Samsung U6A4 Installation Manual Download Page 80

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Installing the Product

English 8/2020. Rev 0.3

19.

Connect Battery Module #8 B+ and Battery Module #9 B- using “RACK FUSE BUSBAR ASSEMBLY” Connect using an M8 screw.
Measure the contact resistance between the terminal and the bus bar.

Figure 3-64: Connect Battery Module #8 B+ and Battery Module #9 B-.

20.

Reattach Battery Module #8’s front cover and remove Battery Module #10’s front cover.

Figure 3-65: Reattach Battery Modules #8’s Front Cover

Summary of Contents for U6A4

Page 1: ...English 8 2020 Rev 0 3 LIB System for UPS U6A4 Installation Manual 128S ...

Page 2: ...English 8 2020 Rev 0 3 Read this manual carefully before starting to install the battery system Keep these instructions for future reference ...

Page 3: ...ation is to be used for any other purpose and it is not to be reproduced copied disclosed transmitted stored in a retrieval system or translated into any human or computer language in any form by any means in whole or in part without prior written consent of SAMSUNG SDI Co Ltd Although every possible effort has been made to ensure the accuracy of this document SAMSUNG SDI Co Ltd assumes no respons...

Page 4: ...English 8 2020 Rev 0 3 ...

Page 5: ...comply with the instructions with this symbol may result in a serious accident causing death or a severe injury WARNING Failure to comply with the instructions with this symbol may result in a serious accident causing a severe injury CAUTION Failure to comply with the instructions with this symbol may result in minor or moderate injury NOTICE Provides information considered important but not hazar...

Page 6: ...uld perform annual preventive maintenance Only qualified personnel who are familiar with the batteries and safety precautions should perform installation or maintenance of the battery Do not allow unauthorized personnel to contact the batteries Safety Precautions The following precautions provide general safety guidelines that should be followed when working with or near the Energy Storage System ...

Page 7: ...there is a serious risk of injury while working around and in equipment enclosures CAUTION STATIC SENSITIVE Electronic appliances can be damaged by electrostatic discharge Proper handling procedures are required Be sure to wear a grounded anti static wrist strap and to discharge static electricity by touching a grounded surface near the equipment before touching any system components Dangerous Vol...

Page 8: ...ted in SAMSUNG SDI safety documentation Before entering potentially hazardous areas or beginning work on the ESS complete the following tasks Identify and wear protective clothing and shoes Identify and isolate all power and stored energy sources Apply appropriate lock out tag out devices When applying lock out tag out to the ESS do not touch anything within the enclosure except as specifically di...

Page 9: ...nt malfunction only adequately trained personnel should modify any programmable machine WARNING Always ensure that applicable standards and regulations are followed and only properly certified equipment is used as a critical component of a safety system Never assume that a safety critical control loop is functioning correctly ...

Page 10: ...Important Safety Instructions vi English 8 2020 Rev 0 3 ...

Page 11: ... 7 2 1 3 SMPS Assembly Type A Type B 8 2 1 4 Rack Frame 9 3 Installing the Product 10 3 1 Grounding the Battery System 10 3 2 Arc Flash Calculations 11 3 3 Installation Procedure 12 3 4 Preparation Stage Procedure 14 3 5 Preparation Stage Unpacking 15 3 6 Preparation Stage Ground Wire and Tools 16 3 6 1 Ground Wires 16 3 6 2 Ground Wire Fasteners 16 3 6 3 Rack Fasteners Anchors 16 3 6 4 Multiple R...

Page 12: ... Cable Connection 78 3 10 7 SMPS Assembly and SMU Power Cable Connection 90 3 10 8 SMPS Assembly and SMU Signal Cable Connection 91 3 10 9 SMPS Assembly AC Input Connection 93 3 10 10 DC Link Cable Connection 99 3 10 11 AC Input Commissioning 102 3 10 12 BMS Configuration 103 3 10 13 Communication Check 103 3 10 14 Reinstall the Front Door 104 3 10 15 Reinstall the Front Panel 105 3 10 16 Switchin...

Page 13: ...s for 128S 3P Rack 15 Table 3 3 Ground Wire Specifications 16 Table 3 4 Ground Wire Fastener Specification 16 Table 3 5 Rack Fastener Specifications 16 Table 3 6 Rack Fastener Specifications Side by side 16 Table 3 7 Recommended Tools and Instruments 17 Table 3 8 Module Voltage and Internal Impedance 19 Table 3 9 Rack Clearance Distances 21 ...

Page 14: ...ction to the SMU 34 Figure 3 22 Inserting SMPS Assembly 35 Figure 3 23 Attaching the SMPS Assembly 35 Figure 3 24 Ground Cable Connection to the SMPS Assembly 36 Figure 3 25 Insertion of Modules on the Ninth Shelf from the Bottom 37 Figure 3 26 Battery Module Arrangement on the Eighth Shelf 38 Figure 3 27 Battery Module Arrangement 38 Figure 3 28 Module Number 39 Figure 3 29 Insertion of modules o...

