Atlas Copco ZBC 250 Instruction Manual
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Atlas Copco ZBC 250 Instruction Manual

Atlas Copco ZBC 250 Instruction Manual

Energy storage system
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Instruction Manual
User and maintenance manual for
Energy Storage System
English
ZBC 250

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Summary of Contents for Atlas Copco ZBC 250

  • Page 1 Instruction Manual User and maintenance manual for Energy Storage System English ZBC 250...
  • Page 3 User and maintenance manual for Energy Storage System ZBC 250 Original instructions Printed matter No. 2960 7110 01 ATLAS COPCO - POWER AND FLOW DIVISION www.atlascopco.com 06/2023...
  • Page 4 Neglecting maintenance or making changes to the setup of the machine can result in major hazards, including fire risk. While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors.

  • Page 5: Table Of Contents

    While every effort has been made to ensure that the Markings ............ 12 11.1 Technical specifications ......57 information in this manual is correct, Atlas Copco Mechanical features ........13 does not assume responsibility for possible errors. 11.2 Dimension drawing ........59 Electrical features ........
  • Page 6 This page has been left blank intentionally. - 6 -...

  • Page 7: Safety Precautions

    Safety precautions Introduction To be read attentively and acted accordingly before The policy of Atlas Copco is to provide the users of towing, lifting, operating, performing maintenance or their equipment with safe, reliable and efficient repairing the ESS. products. Factors taken into account are among...

  • Page 8: Acronyms And Abbreviations

    Acronyms and abbreviations The following acronyms and abbreviations are used in this manual. Abbreviations Full Name Battery Management System Battery Management Unit Battery Cluster Management Unit BAMS Battery Administration Management System Battery Administration Management Unit Balance of Plant Human Machine Interface Personal Protection Equipment Environmental Health and Safety Energy Storage System...

  • Page 9: Main Parts

    Main parts GENERAL DESCRIPTION ZBC 250 integrated ESS design to meet the requirements of applications such as rental, events and micro-grid. Ideal for any metropolitan job or event. Based in lithium-ion batteries, this movable product is ready to supply power in the most demanding situation, working in island mode or a hybrid solution together with a diesel generator.
  • Page 10 - 10 -...
  • Page 11 Description Iron frame fittings package BMS system PCS system Thermal management system Energy storage module Power distribution system Pressure relief port Escape card Emergency light Emergency stop button Industrial air-conditioning Pharmacy cylinder Pressure relief port Waterproof sound & light alarm Waterproof gas release lamp - 11 -...

  • Page 12: Markings

    MARKINGS Markings provide instructions and information. They also warn of hazards. For convenience and safety, Indicates the roof guides. keep all markings in legible condition, replacing them when damaged or missing. Replacement markings are available from the factory. Warning! A brief description of all markings provided on the ESS is given hereafter.

  • Page 13: Mechanical Features

    MECHANICAL FEATURES The mechanical features described in this chapter are standard provided on this Lifting beam and sling guides energy storage pack. A lifting beam is attached to the unit base frame. This single lifting point will allow to lift easily the ESS. Galvanized skid In order to secure the position while transport, use the guides placed in the roof to To be able to lift the ESS by means of a forklift, a galvanized skid with rectangular...

  • Page 14: Electrical Features

    ELECTRICAL FEATURES Control and power cubicle Earth leakage relay The electrical features described in this chapter are standard provided on this ESS. The control cubicle grouping the ESS controller An earth leakage relay provides protection in case of an earth leak current. It detects and indicates an earth (from now on CCGX (Color Control GX)), fuses, Lithium-ion batteries automatic switches sockets, etc., is accessible by...

  • Page 15: Installation And Connection

    Installation and connection LIFTING POSITIONING AND TRANSPORT 9. Avoid large temperature fluctuations. If there are too many differences, condensation may form The lifting eye, to lift the ESS by means of a hoist, is inside the housing, causing a short circuit. Positioning for operation integrated in the bodywork and easily accessible from 10.

  • Page 16: Installation

    Check that the inner earthing system is in lamps, computers, X-ray equipment, audio amplifiers compliance with the local legislation. and elevators. Consult Atlas Copco for measures against the adverse influence of non-linear loads. • Use a cable of suitable section to connect the PE...

