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ANA EBOSS 125kVA Operation Manual

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Operation Manual
V1 - 12.6.24
PN: 3000000212

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  • Page 1 Operation Manual V1 - 12.6.24 PN: 3000000212...
  • 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™ 125kVA specifications. Specifications EBOSS™ 125kVA Hybrid Energy System ANA EBOSS™ Prime Output Three - Phase 125kVA / 100kW Frequency 60Hz Voltage (Three - Phase), Simultaneous 208 / 480 Voltage Regulation Adjustable Output Panel Single - Phase (120V)
  • Page 9 EBOSS™ Specifications (Cont) EBOSS™ 125kVA specifications. Battery Life* EBOSS™ 125kVA Battery Type Lithium Titanate Oxide (LTO) Battery Size 50kWh 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) @ 3kW Average Load 41 Years Operating Temperatures...
  • Page 10 EBOSS™ Components EBOSS™ 125kVA 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 EBOSS™ Trailer Operation Manual EBOSS™...
  • Page 11 EBOSS™ Components EBOSS™ 125kVA hybrid component information. Trailer Jack 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™ 125kVA Operation Manual...
  • Page 12 EBOSS™ Dimensions EBOSS™ 125kVA hybrid specifications. 236.77in 182.55in 97.26in 82.11in Operation Manual EBOSS™ 125kVA...
  • Page 13 EBOSS™ Dimensions EBOSS™ 125kVA hybrid specifications. 83.5in 108.79in 57.17in 82.29in 10.8in EBOSS™ 125kVA Operation Manual...
  • Page 14 EBOSS™ Decals EBOSS™ 125kVA hybrid decal locations. (inside door) TES. IN MINU This KILL n mono xide. rs CAN carbo ator indoo st conta or smell Using a gener exhau canno t see Gene a poiso rator n you OUTS windo Only away...
  • Page 15 EBOSS™ Decals EBOSS™ 125kVA hybrid decal locations. er Exc follo thre e pha g cha ulta ilab rt sho le at t con sett ings . Valu ptio ulta Single Phase ptio n (ma m pow 120V- n from I rec in the in term er ava...
  • 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™ 125kVA 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 SDG65S - 8E1 Using a generator indoors CAN KILL YOU IN MINUTES. SER.
  • Page 18 EBOSS™ Decals EBOSS™ 125kVA 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™ 125kVA 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™ 125kVA 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 EBOSS™ Decals EBOSS™ 125kVA 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™ 125kVA...
  • Page 24 Caution - Equipment Damage Do not perform any meggar or voltage withstand tests on any part of the SBP Drive or its components. Improper testing may result in damage. Caution - Equipment Damage Prior to any tests or measurements of the motor or the motor cable, disconnect the motor cable at the SBP output terminals (U, V, W) to avoid damaging the SBP during motor or cable testing.

  • Page 25: 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 26: 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 27 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 28: 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 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 Towing the EBOSS™ The EBOSS™ can be towed using a properly rated tow vehicle. With the EBOSS™ weighing more than 13,000lbs, 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 35 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 36 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 37: 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 38: 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 39: 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™, firmly press black button under control screen until screen fully turns on.
  • Page 40 Connecting EBOSS™ Power Module to Generator (only if using EBOSS™ with a non-standard hybrid energy system) 1) Before starting the EBOSS™, ground the generator. 2) Connect 3 Phase 480V AC Cam Lock connections from generator to EBOSS™ input (L1, L2, L3, Ground). 480V color scheme is brown, orange, yellow, and green.
  • Page 41 Power Module to Generator Connections Compatible Generator Requirements (only if using EBOSS™ with a non-standard hybrid energy system) 1) The connected generator’s internal battery must be in good condition and hold enough charge to run continuously for at least 12 hours.

  • Page 42: 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 33kW. Thus, ensure legs are balanced as much as possible to ensure reliable operation.

  • Page 43: 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™ 125kVA Battery Specs...

  • Page 44: Operation Sequence

    Operation Sequence EBOSS™ Sequence of Operation 1) After preparing the generator (unit is fueled and properly grounded, voltage set to 480V, and controller placed in AUTO), the EBOSS™ is now ready to operate. 2) On EBOSS™, firmly press black button under control screen until screen fully turns on.