Page 15: ...r 68 Figure 3 75 Remove Module 13 s Front Cover 68 Figure 3 76 Connect Battery Module 12B and Battery Module 13 B 69 Figure 3 77 Reattach Module 12 s Front Cover 70 Figure 3 78 Remove Battery Module 14 s Front Cover 70 Figure 3 79 Connect Battery Module 13 B and Battery Module 14 B 71 Figure 3 80 Reattach Battery Module 13 s Front Cover 72 Figure 3 81 Remove Battery Module 15 s Front Cover 72 Figu...

Page 16: ...Type B 94 Figure 3 119 SMPS Assembly 3 Phase Type A AC Input Terminals with Cables Attached 95 Figure 3 120 SMPS Assembly 3 Phase Type B AC Input Terminals with Cables Attached 95 Figure 3 121 SMPS Assembly 1 Phase Type A AC Input Terminals with Cables Attached 96 Figure 3 122 SMPS Assembly 1 Phase Type B AC Input Terminals with Cables Attached 96 Figure 3 123 AC Input Terminals of SMPS Assembly 3...

Page 17: ...Table of Contents English 8 2020 Rev 0 3 vii ...

Page 18: ......

Page 19: ...s in this manual are based on assembly of a three cabinet system Other configurations are possible and the instructions can be reduced or expanded to accommodate installation of those systems 1 2 Target Audience This installation manual is intended for system administrators and operators who install and configure the product 1 3 Organization This manual is composed of the following chapters Chapte...

Page 20: ...s and Instruments Revised Table 3 2 Parts for 128S 3P Rack Revised 3 10 5 Busbar Installation Revised 3 10 12 3 System BMS Configuration 2019 12 27 0 21 Revised 3 10 5 Busbar Installation Revised for 128S Configuration 2019 02 28 0 3 Product model number updated Product Description Table 3 2 Parts for 128S 3P Rack Revised Table 3 7 Recommended Tools and Instruments 2020 08 12 0 31 Version for end ...

Page 21: ...ibrillator BMS Battery Management System EHS Environmental Health and Safety ESS Energy Storage System LOTO LOCK OUT TAG OUT OT Overtemperature OVP Overvoltage Protection PCS Power Conversion System SMU String Management Unit SMPS Switched Mode Power Supply SOC State Of Charge SOH State Of Health SG Switchgear UT Undertemperature UVP Undervoltage Protection UPS Uninterruptible Power Supply ...

Page 22: ...ase refer to the product specification 2 1 Major Components This product has the following components Battery Module Type A Type B SMU Rack BMS Embedded in SMU Rack Frame SMPS Assembly Type A Type B System BMS Embedded in SMPS Assembly Type A Refer to the Product Specification document for detailed specifications of the components ...

Page 23: ...dule by measuring its voltage and temperature It also communicates with the SMU to send all measured voltage and temperature data and to receive commands to control cell balancing There are two types of 8S1P Battery Module depending on the position of terminal s polarity Type A s plus terminal is on the right side Type B is on the left Type A EM2031AE003A Type B EM2031AE004A Battery Module Type A ...

Page 24: ...2 Product Description 6 English 8 2020 Rev 0 3 Battery Module Type B Isometric Battery Module Type B Front Front cover removed Figure 2 2 Battery Module Type B ...

Page 25: ...ontrols each Battery Module by cell balancing SMU calculates the state of charge SOC and state of health SOH of the battery system Key components in the SMU are Rack BMS MCCB and shunt resistor Rack BMS is the main controller that takes all data from the Module BMS measures the string voltage and current determines the state of the battery and controls the MCCB accordingly UL V049 0011AA Figure 2 ...

Page 26: ...the SMPS depending on the AC input range and cabling 3 phase and 1 phase The System BMS assembly provides data to the external systems i e building management system UPS etc while controlling and monitoring all connected Rack BMS There are two types of SMPS Assembly Type A is with System BMS and Type B is without System BMS SMPS Assembly with 3 Phase AC Input SMPS Assembly with 1 Phase AC Input Ty...

Page 27: ... SMPS assembly and provides ground connections for SMU and SMPS Assembly Grounding cable busbar for the rack frame is necessary for the SMU and SMPS Assembly as they are grounded to the rack frame when installed An equipment grounding conductor is required to ground the rack frames together and to the UPS module Figure 2 6 Rack Frame ...

Page 28: ... CAUTION If available use a mechanical lift for lifting heavy 22 kg 50 lb components If there is no lift two or three workers must move items weighing more than 22 kg 50 lb The ambient temperature range must be 23 C 5 C during installation 3 1 Grounding the Battery System WARNING SHOCK HAZARD Verify with a voltmeter that no power is present on the system before beginning work on the battery system...

Page 29: ...e following battery system is assumed to estimate the worst case scenario Battery configuration 136S Battery voltage 571 2V Battery internal resistance AC IR 65mohm Arc flash related calculation based on this battery system is as follows Bolted fault current Ibf 9000A 1 2 Bolted fault current 1 2 Ibf 4500A Protective device clearing time Tarc 6ms Protective device current interrupt capability i2 t...

