Used to alert to potential hazardous situations.
  • Page 5 Acronyms The following acronyms may appear in this document. Unless otherwise specified, their meanings are as follows: Acronyms Full Form Battery Management System BAMU Battery Array Management Unit BCMU Battery Cluster Management Unit Battery Management Unit Power Conversion System Energy Manage System Energy Storage System Energy Management Unit BESS...

  • Page 6: Table Of Contents

    Table of Contents About This Manual 1. Safety Information··················································································································7 1.1 General Safety Precautions····································································································7 1.2 Personal Safety·······················································································································8 1.3 Electrical Safety····················································································································10 1.4 Environmental Requirements······························································································14 1.5 Mechanical Safety················································································································15 1.6 Handling and Transportation Requirements······································································ 15 1.7 Equipment Safety·················································································································20 1.8 Maintenance and Replacement··························································································26 2. Product Introduction································································································28 2.1 System Configuration Overview······················································································28 2.2 Appearance and Structural Layout······················································································29 2.3 Primary Circuit Topology·····································································································...
  • Page 7 5. System Power On/Off ········································································································· 47 5.1 System Power-On·············································································································· 47 5.2 Normal Power-Off············································································································· 48 5.3 Emergency Power-Off········································································································· 49 6. Fault List Description··········································································································· 50 6.1 Alarm Information Page Common Fault List······································································ 50 6.2 Common Operational Faults List························································································ 53 7. Routine Maintenance···········································································································54 7.1 Precautions Before Maintenance························································································54 7.2 Container Maintenance Items and Cycles···········································································54 7.3 Liquid Cooling System Maintenance····················································································58...

  • Page 8: Safety Information

    1. Safety Information 1.1 General Safety Precautions Before transporting, storing, installing, operating, using, and maintaining the equipment, please carefully read this manual and strictly follow the instructions. Always comply with the safety precautions indicated on the equipment and in the manual. The "Notes,"...

  • Page 9: Personal Safety

    hurricanes, tornadoes, extreme weather, or force majeure events). 6) Damage caused during transportation due to your actions or those of a third party you have entrusted with the transportation. 7) Damage caused by failure to meet the product storage conditions outlined in the documentation.
  • Page 10 1.2.1 General Requirements 1) Do not disable the equipment's protective devices or ignore the warnings, cautions, and preventive measures in the manual and on the equipment. 2) If a malfunction occurs during operation that may cause personal injury or equipment damage, immediately stop the operation, report it to the responsible person, and take effective protective measures.

  • Page 11: Electrical Safety

    Operators must meet the following requirements: 1) When installing, operating, and maintaining the equipment, it is strictly prohibited to wear conductive items such as watches, bracelets, rings, necklaces, or other jewelry, to prevent electric shock and burns. 2) During transportation, transfer, installation, wiring, and maintenance operations, operators must comply with the laws, regulations, and relevant standards of the respective country or region.
  • Page 12 5) Set up temporary barriers or warning ropes in the work area and post "No Entry" signs. Unauthorized personnel are prohibited from entering. 6) Before installing or removing power cables, disconnect the equipment and its upstream and downstream switches. 7) If liquid is found inside the equipment, immediately disconnect the power supply and prohibit further use.
  • Page 13 grounding wire > hang warning signs and set up barriers. 17) Regularly check the terminal screws of the equipment connections to ensure they are tight and not loose. 18) If cables are damaged, they must be replaced by qualified personnel to prevent risks. 19) It is strictly prohibited to alter, damage, or obscure labels and nameplates on the equipment.
  • Page 14 container before entering. 6) Cables of the same type should be bundled together, with a neat and straight appearance, and free from damage to the outer insulation. Cables of different types should be routed at least 30mm apart, and must not be twisted or crossed. 7) After completing the wiring or leaving during wiring work, the cable openings must be immediately sealed with sealing compound to prevent water, moisture, or small animals from entering.

  • Page 15: Environmental Requirements

    1.4 Environmental Requirements Symbol Symbol Meaning 1) It is strictly prohibited to place the equipment in environments with flammable, explosive gases, or smoke. No operations should be performed in such environments. 2) Flammable or explosive materials must not be stored in the equipment area. 3) The equipment must not be placed near heat sources or fire sources, such as fireworks, candles, heaters, or other heating devices.