  • Page 17: Operating Instructions

    Operating instructions In your own interest, always strictly observe all BEFORE STARTING relevant safety instructions. 1. Perform all daily checks and maintenance as Do not operate the ESS in excess of the limitations specified in the “Maintenance schedule”. mentioned in the Technical Specifications. 2.
  • Page 18 To install the resettable electrical release head, follow the instructions below: 1. Ensure that the cylinder is properly secured by its brackets. Check that the valve outlet is screwed to the discharge hose and this, in turn, to the manifold or discharge pipe.
  • Page 19 4. Once the electrical connection is made, re-connect the electrical connector to Position 227SOL 227SOL-E the release head. Operating medium HFC-227ea, HFC-125, HFC- 5. With the discharge head in your hand (still not screwed into the valve), do a proper functional test with power from the fire panel. When the head is Valve type RGS-MAM-20/40/50 and energised, the actuation needle moves to POSITION 2.
  • Page 20 6. Manually reset the 227SOLP or 227SOL electrical release head. To do this, apply force with the resetting screw, or failing that with a sharp instrument (e.g. a punch) until the actuation pin moves to POSITION 1. To check that the resetting has been carried out properly, give the head a light sharp tap on a hard surface, and then check that the actuation pin is still in POSITION 1.
  • Page 21 7. Remove the plastic safety plug from the valve actuation port and screw in, in its place, the swivel nut of the electrical release head. Do not use Teflon, adhesive Before screwing the electrical release head to the valve actuation or any other type of thread sealant;...

  • Page 22: Operating The Ess

    OPERATING THE ESS 1. Before starting the system, check that all the automatic switches (general ELCB, sockets protections and main circuit breaker) are in the OFF position (1). 2. Select the desired operating mode with S20 (Genset/OFF/Mains). See also chapter Checks and trouble shooting. Below is the SLD of the BESS: - 22 -...

  • Page 23: Operating The Asc Controller

    OPERATING THE ASC CONTROLLER 1. Check Communication - DEIF Can Bus; 2. Check Communication - ASC4 to PCS & BMS; If communication is not okay, below alarm shows in ASC; PCS: SinExcel Mod-bus RTU, 9600, n, 8, 1, ID = 5 (or any other ID not occupied by BMS) BMS: Narada, Version unknown, SPC Mod-bus RTU, 9600, n, 8, 1.
  • Page 24 Mode 1: Diesel Generator (DG) only Step 1: Start DG Step 2: Close DG breaker DG will run in VF mode and take all the loads Mode 2: ESS only Step 1: Set PCS in Remote mode Step 2: Clear PCS alarms if exists Step 3: Press start command on ASC-4 ESS will run in VF mode and take all the loads ASC-4 will request PCS to run in off-grid mode automatically when...
  • Page 25 Mode 3.1: DG // ESS- Energy Source Mode Set Par 8081 as Energy Source. Condition: Battery SOC below Par 8053 Threshold 1. DG will charge ESS. Charging limit will Par 7064 Max charging limit be minimized by: Par 8032 DG Charge P Charging limit read from BMS: Example: DG Nominal Power 400kW (set in AGC);...
  • Page 26 Set Par 8081 as Energy Source. Condition: Battery SOC above Par 8053 Threshold 1 but below Par 8054 Threshold 2. DG is charging ESS. If discharging required, battery can discharge as a backup source. Charging limit will be Par 7064 Max charging limit minimized by: Par 8032 DG Charge P Charging limit read from BMS...
  • Page 27 Set Par 8081 as Energy Source. Condition: Battery SOC above Par 8054 threshold 2. Battery will discharge. Discharging limit will Par 7063 Max discharging limit be minimized by: Par 8011 Min DG load Discharging limit read from BMS Example: DG Nominal Power 400kW (set in AGC); ESS Nominal Power 250kW (set in Par 6002);...
  • Page 28 Mode 3.2: DG // ESS- Power Source Mode Set Par 8081 as Energy Source. Condition: Battery SOC below Par 8051 SOC Minimum 1. DG will charge ESS. Charging limit will be Par 7064 Max charging limit minimized by: Par 8032 DG Charge P Charging limit read from BMS Example: DG Nominal Power 400kW (set in AGC);...
  • Page 29 Set Par 8081 as Energy Source. Condition: Battery SOC below Par 8051 SOC Minimum 1 but above Par 8053 threshold. DG will charge ESS. If discharging required, battery can discharge as a backup source. Charging limit will be Par 7064 Max charging limit minimized by: Par 8032 DG DG Charge P Charging limit read from BMS...
  • Page 30 Set Par 8081 as Energy Source. Condition: Battery SOC above Par 8054 threshold 2. Battery will discharge but not before DG is full load. Discharging limit will Par 7063 Max discharging limit be minimized by: Discharging limit read from BMS Example: DG Nominal Power 400kW (set in AGC);...