Page 30: ...ions Rack Installation Stage Transport the battery modules to the installation location Insert the SMU in the rack frame Insert the SMPS Assembly in the rack frame After all components are inserted in the rack frame attach them to the rack frame Place the battery modules in the rack frame Connect the busbars Connect the signal cables from SMU to module and module to module Connect the signal cable...

Page 31: ... 1 Unpacking 00 30 00 30 2 Inspection 01 00 01 30 3 Rack Anchoring 04 00 05 30 4 Rack Installation Battery Module 00 20 05 50 SMU 00 10 06 00 SMPS Assembly 00 10 06 10 Rack Fuse Assembly 00 30 06 40 Busbar 01 00 07 40 Signal Cables 00 20 08 00 Power and Control Cables 00 20 08 20 AC Input Installation 00 20 08 40 Cable Installation 00 10 08 50 BMS Configuration 00 10 09 00 ...

Page 32: ...uments for installation 2 Check the arrival schedule of the parts required 3 Unpack the equipment 4 Inspect the equipment WARNING Do not wear watches rings jewelry or any other metal objects Wear electrically insulated gloves and safety shoes CAUTION Store the product in a dust free place with the moisture level of below 60 and the temperature level of 23 C 5 C Keep components out of direct sunlig...

Page 33: ...les 13 and 14 16 FUSE BUSBAR RIGHT UPPER V050 00003A 3 Connect between modules 5 and 6 17 FUSE BUSBAR RIGHT LOWER V050 00004A 3 Connect between modules 5 and 6 18 WIREASSYRACKTOMODULE V046 0005BA 3 Connect Battery Module 1 and SMU 19 WIREASSYMODULETOMODULE 1 SJ39 00673A 42 Signal Connection for Modules 20 WIREASSYRACKTORACK 2 SJ39 00674A 2 Connect Rack between 1 2 and 3 21 WIRE ASSY RACK TO SYSTEM...

Page 34: ...rial M12 30L 70 Grade 7 1 25 mm 0 05 in SS304 3 6 3 Rack Fasteners Anchors Specifications for the rack fastener screws for anchoring the rack frame to the floor are Table 3 5 Rack Fastener Specifications3 Size Hardness Thread Pitch Material M16 L Bottom Anchor 70 Grade 7 2 0 mm 0 08 in SS304 3 6 4 Multiple Rack Fasteners Rack fasteners are factory provided Refer to Table 3 2 Parts for 128S 3P Rack...

Page 35: ...he rack frames 5 1 6 1Nm 50 60 kgf cm 2 Torque Limiter For use with torque wrench 3 Phillips Screwdriver or Bit To fasten SMU and SMPS assemblies to the rack frames M5 Tip 4 Box Cutter Opening boxes 5 Forklift Moving rack frames and pallets containing modules and SMU 6 Insulated Torque Wrench Installing a high current cable 10 50 N m 100 500 kgf cm 7 Insulated Sockets 13 mm 17mm and 19mm Installin...

Page 36: ...y is recommended Voltage resolution 1mV Voltage accuracy 0 1 of reading Resistance resolution 0 001mΩ Resistance accuracy 1 of reading Battery tester may be used to measure the contact resistance between bus bar and the joining terminal if a dedicated resistance meter is unavailable 11 Resistance Meter Measure the contact resistance between bus bar and the joining terminal Hioki RM3548 or meters w...

Page 37: ...check for Physical damage to the exterior Damaged or protruding screws Proper voltage and internal impedance of the battery modules using the battery tester Table 3 8 Module Voltage and Internal Impedance No Items Value 1 Voltage Check 28 080 29 104V 2 Internal Impedance Check 3 0 4 3 mΩ After completion install the battery module in the previously installed rack or return the battery module to it...

Page 38: ...sembly After transporting the SMPS Assembly to its installation location check for Physical damage Paint peeling Damaged or protruding screws After completion install the SMPS in the previously installed rack or return the SMPS to its original packing for protection during storage ...

Page 39: ...ally active areas all four anchor points of the rack must be installed To reduce the product footprint the racks can be installed side by side and rear to rear against a wall or next to another rack In this case only two anchor points on the front side of each rack can be installed Proper cooling and ventilation of the installed area is recommended for racks installed with no side and rear clearan...

Page 40: ...tance 1000 recommended 4 All Telcordia Zone 4 Workable distance 800 recommended 0 Workable distance 800 recommended Workable distance 1000 recommended Two anchor points not rated for seismic event Four anchor points Telcordia Zone 4 Figure 3 2 Clearance Distance for Single Rack Frame Two anchor points not rated for seismic event Four anchor points Telcordia Zone 4 Figure 3 3 Clearance Distance for...

Page 41: ...de and Rear to Rear 1 After unpacking the rack frame transport it to its installation location 2 Remove the front panels side panels and rear panel from the rack frame Unscrew the screws on each panel and lift the panel to undo the hooks to the frame on each panel Do not misplace the screws as they are needed when installing the panels back after anchoring the rack frame Figure 3 5 Front panel scr...

