Retrofitting existing photovoltaic systems to maximise self-consumption

For many commercial and industrial facilities equipped with photovoltaic systems installed several years ago, adding battery storage has become an effective way to improve the return on investment.

Exported electricity is becoming less valuable, while self-consumed energy directly offsets electricity purchased from the grid. Battery storage also helps reduce peak demand, lowering costs associated with maximum power consumption.

With its AC-coupled configuration, ZCS Azzurro Power Magic operates downstream of the existing photovoltaic system, leaving the installed inverters, PV strings and electrical configuration unchanged. This makes it particularly suitable for manufacturing facilities where production downtime must be kept to an absolute minimum.

The AC power-to-battery capacity ratio remains ≤ 0.5 (C-rate), making the system ideal for applications focused on self-consumption, peak shaving and multi-hour energy management.

On site, installation is limited to positioning the cabinet and completing the electrical connections, reducing installation time while minimising integration risks.

Each storage cabinet connects to a 400 V three-phase supply, delivering 125 kW nominal output power and up to 138 kW peak power.

Its adjustable power factor, ranging from -1 to +1, also enables reactive power control without requiring additional compensation equipment.

Designed for outdoor commercial and industrial applications

ZCS Azzurro Power Magic has been specifically engineered for outdoor installations and includes features suitable for demanding industrial environments:

• IP55 protection rating
• C3 anti-corrosion protection
• ground-mounted installation
• integrated liquid cooling
• anti-condensation design
• physical separation between electrical and hydraulic circuits

These features eliminate the need for dedicated technical rooms or forced ventilation systems, simplifying both engineering and installation.

Scalable architecture up to more than 6 MWh

The architecture of ZCS Azzurro Power Magic keeps the power conversion and battery storage sections separate, allowing independent expansion of both power output and storage capacity.

The system supports:

• up to three Battery Cabinets connected in parallel to increase storage capacity while maintaining the same output power;
• up to five additional Storage Cabinets, connected through a 400 V Junction Box, to increase installed power.

Battery cabinets are available in 215 kWh and 258 kWh versions, enabling storage systems exceeding 6 MWh. This modular approach allows projects to be sized according to current energy requirements while leaving room for future expansion without replacing existing equipment.

Certified safety for industrial battery storage

Safety is a fundamental aspect of the system design.

ZCS Azzurro Power Magic incorporates a multi-level fire protection system including:

• perfluorohexanone fire suppression at battery module level;
• fire suppression at cabinet level;
• optional water hydrant connection;
• dedicated gas venting openings;
• automatic pressure relief hatch.

The battery system also complies with major international standards, including IEC 62619 and UN38.3, providing valuable reassurance during project design, certification and insurance assessments.

Ready for CEI 0-16 grid connection requirements and Central Plant Controller integration

For this power range, grid connection in Italy falls under the requirements of the CEI 0-16 standard.

Zucchetti Centro Sistemi provides the technical documentation and conformity certificates required for the grid connection application with the local Distribution System Operator (DSO).

These systems also require integration with a Central Plant Controller (CCI).

ZCS Azzurro Power Magic provides a comprehensive register map for monitoring and controlling both active and reactive power via:

• MODBUS RTU over RS485;
• MODBUS TCP over Ethernet LAN.

This enables seamless integration with plant controllers and supervisory systems without requiring dedicated hardware.

VP Solar also supports installers, EPCs and system integrators through its specialist engineering services for Central Plant Controller configuration and commissioning.

VP Solar: technical support for retrofit battery storage projects

As a specialist B2B distributor of photovoltaic and energy storage solutions, VP Solar supports installers, EPC contractors and system integrators throughout every stage of the project, from technical sizing and product selection to commissioning support and Central Plant Controller integration.