  • Page 31: Operating The Pcs

    OPERATING THE PCS Switches Introduction AC switch DC Switch The AC disconnection unit disconnects the PCS from the Grid. The NA series PCS The DC disconnection unit disconnects the PCS from the Battery module arrays. breaker is comply to the UL certification. The NA series PCS breaker is comply to the UL certification.
  • Page 32 AUX power supply AC Switch UI Design of the touch display Position Designation Explanation AUX power supply switch SPD switch Menu Menu can be different before/after log-in and other setting. System Topology Version and Time Symbols Explanation Symbol Designation Touch Screen Grid User Interface Load in AC side...
  • Page 33 LEDs of the System The appearance of the PCS is shown in below. Front door body is mainly composed of touch screen, normal indicator light, alarm indicator light and emergency shut- down button etc. Front view for PCS-AC module LEDs on the front panel LED designation Description Explanation...
  • Page 34 Label Explanation Label-Dot label-A phase Label-Dot label-B phase Label-Dot label-C phase Label-Dot label-Negative electrode Label-Dot label-Negative electrode Label-Dot label-Negative electrode Label-Dot label-Neutral line Label-Dot label-Grounding Warning label position Label-Warning label-Danger High Voltage Label-Warning label-Danger large leak current - 34 -...

  • Page 35: Operating The Battery Rack

    OPERATING THE BATTERY RACK 1. Protection function • Check the Alarm history in terms of critical alarm • Check the interface of HVAC in case of any faults and the alarm which may not been sent to the in terms of communication, operation status, EMS.
  • Page 36 Table Capacity test result record - 36 -...

  • Page 37: Maintenance

    Maintenance MAINTENANCE SCHEDULE Every 3 Every 6 System Maintenance Item Weekly Monthly Yearly months months Check the voltage of battery system through the monitor system if abnormal or not. Check the SOC of battery system through the monitor system if abnormal or not. Visual inspect all the cables of the battery system if any broken, aging, getting loose or not.
  • Page 38 Every 3 Every 6 System Maintenance Item Weekly Monthly Yearly months months Check the cylinder, make sure all cylinders are securely mounted to the support. Check the corrosion of cylinder. Check the equipment damage of cylinder. Check that the starter is installed in the correct position. Check all startup lines.
  • Page 39 Clean/replace air ventilation and exhaust cotton filter. Container Check container/battery cabinets door function. Remarks: * Requires Atlas Copco authorized service technician 1. Unfavourable environmental conditions shorten maintenance intervals. 2. Location and environmental conditions. 3. Check/inspect and record for below components.

  • Page 40: Checks And Trouble Shooting

    Checks and trouble shooting GENERAL INTRODUCTION Never perform a test run with connected power cables. Never touch an electrical connector without a volt- age check. When a failure occurs, always report what you experienced before, during and after the failure. Information with regard to the load (type, size, power factor, etc.), vibrations, insulation check odours, output voltage, damaged parts, ambient temperature,...

  • Page 41: Trouble Shooting Of Pcs

    TROUBLE SHOOTING OF PCS Communication Alarm Failure Name Alarm classification + Reason Troubleshooting ways clearance method Clearance method: Auto - After the cause of the alarm disappears, the alarm is Alarm classification: Fault shut down (or red lights) automatically cleared. Warning alarm but not shut Manual - After the cause of the alarm disappears, you need to down (red light flashing)
  • Page 42 1. Check the J9 jumper port on the X2 board on the cabinet rack. U2/AC/DC/STS Fault + Auto There are problem in the 485 module offline communication BUS between Only the front and the end of the communication line this two X2 the AC module and the boards allow the jumper cap to be installed.
  • Page 43 RS485 comm. Fault Fault + Auto RS485 communication This alarm is usually reported after the recovery of AC module interruption between module and offline. The module will be offline when the RS485 communication monitor. failure. During troubleshooting, follow the offline steps of troubleshooting module.
  • Page 44 1. Check the J 20 jumper on the X2 board on the cabinet rack, only CAN B comm. Fault Fault + Auto 1. CANB communication between modules in the cabinet the front and the end of the communication line these two X2 was interrupted;...
  • Page 45 Synchronous signal 1 Fault + Manual When the module is running, it is If only some modules are alarmed. For the module that have Fault found that the hardware circuit of alarm, reinforce the communication cable between the front Synchronization signal 1 is panel communication port (round port) of the module and the X2 abnormal.
  • Page 46 Synchronous signal 2 Fault + Manual When the module is running, it is 1. If only some modules are alarmed. For the module that have Fault found that the hardware circuit of alarm, reinforce the communication cable between the front panel Synchronization signal 2 is communication port (round port) of the module and the X2 board.

  • Page 47: Trouble Shooting Of Battery

    TROUBLE SHOOTING OF BATTERY The BESS is a high voltage DC system, operated by qualified and authorized person only! Before check the failure, must check all the cables connection and setting of Inverter and BMS are right or not, and the BESS system can turn on normally or not Number Fault Phenomenon...