Page 42: ...3 Installing the Product 24 English 8 2020 Rev 0 3 Figure 3 6 Front panel hooks four Figure 3 7 Side panel screws six ...

Page 43: ...3 Installing the Product English 8 2020 Rev 0 3 25 Figure 3 8 Side panel hooks four Figure 3 9 Rear panel screws eight ...

Page 44: ...holes in the frame and anchoring points are aligned 4 Connect four anchoring points on the bottom of the rack NOTICE Anchor the frame with M16 bolts and nuts The fastening torque should be 140Nm 1 425kgf cm Check the rack and other parts for distortion caused by unpacking Figure 3 11 Rack Anchoring Points 4 EA Bottom of the Rack Frame ...

Page 45: ... 300kgf cm Figure 3 12 Holes on the sides of the rack six 6 Optional step After all the rack frames are anchored and connected reattach the side panels to the outermost rack frames using the provided M5 Screws for each side panel Fasten the screws using torque of 5 1 6 1 Nm 50 60 kgf cm Make sure all the hooks are inserted to the slot and the panel is flush with the rack frame before screwing ...

Page 46: ... hooks and six screws for each panel 7 Reattach the rear panels to the rack frames using the provided M5 Screws for each rear panel Fasten the screws using torque of 5 1 6 1 Nm 50 60 kgf cm Make sure all the hooks are inserted to the slot and the panel is flush with the rack frame before screwing ...

Page 47: ...3 Installing the Product English 8 2020 Rev 0 3 29 Figure 3 14 Reattaching the Rear Panels 8 Front panels will be reattached after all the components are installed ...

Page 48: ...ny work on this energized equipment WARNING Sharp Edges Wear gloves and other protective gear to prevent injury WARNING Pinch Point Use caution when working in the enclosure to prevent injury CAUTION Heavy Object Can cause muscle strain or back injury Use lifting aids and proper lifting techniques when moving trays batteries and other heavy objects ...

Page 49: ... door of the panel using the provided key Figure 3 15 Front door ajar 2 Remove the earth cable from the rack frame to the front door Do not misplace the two screws and the earth cable Figure 3 16 Removing the earth cable 3 Lift the front door to remove it from its hinge Do not misplace the door ...

Page 50: ...3 Installing the Product 32 English 8 2020 Rev 0 3 Figure 3 17 Removing the front door 4 If installing more than one rack remove all the doors Figure 3 18 All doors and front panels removed ...

Page 51: ... that the torque setting is correct 1 Insert the SMU through the front of the rack as shown in Figure 3 19 Inserting SMU Figure 3 19 Inserting SMU 2 After all SMU s are inserted in the rack frames attach each to the rack frame with four M5 x 10L bolts Torque 5 1 6 1 Nm 50 60 kgf cm Figure 3 20 Attaching a SMU to a Rack Frame 3 After all SMU s are inserted into the rack frame connect the ground cab...

Page 52: ... 34 English 8 2020 Rev 0 3 NOTICE Connect a ground cable between the SMU and the Rack Frame SCREW M5 x 10L Torque 5 1 6 1 Nm 50 60 kgf cm Verify that the torque setting is correct Figure 3 21 Ground Cable Connection to the SMU ...

Page 53: ...ws Torque 5 1 6 1 Nm 50 60 kgf cm Verify that the torque setting is correct 5 Slide the SMPS Assembly into the rack frame on the shelf designated for the SMPS Assembly as shown below Figure 3 22 Inserting SMPS Assembly 6 After all SMPS Assemblies are inserted into the rack frames attach them to the rack frame with screws Torque 5 1 6 1 Nm 50 60 kgf cm Figure 3 23 Attaching the SMPS Assembly 7 Afte...

Page 54: ...2020 Rev 0 3 NOTICE Connect a ground cable between the SMPS Assembly and the Rack Frame with an M5 x 10L screw Torque 5 1 6 1 Nm 50 60 kgf cm Verify that the torque setting is correct Figure 3 24 Ground Cable Connection to the SMPS Assembly ...

Page 55: ...ference of 1 3mΩ Refer to Table 3 8 Module Voltage and Internal Impedance 3 Place the battery modules on the rack frame Important Samsung recommends installing Battery Modules in the upper shelves first and proceeding to the bottom Two Type B battery modules are inserted in the ninth shelf from the bottom Sixteen battery modules can be inserted into a rack frame as shown in Figure 3 27 Refer to 2 ...

Page 56: ...e Eighth Shelf Figure 3 27 Battery Module Arrangement Two Type A Battery Modules Two Type B Battery Modules Two Type A Battery Modules Two Type B Battery Modules Two Type A Battery Modules Two Type B Battery Modules Two Type A Battery Modules Two Type B Battery Modules Two Type A Battery Modules ...

Page 57: ...rom top to bottom The bottom shelf 2st shelf has two Type A modules as shown in Figure 3 29 The bottommost shelf 1st shelf is empty Figure 3 29 Insertion of modules on 1st shelf Module 8 Module 7 Module 6 Module 5 Module 4 Module 3 Module 2 Module 1 Module 9 Module 10 Module 11 Module 12 Module 13 Module 14 Module 15 Module 16 ...

