Interchangeable batteries make generator unnecessary

Toward a 100% emission-free project site

Sustainable, clean and emission-free construction. With the 2050 climate goals in sight, more and more construction and civil engineering companies are switching from fuel-fired to hybrid or 100% electric equipment. Not only because they aspire to do so themselves, but also because municipalities, provinces and other clients are asking for it. Top Systems supports these companies with an extensive package of (autonomous) energy systems, such as the Li-Swap interchangeable battery system. This latest innovation from Top Systems makes construction equipment even 100% electric!

Energy anytime, anywhere

Top Systems' mission is energy independence in the broadest sense of the word. The Bodegraven-based specialist has been a market leader in independent energy supplies for more than 35 years, of which the Li-Swap interchangeable battery system is a sophisticated example. "The Li-Swap interchangeable battery system is ideally suited for construction and infrastructure projects where no grid connection is available and/or where traditional generators are not desirable (anymore)," says Ronald van den Berg, sector specialist Construction and Infrastructure at Top Systems. "The first step toward a green construction site often involves making the construction shack or shovel more sustainable. Not for nothing are zero-emission construction huts and shelters now the standard on construction and infrastructure projects. The Li-Swap interchangeable battery system is a logical next step in this."

'You ask, we engineer'

The development of the Li-Swap batteries is the result of findings and questions from the market, he says. "Over the past period, we have supplied many battery systems from Victron Energy and MG Energy Systems, for use in hybrid and 100% electric utility vehicles, among others. The batteries were installed in combination with an inverter and MPPT controller. Next, the roofs of the construction huts and shelters were filled with solar panels to provide energy-neutral power. In the process, we faced a number of challenges. For example, space on the roof is limited, while the energy demand in the construction huts and shelters is quite high. To power the coffee maker and lights, heating/air conditioning, laptops and smartphones, quite a bit of power is needed. Power that the limited number of solar panels cannot always provide on winter and cloudy days. Since a grid connection is often lacking, connecting to the generator can offer a solution. However, this is no longer allowed in more and more locations. Couldn't we engineer a solution for this?"

Handy batteries, now also as 3-phase system

Dismantling the batteries and charging them elsewhere seems like a simple solution in this case, but it is anything but, Van den Berg emphasizes. "After all, you have to deal with all kinds of safeguards. Moreover, standard lithium batteries are far too heavy for these capacities. Our Li-Swap interchangeable battery system provides a solution for this. We initially worked out a single-phase (230 VAC) power supply. Here the battery system is divided into several handy Li-on batteries (48V/45.5Ah) of about 2.3 kWh and 10 kg each, including a handle and Anderson connector. The batteries can be easily placed in a rack in three or four pieces, giving a maximum capacity of 9.2 kWh." Meanwhile, a 3-phase (400 VAC) Li-Swap power system is also available, in which up to eight (!) batteries can be coupled. "This provides construction and infrastructure companies with even more power (18.4 kWh)." In addition, Top Systems has designed in-house a Li-Swap battery precharge cabinet, to which the batteries, a Victron MultiPlus-II inverter/charger, a Victron SmartSolar MPPT charge controller and a Victron Cerbo GX with touch panel are connected.

Reliable and safe 

Thanks to the Li-Swap precharge cabinet, arcing when exchanging batteries is not an issue, Van den Berg says. "An important safety aspect, which also applies to the Anderson connectors. In fact, these connectors are designed in such a way that the connections (metal pins) can never make contact with each other. Not even when they are loose on the ground. This prevents short circuits and burning of the connectors." When the energy system is not used for a predetermined time, the system switches itself off. This also cleverly overcomes energy waste. A CAN-bus communication protocol and Bluetooth connection guarantee optimal connectivity. "A Victron Cerbo GX communication module handles the control and monitoring. The status of each battery can also be read with the advanced Top Systems app."

Easily interchangeable

The moment the batteries are empty, they can easily be exchanged with a full battery, Van den Berg says. "Then the empty batteries can easily and with the help of a battery charger be recharged in the workshop, at home or at any other location. This keeps construction and infrastructure companies adequately powered under all (weather) conditions. An on-site generator is no longer necessary." The weight of the Li-Swap batteries is well within occupational health and safety standards. "Moreover, the batteries are very compact. This makes them easy to pick up and carry around."

Homegrown

All components of the Li-Swap interchangeable battery system are manufactured by Dutch companies (Top Systems and Victron Energy). "Users are also assured of the latest technology," Van den Berg emphasizes. "The Li-Swap battery system contributes to a sustainable and emission-free future for our children and, thanks to its long service life, the number of raw materials is limited. With the Li-Swap interchangeable battery system, we are therefore taking a huge step forward, towards a 100% emission-free construction site without CO₂, NOx and particulate matter! In the words of Neil Armstrong, 'That's one small step for man, one giant leap for mankind'."

Numerous application possibilities

The Li-Swap interchangeable battery system is now available to everyone. "Besides construction huts and utility vehicles, the Li-Swap Li-on batteries are ideally suited for electric boats, tiny houses, company and service vehicles and other mobile solutions," Van den Berg concludes. As an example, he mentions the mobile energy cart, which can easily be driven to the right spot on the project site. "The possibilities are almost endless. We are happy to think along with you for a customized solution."  

The advantages of the Li-Swap interchangeable battery system

- 100% emission-free, no emissions of CO₂, NOx and particulate matter;

- Reliable and safe;

- Weight of the batteries is well within occupational health and safety standards;

- Sufficient power anytime, anywhere;

- Certified and complies with UN 38.3;

- Scalable, making it easy to expand;

- Available as a 1-phase (230 VAC) or 3-phase (400 VAC) system;

- Conversion power up to 15 kVA possible;

- Remote monitoring via an advanced app;

- Numerous application possibilities also outside the construction and infrastructure sector.