  • Page 48: Replacement Of Batteries

    REPLACEMENT OF BATTERIES The NESP is a high voltage DC system, operated by qualified and authorized person only. Before replace the main component must shut off the maintenance battery string's power. All servicing and replacement of parts are to be done by qualified persons only and that only approved materials, components and parts are to be used for replacements.
  • Page 49 Before remove the battery module, please confirm the positive and negative polarity of each module. The A module has a positive pole on the left side and a negative pole on the right side, as shown in the following figure with A mark. The B module has a negative pole on the left side and a positive pole on the right side with B mark.

  • Page 50: Trouble Shooting Of Fss

    TROUBLE SHOOTING OF FSS Troubleshoot the Sigma A-XT Releasing Fire Control Panel when conflicts exist after installing or configuring. Monitor the lower fascia indicators of the fire control panel to determine the cause of the trouble condition. The lower indicators of the fascia are visible after opening the cabinet-door of the Sigma A-XT Releasing Fire Control Panel. The figure below illustrates lower fascia indicators of the Sigma A-XT Releasing Fire Control Panel: Indicator Description...
  • Page 51 Exting Trbl A short or open circuit exist on the releasing agent output. Remove wiring and reconnect EOL resistors. Check releasing agent circuit wiring. The exiting trouble LED will be accompanied by the front panel flooding zone trouble LED to indicate a common trouble condition within the releasing agent section of the fire control panel.

  • Page 52: Hvac Trouble Shooting

    HVAC TROUBLE SHOOTING Fan faults and recovery measures Symptom Possible cause Check items or processing method Internal cycling fan cannot run Air conditioner is in the standby state It is normal case, air conditioner will get into the automatic control logic after being power on and in the standby for 30s.
  • Page 53 Cooling system faults and recovery measures Symptom Possible cause Check items or processing method The compressor cannot start The power supply is not started (standby) Check the main power switch, and check if the startup interface is displayed. Loose circuit connection Tighten the circuit connectors The compressor motor burns out Check the motor and replace it if any defect is found.

  • Page 54: Storage Of The Ess

    Storage of the ESS STORAGE PREPARING FOR OPERATION AFTER STORAGE The ESS has been developed for outdoor installation and operation. However, in order to avoid Before operating the ESS again, remove the unnecessary weathering and prolong the service life wrapping, VCI paper and silica gel bags and check the of the battery set, it is recommended that the device is ESS thoroughly (go through the checklist Before stored in the interior, if possible.

  • Page 55: Disposal

    Remove spilled fluid mechanically; pick up the recyclable materials. rest with absorbing agent (for example sand, Your Atlas Copco ESS mainly consists of metallic sawdust) and dispose it according the applicable materials, that can be re-melted in steelworks and local disposal regulations. Do not drain into the smelting works and that is therefore almost infinite sewage system or surface water.

  • Page 56: Disposal Of Li-Ion Batteries

    DISPOSAL OF LI-ION BATTERIES The way of decommissioning and disposing of the energy storage system at the end of its life shall be the responsibility of the owner of the system and in accordance with local codes or requirements on waste disposal or recycling. The decommissioning and disposing of Lithium ion batteries shall be in line with the following instructions.

  • Page 57: Technical Specifications Of The Ess

    Technical specifications of the ESS TECHNICAL SPECIFICATIONS Designation Unit ZBC 250 System Info Battery chemistry Lithium Iron phosphate LiFePO4 Sound power level dB (A) Relative humidity <70 IP grade Performance data Model name ZBC 250 Rated frequency 50/60 Rated voltage...
  • Page 58 Designation Unit ZBC 250 Battery Voltage 716.8 Life Time Nº Cycles @90%DoD @60%EoL cycles 5000.0 Recommend Maximum Deep Of Discharge (DoD) 90.0 Discharge autonomy time at full 250kW power Discharge autonomy time at 125kW power Discharge autonomy time at 50kW power...

  • Page 59: Dimension Drawing

    DIMENSION DRAWING 9829 3206 00 - 59 -...

  • Page 60: Electrical Diagram

    ELECTRICAL DIAGRAM - 60 -...

  • Page 61: Data Plate

    DATA PLATE Reference Description Rated Frequency Rated Voltage Rated Power kVA/kWh Nominal Energy Standby Power Rated Current Power Factor -1~+1 Output THDi < 3% Output THDu < 2% Prot. Cl. IP54 Series No. Manufacturer Year Following documents are provided with this unit: - Test Certificate - EC Declaration of Conformity: - 61 -...

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