Page 58: ...o assemble the busbars and fuse The fastening torque should be 30 Nm 300 kgf cm After torqueing torque mark the screws using a colored marker or a torque seal When assembling the fuse make sure the red indicator arm on the fuse is facing the front of the unit 1 Assemble the Rack fuse Bus bar assembly Rack fuse bus bar assembly is comprised of one RACKFUSE BUSBAR_R_128S one RACKFUSE BUSBAR_L_128S t...

Page 59: ...Rack Fuse Busbar Assembly Fuse Cover 2 Assemble the Fuse Busbar Left Assembly Fuse Busbar Left Assembly is comprised of one FUSE BUSBAR LEFT UPPER one one FUSE BUSBAR LEFT LOWER two SCREW M12 X 16 two FUSE COVER 2 and one FUSE Figure 3 32 Fuse Busbar Left Assembly ...

Page 60: ...3 Installing the Product 42 English 8 2020 Rev 0 3 Figure 3 33 Fuse Busbar Left Assembly Fuse Cover ...

Page 61: ...Fuse Busbar Right Assembly Fuse Busbar Right Assembly is comprised of one FUSE BUSBAR RIGHT UPPER one one FUSE BUSBAR RIGHT LOWER two SCREW M12 X 16 two FUSE COVER 2 and one FUSE Figure 3 34 Fuse Busbar Right Assembly Figure 3 35 Fuse Busbar Right Assembly Fuse Cover ...

Page 62: ...rminal for the batteries with rack frame There is no evidence of dielectric breakdown because of electrical isolation between the battery positive or negative terminals and rack frame However it is recommended not to touch them for safety because It is possible to touch between battery positive and negative through the rack frame NOTICE Connect the power busbar with an M8 screw for battery module ...

Page 63: ...hing the surface of the busbar apply the grease on the busbar and spread it evenly and thinly on the surface using a wire brush or a dry cloth Refer to Figure 3 37 Conductive Grease on Busbar for the application of the grease on the busbar NOTICE After polishing the busbar make sure the metallic particle does not settle on the electronics Clean the surface with a dry cloth before assembling the bu...

Page 64: ...e Probe Points Battery Module Terminal to Busbar for location of the measurement Use similar probe locations for SMU terminal to busbar contact resistance and fuse to busbar contact resistance Make sure each probe is in contact with only the intended location The contact resistance must be measured below 40μΩ It is recommended to keep the contact resistance in all terminals below 30μΩ Figure 3 38 ...

Page 65: ...39 Removing the Module 1 s Cover and SMU B Terminal Cover 2 Connect SMU B and Module 1 B using BUSBAR M TO SMU SMU B terminal is connected using an M12 screw and Battery Module 1 B terminal is connected using an M8 screw Measure the contact resistance between the terminals and the bus bar Figure 3 40 Connect SMU B and Module 1 B ...

Page 66: ...talling the Product 48 English 8 2020 Rev 0 3 3 Reattach SMU s B terminal cover Figure 3 41 Restore SMU s B Terminal 4 Remove Battery Module 2 s front cover Figure 3 42 Remove Battery Module 2 s Front Cover ...

Page 67: ...US BAR MAIN Connect using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 43 Connect Battery Module 1 B and Battery Module 2 B 6 Reattach Battery Module 1 s front cover and remove Battery Module 3 s front cover Figure 3 44 Reattach Battery Module 1 s Front Cover ...

Page 68: ...Remove Battery Module 2 s Front Cover 7 Connect Battery Module 2 B and Battery Module 3 B using BUS BAR MAIN Connect using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 46 Connect Battery Module 2 B and Battery Module 3 B ...

Page 69: ...Product English 8 2020 Rev 0 3 51 8 Reattach Battery Module 2 s front cover and remove Battery Module 4 s front cover Figure 3 47 Reattach Battery Module 2 s Front Cover Figure 3 48 Remove Battery Module 4 s Front Cover ...

Page 70: ...glish 8 2020 Rev 0 3 9 Connect Battery Module 3 B and Module 4 B using BUS BAR MAIN Connect using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 49 Connect Battery Module 3 B and Module 4 B ...

Page 71: ...roduct English 8 2020 Rev 0 3 53 10 Reattach Battery Module 3 s front cover and remove Battery Module 5 s front cover Figure 3 50 Reattach Battery Module 3 s Front Cover Figure 3 51 Remove Battery Module 5 s Front Cover ...

Page 72: ...2020 Rev 0 3 11 Connect Battery Module 4 B and Battery Module 5 B using BUS BAR MAIN Connect using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 52 Connect Battery Module 4 B and Battery Module 5 B ...

Page 73: ...roduct English 8 2020 Rev 0 3 55 12 Reattach Battery Module 4 s front cover and remove Battery Module 6 s front cover Figure 3 53 Reattach Battery Module 4 s Front Cover Figure 3 54 Remove Battery Module 6 s Front Cover ...