  • Page 16: Mechanical Safety

    gravel. 12) Before opening doors during installation, operation, or maintenance, ensure that any accumulated water, snow, or debris on the top is cleaned off to prevent debris from falling into the equipment. 13) When installing the equipment, ensure the installation surface is sturdy and meets the weight-bearing requirements of the equipment.
  • Page 17 2) It is prohibited to perform arc welding, cutting, or similar operations on the equipment without prior evaluation by the company. 3) It is prohibited to install any other equipment on top of the device without prior evaluation by the company. 4) When working in the space above the equipment, additional protection should be added to the top of the equipment to prevent damage.
  • Page 18 7) The inclination angle of the container should comply with the following Figure requirements: with packaging, the inclination angle α ≤15°; without packaging, the inclination angle α ≤10°. 1.6.3 High-altitude Work Safety 1) Any work conducted more than 2 meters above the ground is considered high-altitude work, and a supervisor must be assigned for such tasks.
  • Page 19 9) Simultaneous work on multiple levels should be avoided. If it is unavoidable, dedicated protective shelters or other safety measures must be in place between levels, and tools and materials must not be stored on the upper levels. 10) When dismantling scaffolding after work is completed, it should be done from top to bottom in layers, and simultaneous dismantling on multiple levels is strictly prohibited.
  • Page 20 1.6.5 Lifting Operation Safety 1) Personnel conducting lifting operations must undergo relevant training and be certified before they can be employed. 2) The lifting area must be marked with temporary warning signs or barriers to ensure segregation. 3) The ground where lifting operations are performed must meet the load-bearing requirements for crane work.

  • Page 21: Equipment Safety

    4) Protect the equipment with covers during drilling to prevent debris from entering the interior of the device, and ensure that all debris is promptly cleared away after the drilling is completed. 1.7 Equipment Safety 1.7.1 Energy Storage System Safety 1) During system operation, opening the container doors is prohibited.

  • Page 22: Battery Safety

    1.7.2 Battery Safety 1) It is strictly forbidden to short-circuit the positive and negative terminals of the battery, as this can cause a short circuit. A short circuit can instantly generate a large current and release a significant amount of energy, leading to battery leakage, smoking, release of flammable gases, thermal runaway, fire, or explosion.
  • Page 23 Disclaimer: The company shall not be held responsible for damages to the batteries provided by us due to the following reasons: 1) Damage caused by earthquakes, floods, volcanic eruptions, landslides, mudslides, lightning strikes, fires, wars, armed conflicts, typhoons, hurricanes, tornadoes, extreme weather, or force majeure events;...
  • Page 24 15) The batteries have exceeded the maximum storage period; 16) The batteries have exceeded the warranty period. 1.7.2.1 General Requirements 1) Do not expose the battery to high-temperature environments or place it near heat sources such as direct sunlight, flames, transformers, or heaters. Overheating the battery may lead to fire or explosion.
  • Page 25 8) Dispose of used batteries according to local laws and regulations. Do not treat batteries as household waste. Improper disposal of batteries may lead to environmental pollution. 9) Do not use damaged batteries (e.g., battery casing dents or other damage). Damaged batteries may release flammable gases.
  • Page 26 2) Before installation, check if the packaging is intact. Do not use batteries with damaged packaging. 3) The battery should be placed horizontally and securely fixed. 4) During installation, do not place tools, debris, or other objects on the battery. 5) During installation, pay attention to the correct polarity.

  • Page 27: Maintenance And Replacement

    1.7.2.7 Handling Battery Drops 1) If the battery is dropped (whether or not it is in its packaging) but shows no visible deformation, damage, or signs of unusual odor, smoke, or fire, proceed with operation only if safety is ensured. 2) In the warehouse: Evacuate personnel, and use mechanical tools by qualified personnel to move the battery to an open, safe location.
  • Page 28 7) For equipment other than the battery pack, after disconnecting the power, wait for 15 minutes to ensure that the equipment is fully powered down before proceeding with any operations. 8) Switches that need to be disconnected for maintenance should have clearly visible labels placed on them.

  • Page 29: Product Introduction

    2. Product Introduction 2.1 System Configuration Overview This product is a container-type liquid-cooling energy storage system, housed in a 20HQ container. The system primarily comprises battery PACKs, high-voltage control boxes, a main control cabinet, a thermal management system, a fire protection system, an environmental monitoring system, and auxiliary power distribution.

  • Page 30: Appearance And Structural Layout

    2.2 Appearance and Structural Layout (1) Structural Introduction Figure 2-2 Front View of Battery Container Pressure Relief Port (Applicable to Perfluorohexanone System Only) Air Inlet of LiquidCooling Unit Air Inlet of LiquidCooling Unit DN65 Wate Firefighting Interface Grounding Lifting Lifting Point 1 Inlet Point 1...