  • Page 45: Cold Weather Operation

    EBOSS™ Sequence of Operation (cont) 10) To fully shutdown the EBOSS™, press the FAULTS button on the home screen and the SHUTDOWN button on the FAULTS page. 11) Remember to turn off the control power switch on the generator and open the main breaker to prevent unnecessary battery drain on the generator.
  • Page 46 Enclosure Heater Location Enclosure Heater Operation Manual EBOSS™ 125kVA...

  • Page 47: 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 48 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 49 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 AFE (AC) AFE to DC Bus DC Bus to DC/DC Inverter...
  • Page 50 EBOSS™ Supplying Power and Charging the Batteries The screen below shows power from the generator going to the AFE inverter. AFE inverter is inverting this to the DC Bus. The DC/ DC inverter is using the DC Bus to charge the batteries, and the grid converter is using the DC Bus to convert this to AC voltage to supply the load.
  • Page 51 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 52 Trending Information The trending screen will display a graph of information including: State of charge (SOC), Charge Current, Discharge Current, and Grid kilowatts (kW). This information is only displayed on the graph for the first 24hrs after starting the EBOSS™. Scheduler Operation The Scheduler screen allows for 3 scheduled start charge times and multiple day selection.
  • Page 53 Please note the local time in the upper left corner and ensure its accuracy before enabling the scheduler. Adjust if necessary. When a scheduler selection is enabled, the indicator will display as green and enabled. If the EBOSS™ is currently running a scheduled charge cycle, the red inactive indicator will change to green and display as active.

  • Page 54: Remote Monitoring

    Directly interact with devices in a similar display as the human- machine interface (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: Warnings And Alarms

    Warnings and Alarms Please refer to your generator’s manual for more information and description of the following warnings and alarms. Warnings and Alarms Warning Description Solution The battery minimum Press start and let the cell voltage has reached Battery Charging Request batteries charge to full 2.25VDC and is not in a before shutting down.
  • Page 59 3. If these faults occur pressed. individually: AFE F94-External Fault 2 a. Verify wiring on the Emergency Stop relays. b. Contact ANA Tech Support There is temperature switch in the top tube 1. Check fan operation. of magnetics. The temperature switch 2.
  • Page 60 Warnings and Alarms Shutdown Description Solution 1. Check the indicator on the surge arrestor to verify if it has blown. Replace surge arrestor. A voltage spike has 2. Verify auxiliary Surge Arrestor Blown caused the surge wiring on surge arrestor to open. arrestor is secure.
  • Page 61 (bottom left set). AFE Precharge Error bus voltage needs to be higher than 625VDC to 3. Verify precharge get out of precharge. contactor is closing. 4. Check precharge fuses (top left set). 5. Contact ANA Tech Support. EBOSS™ 125kVA Operation Manual...
  • Page 62 Warnings and Alarms Shutdown Description Solution 1. Verify the control power switch for the generator is powered “ON”. 2. Verify the serial connector is securely plugged into the back of the HMI. Generator The HMI cannot 3. Verify the RS485 Communication communicate with the connector is plugged...

  • Page 63: Technical Support

    Fault issues between the response from the BMU and the batteries. batteries. 3. Call ANA Tech Support to continue diagnosis. Technical Support Any servicing, diagnostics, or repairs should only be performed by trained personnel equipped with the proper tools and safety equipment.

  • Page 64: 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 65: Troubleshooting Chart

    “Control Power been switched on but there Sealed -All” is no display on HMI screen. The battery pack voltage Contact ANA technical may be too low. support. The AC input Fuses may Check the AC input be disconnected fuses, connect or or blown.
  • Page 66 AFE input power fuses panel. Replace blown continually blow fuses if necessary. Internal short circuit Contact ANA technical within the EBOSS™. support. Verify home screen Start signal not being displays “Generator sent. Run Command” above the generator.
  • Page 67 Notes EBOSS™ 125kVA Operation Manual...
  • Page 68 Notes Operation Manual EBOSS™ 125kVA...
  • Page 69 Notes EBOSS™ 125kVA Operation Manual...

  • Page 70: Warranty Information

    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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