Page 74: ...v 0 3 13 Connect Battery Module 5 B and Battery Module 6 B using FUSE BUSBAR RIGHT ASSEMBLY Connect using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 55 Connect Battery Module 5 B and Battery Module 6 B ...

Page 75: ...roduct English 8 2020 Rev 0 3 57 14 Reattach Battery Module 5 s front cover and remove Battery Module 7 s front cover Figure 3 56 Reattach Battery Module 5 s Front Cover Figure 3 57 Remove Battery Module 7 s Front Cover ...

Page 76: ...2020 Rev 0 3 15 Connect Battery Module 6 B and Battery Module 7 B using BUS BAR MAIN Connect using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 58 Connect Battery Module 6 B and Battery Module 7 B ...

Page 77: ...roduct English 8 2020 Rev 0 3 59 16 Reattach Battery Module 6 s front cover and remove Battery Module 8 s front cover Figure 3 59 Reattach Battery Module 6 s Front Cover Figure 3 60 Remove Battery Module 8 s Front Cover ...

Page 78: ...g BUS BAR MAIN Connect using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 61 Connect Battery Module 7 B and Battery Module 8 B 18 Reattach Battery Modules 7 s front cover and remove Battery Modules 9 s front cover Figure 3 62 Reattach Battery Modules 7 s Front Cover ...

Page 79: ...3 Installing the Product English 8 2020 Rev 0 3 61 Figure 3 63 Remove Battery Modules 9 s Front Cover ...

Page 80: ... FUSE BUSBAR ASSEMBLY Connect using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 64 Connect Battery Module 8 B and Battery Module 9 B 20 Reattach Battery Module 8 s front cover and remove Battery Module 10 s front cover Figure 3 65 Reattach Battery Modules 8 s Front Cover ...

Page 81: ...nnect Battery Module 9 B and Battery Module 10 B using BUS BAR MAIN Connect using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 67 Connect Battery Module 9 B and Battery Module 10 B 22 Reattach Battery Module 9 s front cover and remove Battery Module 11 s front cover ...

Page 82: ...3 Installing the Product 64 English 8 2020 Rev 0 3 Figure 3 68 Reattach Battery Module 9 s Front Cover Figure 3 69 Remove Battery Module 11 s Front Cover ...

Page 83: ...Rev 0 3 65 23 Connect Battery Module 10 B and Battery Module 11 B using BUS BAR MAIN Connect using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 70 Connect Battery Module 10 B and Battery Module 11 B ...

Page 84: ... Product 66 English 8 2020 Rev 0 3 24 Reattach Battery Module 10 s front cover and remove Module 12 s front cover Figure 3 71 Reattach Battery Module 10 s Front Cover Figure 3 72 Remove Battery Module 12 s Front Cover ...

Page 85: ...Rev 0 3 67 25 Connect Battery Module 11 B and Battery Module 12 B using BUS BAR MAIN Connect using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 73 Connect Battery Module 11 B and Battery Module 12 B ...

Page 86: ... the Product 68 English 8 2020 Rev 0 3 26 Reattach Battery Module 11 s front cover and remove Battery Module 13 s front cover Figure 3 74 Reattach Module 11 s Front Cover Figure 3 75 Remove Module 13 s Front Cover ...

Page 87: ...Rev 0 3 69 27 Connect Battery Module 12 B and Battery Module 13 B using BUS BAR MAIN Connect using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 76 Connect Battery Module 12B and Battery Module 13 B ...

Page 88: ... Product 70 English 8 2020 Rev 0 3 28 Reattach Battery Module 12 s front cover and remove Battery Module 14 s front cover Figure 3 77 Reattach Module 12 s Front Cover Figure 3 78 Remove Battery Module 14 s Front Cover ...

Page 89: ... 71 29 Connect Battery Module 13 B and Battery Module 14 B using FUSE BUSBAR LEFT ASSEMBLY Connect using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 79 Connect Battery Module 13 B and Battery Module 14 B ...

Page 90: ...duct 72 English 8 2020 Rev 0 3 30 Reattach Battery Module 13 s front cover and remove Battery Module 15 s front cover Figure 3 80 Reattach Battery Module 13 s Front Cover Figure 3 81 Remove Battery Module 15 s Front Cover ...

Page 91: ...Rev 0 3 73 31 Connect Battery Module 14 B and Battery Module 15 B using BUS BAR MAIN Connect using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 82 Connect Battery Module 14 B and Battery Module 15 B ...

Page 92: ...duct 74 English 8 2020 Rev 0 3 32 Reattach Battery Module 14 s front cover and remove Battery Module 16 s front cover Figure 3 83 Reattach Battery Module 14 s Front Cover Figure 3 84 Remove Battery Module 16 s Front Cover ...

Page 93: ... Rev 0 3 75 33 Connect Battery Module 15 B and Battery Module 16 B using BUS BAR MAIN Connect using M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 85 Connect Battery Module 15 B and Battery Module 16 B ...

Page 94: ...ng the Product 76 English 8 2020 Rev 0 3 34 Reattach Battery Module 15 s front cover and remove SMU s B terminal cover Figure 3 86 Reattach Battery Module 15 s Front Cover Figure 3 87 Remove SMU B Terminal Cover ...