  • Page 31: Appearance Dimension

    (2) Appearance Dimension Figure 2-4 Battery Container Dimensions Figure (3) Structural Layout The schematic Figure of the internal layout of the battery box is shown in the figure below: Figure 2-5 The schematic figure of the internal layout of the battery container Main Control Cabinet...

  • Page 32: Primary Circuit Topology

    2.3 Primary Circuit Topology The unified primary power circuit equipment mainly includes battery PACKs, high-voltage control boxes, and the main control cabinet. Every 4 battery PACKs are connected in series to form 1 cluster, with every 2 clusters connected to 1 high-voltage control box. Subsequently, every 6 clusters converge into 1 PCS rated at 1250 kW.

  • Page 33: System Parameters

    2.4 System Parameters Table 2-1 System Specification Parameters Table Name Parameter Remark Cell Type LFP-3.2V-314Ah Nominal System Capacity 5015kWh Nominal Voltage 1331.2Vdc Voltage Range 1164.8~1497.6Vdc Charge and discharge rate ≤0.5CP Cooling Method Smart Liquid Cooling Auxiliary Electrical Parameter 50kVA-400V/50Hz ~3N+PE Aerosol gas fire suppression + Novec 1230 Firefighting System...

  • Page 34: Structural Fixing And Installation

    3. Structure Fixing and Installation 3.1 Installation Environment Requirements 3.1.1 Site Selection Requirements The site selection must comply with the requirements of GB 51048: Design Code for Electrochemical Energy Storage Stations, NFPA 855: Standard for the Installation of Stationary Energy Storage Systems, and local regulations. Energy storage systems are only suitable for outdoor installations and should not be installed indoors.
  • Page 35 Site selection should avoid locations and scenarios not recommended by industry standards and regulations, including but not limited to the following: 1) Areas with strong vibrations, loud noise, and strong electromagnetic interference. 2) Locations that generate or contain dust, oil fumes, harmful gases, or corrosive gases. 3) Sites involved in the production or storage of corrosive, flammable, or explosive materials.
  • Page 36 4) The spacing design above only considers installation and maintenance requirements. The final spacing must also comply with local fire safety regulations. Figure 3-1 Installation Space for Single Container Figure 3-2 Installation Space for Parallel Containers 3.1.3 Installation Foundation and Positioning Requirements The battery container is relatively heavy, so before constructing the foundation, a thorough assessment of the installation site conditions (primarily geological and environmental conditions) should be conducted.
  • Page 37 The storage location for the battery container must be pre-prepared by a professional construction team, ensuring enough space is left around the Container for installation and maintenance. If the power cables are routed through a bottom cable trench, foundation preparation should be done in advance. The overall foundation should meet the requirements for lightning protection, waterproofing, rodent and insect prevention, and ventilation.

  • Page 38: Pre-Installation Inspection

    sufficient space should be reserved for AC/DC cable channels during the foundation construction, and cable conduits should be embedded in advance. 10) The specifications and number of embedded conduits should be determined based on the cable type and the number of cable entries and exits. 11) A drainage system should be installed to prevent flooding of the Container's bottom or internal equipment during rainy seasons or heavy precipitation.

  • Page 39: Installation Tools

    1) Installation Tools Table 3-1 Common Installation Tools List Impact Drill Complete Set of Socket Wrenches Torque Wrench Diagonal Pliers (Φ14mm, Φ16mm, Φ20mm) Wire Strippers Phillips/Flathead Screwdriver Rubber Mallet Utility Knife Multimeter Cable Cutters RJ45 Crimping Tool Vacuum Cleaner DC voltage range ≥ 1500V DC Marker Pen Steel Tape Measure Digital or Bubble Level...

  • Page 40: Installation Environment Inspection

    3.2.2 Installation Environment Inspection Conduct a check against the site requirements item by item, and proceed with the installation only after meeting the requirements. Our company will not assume any responsibility for any losses caused by forced installation when the requirements are not met.
  • Page 41 receive proper training, particularly in safety protocols. Professional personnel must be on- site to supervise the lifting and installation throughout the process. 10) Based on site conditions, choose appropriate lifting machinery and tools. The lifting equipment should have a weight capacity of at least 150 tons (sufficient to handle the load of the item being lifted), with an arm length and rotation radius suitable for the lifting requirements.
  • Page 42 and the slings supported by beams. The contractor must strictly follow the requirements outlined in this section for lifting operations. The company will not be responsible for any tipping damage caused by the use of non- specialized lifting equipment or improper securing of slings. Please consult the company’s after-sales team before lifting.
  • Page 43 bottom corner steel supports. Refer to the figure below for the lifting sling connection setup: Figure 3-7 Lifting Sling Connection Figure 1) When lifting the battery container, ensure that it is raised and lowered horizontally to avoid tilting. Maintain a uniform speed during both ascent and descent to prevent damage to the internal equipment.
  • Page 44 2) Installation Steps Open the front door of the accessory storage box and retrieve the angle steel from the packaging box. Use the 6 angle steel pieces to secure the battery container. The flatness of the concrete support platform is crucial for the installation of the battery container.