Page 95: ...ted using an M12xL25 screw and Module 16 B terminal is connected using an M8 screw Measure the contact resistance between the terminal and the bus bar Figure 3 88 Connect SMU B and Module 16 B 36 Reattach Battery Module 16 s front cover and SMU B terminal cover Figure 3 89 Reattach Battery Module 16 s Front Cover and SMU B Terminal Cover ...

Page 96: ...roper signal cables as specified by the part numbers below WARNING Rack BMS Module BMS Damage Do not insert both ends of the signal cable WIRE ASSY MODULE TO MODULE 1 or WIRE ASSY MODULE TO MODULE 2 into the same Battery Module 1 Connect the signal cable WIRE ASSY RACK TO MODULE between the SMU MODULE connector and Module 1 Right Connector Figure 3 90 SMU to Module 1 Signal Cable ...

Page 97: ...SY MODULE TO MODULE 1 from Module 1 Left Connector to Module 2 Right Connector Figure 3 91 Module 1 to Module 2 Signal Cabling 3 Connect the signal cable WIRE ASSY MODULE TO MODULE 1 from Module 2 Left Connector to Module 3 Right Connector Figure 3 92 Module 2 to Module 3 Signal Cabling ...

Page 98: ...SY MODULE TO MODULE 1 from Module 3 Left Connector to Module 4 Right Connector Figure 3 93 Module 3 to Module 4 Signal Cabling 5 Connect the signal cable WIRE ASSY MODULE TO MODULE 1 from Module 4 Left Connector to Module 5 Right Connector Figure 3 94 Module 4 to Module 5 Signal Cabling ...

Page 99: ...SY MODULE TO MODULE 1 from Module 5 Left Connector to Module 6 Right Connector Figure 3 95 Module 5 to Module 6 Signal Cabling 7 Connect the signal cable WIRE ASSY MODULE TO MODULE 1 from Module 6 Left Connector to Module 7 Right Connector Figure 3 96 Module 6 to Module 7 Signal Cabling ...

Page 100: ...SY MODULE TO MODULE 1 from Module 7 Left connector to Module 8 Right connector Figure 3 97 Module 7 to Module 8 Signal Cabling 9 Connect the signal cable WIRE ASSY MODULE TO MODULE 2 from Module 8 Left Connector to Module 9 Right Connector Figure 3 98 Module 8 to Module 9 Signal Cabling ...

Page 101: ...ODULE TO MODULE 1 from Module 9 Left Connector to Module 10 Right Connector Figure 3 99 Module 9 to Module 10 Signal Cabling 11 Connect the signal cable WIRE ASSY MODULE TO MODULE 1 from Module 10 Left Connector to Module 11 Right Connector Figure 3 100 Module 10 to Module 11 Signal Cabling ...

Page 102: ...DULE TO MODULE 1 from Module 11 Left Connector to Module 12 Right Connector Figure 3 101 Module 11 to Module 12 Signal Cabling 13 Connect the signal cable WIRE ASSY MODULE TO MODULE 1 from Module 12 Left Connector to Module 13 Right Connector Figure 3 102 Module 12 to Module 13 Signal Cabling ...

Page 103: ...DULE TO MODULE 1 from Module 13 Left Connector to Module 14 Right Connector Figure 3 103 Module 13 to Module 14 Signal Cabling 15 Connect the signal cable WIRE ASSY MODULE TO MODULE 1 from Module 14 Left Connector to Module 15 Right Connector Figure 3 104 Module 14 to Module 15 Signal Cabling ...

Page 104: ...h 8 2020 Rev 0 3 16 Connect the signal cable WIRE ASSY MODULE TO MODULE 1 from Module 15 Left Connector to Module 16 Right Connector No connection to Module 16 Left Connector is needed Figure 3 105 Module 15 to Module 16 Signal Cabling ...

Page 105: ... 2 between each rack s SMU Push the pre punched hole to pass the cable through a circular hole in the side of the rack frame and through the opening above Module 1 and Module 16 NOTICE See the examples for correct signal cable wire connections for both left and right rack alignments Figure 3 106 Pre Punched Hole for Signal Cable ...

Page 106: ...ish 8 2020 Rev 0 3 Signal Cabling Examples of Left Alignment of Trays System BMS on the left Figure 3 107 Signal Cabling Examples of Left Alignment of SMU 18 Turn the termination resistor switch on for the last SMU in the CANbus loop ...

Page 107: ...lish 8 2020 Rev 0 3 89 Figure 3 108 Termination Resistor Setting for Last SMU NOTICE Factory provided cables are adequate for systems with Rack Frames bolted together Different configurations may require cable length modification ...

Page 108: ...8 2020 Rev 0 3 3 10 7 SMPS Assembly and SMU Power Cable Connection Connect the SMU DC power cables Figure 3 109 DC Power Cables from SMPS Assembly 3 Phase Type A to SMU Figure 3 110 DC Power Cables from SMPS Assembly 3 Phase Type B to SMU ...

Page 109: ...cable from the SMPS Assembly to SMU WIRE ASSY RACK TO SYSTEM Figure 3 111 CAN Signal Cable Connection from SMPS Assembly 3 Phase Type A to SMU 2 Connect the MODBUS TCP IP Cable4 to the SMPS Assembly Type A Figure 3 112 TCP IP Cable Connection to SMPS Assembly 3 Connect the Dry Contact Cable to SMPS Assembly Type A 4 Not factory provided Must be provided by the installer or customer ...

Page 110: ...3 Installing the Product 92 English 8 2020 Rev 0 3 Figure 3 113 Dry Contact Cable Connection to SMPS Assembly 4 Optional Connect the SMU MCCB Cable Figure 3 114 MCCB Extra Auxiliary Connection ...

Page 111: ...0 Rev 0 3 93 3 10 9 SMPS Assembly AC Input Connection 1 Remove the protective covers from the AC input terminals Figure 3 115 AC Input Terminals of SMPS Assembly 3 Phase Type A Figure 3 116 AC Input Terminals of SMPS Assembly 3 Phase Type B ...

Page 112: ...3 Installing the Product 94 English 8 2020 Rev 0 3 Figure 3 117 AC Input Terminals of SMPS Assembly 1 Phase Type A Figure 3 118 AC Input Terminals of SMPS Assembly 1 Phase Type B ...

Page 113: ... Make sure the AC cables are not energized 5 Figure 3 119 SMPS Assembly 3 Phase Type A AC Input Terminals with Cables Attached Figure 3 120 SMPS Assembly 3 Phase Type B AC Input Terminals with Cables Attached 5 AC Cables are not factory provided They must be provided by the installer or customer ...

Page 114: ... SMPS Assembly 1 Phase Type A AC Input Terminals with Cables Attached Figure 3 122 SMPS Assembly 1 Phase Type B AC Input Terminals with Cables Attached 3 Reattach the protective covers to the AC input Figure 3 123 AC Input Terminals of SMPS Assembly 3 Phase Type A ...

Page 115: ...3 Installing the Product English 8 2020 Rev 0 3 97 Figure 3 124 AC Input Terminals of SMPS Assembly 3 Phase Type B Figure 3 125 AC Input Terminals of SMPS Assembly 1 Phase Type A ...

Page 116: ...3 Installing the Product 98 English 8 2020 Rev 0 3 Figure 3 126 AC Input Terminals of SMPS Assembly 1 Phase Type B ...

Page 117: ...nnect the ground cables Figure 3 127 Grounding Points 2 EA NOTICE Connect the rack ground wire with an M12 screw Rack ground screws and cables are not factory provided and must be provided by the installer or customer The fastening torque should be 30Nm 300kgf cm 45 mm Pitch Between Holes ...

Page 118: ...is step In this step the battery and UPS are isolated by the SMU because the circuit breaker in the SMU is opened NOTICE Connect the high voltage terminals using an M12 bolt The fastening torque should be 30 Nm 300 kgf cm Figure 3 128 Connecting the DC Link High Current Terminals 3 Special case if connecting the battery system in three wire system connect two racks to the three wire DC bus connect...

Page 119: ...the Product English 8 2020 Rev 0 3 101 After installation is complete check the following Bolt fastening condition Screw fastening torque by sampling High voltage cable connection Module connections SMU connections ...

Page 120: ...3 Installing the Product 102 English 8 2020 Rev 0 3 3 10 11 AC Input Commissioning When the installation of the battery system is complete SMPS Assembly s AC inputs must be powered to turn the BMS on ...

Page 121: ...nd System BMS be done by experienced service personnel Incorrect configuration of the Rack BMS and System BMS will cause communication failure This section has been removed from the customer facing copy of the installation manual 3 10 13 Communication Check This section has been removed from the customer facing copy of the installation manual ...

Page 122: ... access to high voltage parts of the SMU and SMPS Assembly 2 Align the hinges on the rack frame and front door and slide the door down Figure 3 129 Reattaching the Front Door 3 Reattach the earth cable from the rack frame to the front door Figure 3 130 Reattaching the earth cable 4 Close and lock the front door using the provided key Do not misplace the key ...

Page 123: ... hooks that hold the front panel to the slots in the rack frame and insert the front panel to the rack frame Make sure all the hooks are inserted to the slot and the panel is flush with the rack frame before screwing Figure 3 131 Front panel hooks four 3 Screw in the front panel using the provided M5 screws for each front panel Fasten the screws using torque of 5 1 6 1 Nm 50 60 kgf cm Figure 3 132...

Page 124: ...pecification and Operation and Maintenance Manual for information on the indicator LED CAUTION Follow the instruction and guidelines for the UPS on connecting the battery to the UPS before switching on the MCCB The MCCB in the SMU should be in the TRIP position during installation Figure 3 133 MCCB Handle in Trip Position Shift the handle of the MCCB to OFF Figure 3 134 MCCB Handle in Off Position...

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Page 128: ...www SamsungSDI com ...

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Samsung U6A4, Installation Manual

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