  • Page 45: Electrical Installation

    4 Electrical Installation 4.1 Grounding Connection 4.1.1 Prerequisites It is strictly prohibited to install fuses, switches, or other devices on the protective earth conductor. The grounding system must comply with local electrical safety regulations. 1) The installation of the energy storage system has been completed. 2) Grounding requirements have been clearly defined.

  • Page 46: Dc Circuit Wiring

    4.2 DC Circuit Wiring 1) Ensure that the energy storage system is powered off. 2) The installation personnel should take the necessary safety precautions, such as wearing insulating gloves and insulating shoes. 3) The DC cables should have been pre-installed according to the standards. 4) The OT/DT terminals should be crimped according to the standards.

  • Page 47: Communication Cable Wiring

    as required, and secure the anti-loosening wire. Table 4-3 AC Side Incoming Cable Reference Name Function Definition Cable Specification Securing Bolt Specification M8×20mm Single multi-core cable M8×20mm AC Side Incoming Cable 4×25mm²Recommended cable: M8×20mm ZC-YJV22- 0.6/1kV 4x25 M8×20mm 1) When connecting the AC cables, ensure that no cables are damaged or disconnected. It is essential to ensure the reliable connection of the ground wire (connected to PE2) and the N wire;...

  • Page 48: System Power On/Off

    5 System Power-On/Off 5.1 System Power-On 1) Only after confirmation by professional personnel and obtaining permission from the local power department can the energy storage system be put into grid-connected operation. 2) For systems that have been shut down for a long time, a comprehensive and detailed inspection and safety tests must be conducted before power-on to ensure that all indicators meet the requirements before proceeding with the power-on.

  • Page 49: Normal Power-Off

    supply indicator light on the main control cabinet is lit. 5) Close the UPS output switch between the main control cabinet and the AC cabinet. 6) Close the power supply switch for the liquid cooling unit (located at the bottom of the unit), and observe if the liquid cooling unit is powered on (indicated by the display screen lighting up).

  • Page 50: Emergency Power-Off

    Step 4: Power-off the battery container auxiliary power supply: 1) Open the UPS output switch between the main control cabinet and the AC cabinet, and confirm that the indicator light is off. 2) Press and hold the UPS (right side OFF) and the combination button (center position) for 10 seconds.

  • Page 51: Fault List Description

    6 Fault List Description 1) Personnel responsible for fault handling must be professionally trained, certified, and qualified to perform the tasks. 2) Unauthorized wiring measurements or equipment disassembly without prior permission from the company are strictly prohibited. Any resulting irreversible damage will not be covered under warranty conditions.

  • Page 52: Common Operational Faults List

    Main Controller 1) Restart. Alarm Protection Hardware fault. Initialization Failure 2) Replace BCMU. Combustible Gas Low- 1) Incorrect threshold configuration. 1) Adjust the threshold settings. Alarm Protection Level Alarm 2) Sensor malfunction. 2) Replace the gas sensor. 1) Incorrect threshold configuration. 1) Adjust the threshold settings.
  • Page 53 1) Loose communication cable connectors. 1) Check for loose cable connections. Unstable Internal 2) Duplicate BCMU (Battery Cluster 2) Verify BCMU addresses for duplication. Communication in Management Unit) addresses. 3) Inspect the bus terminating resistor (CAN bus 3) Incorrect terminating resistor. resistance of 120Ω) for correctness.
  • Page 54 1) Threshold parameters are improperly configured. 1) Adjust the threshold parameters. 2) System temperature exceeds protection Over-temperature 2) Verify proper operation of the thermal management limits. Shutdown Protection system. 3) Sampling connector connection is During Charge/ 3) Reset BMU sampling and power connectors. unreliable.

  • Page 55: Routine Maintenance

    7 Routine Maintenance 7.1 Precautions Before Maintenance 1) Do not perform battery box maintenance or open the battery box doors during rainy, humid, windy, or lightning weather conditions. Any damages caused under such circumstances will not be the responsibility of the company. 2) Avoid opening the battery box doors in rainy, snowy, or foggy weather with high humidity.
  • Page 56 1. The appearance and structure of the battery room or compartment should be intact. 2. The temperature and humidity inside the battery room or compartment should be within the normal operating range for the batteries. Air conditioning/liquid cooling systems, ventilation, and other temperature control equipment should be functioning properly.
  • Page 57 7.2.3 Battery Maintenance 1) Maintenance Precautions To safely and effectively maintain the system, personnel must carefully review and adhere to the following safety requirements: a.Personnel must possess an electrician certificate issued by the safety supervision bureau and undergo professional training before performing maintenance tasks. b.
  • Page 58 the battery's optimal performance. e. Regularly check the ventilation system for blockages, and clean the system, especially the air inlet and outlet of the fans. Use a vacuum cleaner for cleaning if necessary. Power must be turned off before cleaning. Water washing is strictly prohibited. f.

  • Page 59: Liquid Cooling System Maintenance

    1) Inspect detectors weekly to ensure normal display, secure installation, and proper ventilation at the inlet. 2) Clean intake vents quarterly (turn off power before cleaning). If vents are severely Combustible Gas Detectors blocked, contact the company’s after-sales service. 3) Calibrate or test detectors annually through a certified organization. Note: Hydrogen gas detectors should be replaced every three years.

  • Page 60: Maintenance Of The Container

    In the shutdown state of the liquid cooling unit, open the inlet valve, connect Pre-liquid Vacuum pump, Pipeline the pressure gauge and vacuum gauge, and use a vacuum pump to evacuate the change pressure gauge, Vacuuming pipeline. When the vacuum gauge shows a negative pressure of ≤-900 kPa and the vacuuming pressure meter pressure gauge shows a pressure of ≤-50 kPa, the vacuum process is complete.
  • Page 61 Table 7-7 Maintenance Steps for Irremovable Dirt on the Exterior Surface of the Container Illustration Maintenance Step 1) Use sandpaper to sand the areas with peeling paint or scratches, ensuring the surface is smooth. 2) Use a cloth dampened with water or 97% alcohol to clean the damaged areas and remove surface stains.

  • Page 62: Electrical Maintenance

    It is necessary to inspect the protective paint coating on the shell of the energy storage integration system for signs of peeling or chipping. If such issues are identified, promptly repair them. The entire exterior of the energy storage integration system should be re-coated with specialized protective paint every 5 years.

  • Page 63: Appendix

    Appendix A Crimping OT/DT Terminal A.1 OT/DT Terminal Requirement 1)When using copper core cables, please use copper terminals. 2)When using copper-clad aluminum cables, please use copper terminals. 3)When using aluminum alloy cables, please use copper-aluminum transition terminals or aluminum terminals with copper-aluminum transition pads. 1)It is strictly prohibited to connect aluminum terminals directly to terminal blocks, as this can cause galvanic corrosion, affecting the reliability of cable connections.
  • Page 64 Figure A2.1 Crimping OT Terminal (1)→Cable (2)→Conductor (3)→Heat Shrink Tubing (4)→OT Terminal (5)→Hydraulic Crimping Tool (6)→Hot Air Gun Figure A2.2 Crimping DT Terminal (1)→Cable (2)→Conductor (3)→Heat Shrink Tubing (4)→OT Terminal (5)→Hydraulic Crimping Tool (6)→Hot Air Gun Table A2.1 Pulling Force Standards Conductor Size Pull-out Force Standard Conductor Size...

  • Page 65: B How To Touch Up Paint

    Note: For national standard cables, choose the closest conductor size value, and the use of the difference method is allowed. B How to Touch Up Paint B.1 Precondition 1) It is strictly prohibited to perform touch-up painting in adverse weather conditions such as rain, snow, strong winds, or sandstorms, especially when outdoors without shelter.

  • Page 66: Operation Step

    B.3 Operation Step Step 1: Lightly sand the damaged area with fine sandpaper to remove dirt or rust. Figure B3.1 Sanding the coating damage with fine sandpaper Step 2: Moisten a cotton cloth with anhydrous ethanol and wipe the sanded or repair area to remove surface dirt and dust, then dry with a clean cotton cloth.

  • Page 67: Paint Resource

    Figure B3.3 Touching up the coating damage on the equipment. Step 5: After brushing the paint, leave it for approximately 30 minutes, then observe whether the touch-up area meets the requirements. 1) The touch-up area should match the color of the surrounding area. Use a colorimeter to measure the color difference, ensuring that the color difference ΔE ≤...
  • Page 68 VISIT FOLLOW WEBPAGE Energy for Life...

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