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Samsung 93PM Installation Manual
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Samsung 93PM Installation Manual

Samsung 93PM Installation Manual

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LIB System for UPS – U6A4
Installation Manual
(136S)
English 8/2020. Rev 0.3

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Summary of Contents for Samsung 93PM

  • Page 1 LIB System for UPS – U6A4 Installation Manual (136S) English 8/2020. Rev 0.3...
  • Page 2 Read this manual carefully before starting to install the battery system. Keep these instructions for future reference. English 8/2020. Rev 0.3...
  • Page 3 Copyright © 2019 SAMSUNG SDI Co., Ltd. All rights reserved. This document contains information that is the property of SAMSUNG SDI Co., Ltd., and provides for the sole purpose of the installation, operation, and maintenance of products of SAMSUNG SDI Co., Ltd. No part of...
  • Page 4 English 8/2020. Rev 0.3...

  • Page 5: Important Safety Instructions

    Important Safety Instructions Important Safety Instructions Read and follow these instructions! The following precautions are intended to ensure your safety and prevent property damage. Before installing this product, be sure to read all safety instructions in this document for proper installation. DANGER Failure to comply with the instructions with this symbol may result in a serious accident, causing death or a severe injury.

  • Page 6: General Instructions

    Important Safety Instructions General Instructions Please be aware that a battery presents a risk of electrical shock including high short-circuit current. Follow all safety precautions while operating the batteries.  Remove watches, rings, and other metallic accessories.  Use tools with insulated handles in order to avoid inadvertent short circuits. ...

  • Page 7: Personnel And Equipment Warnings

    Important Safety Instructions Personnel and Equipment Warnings Personnel in contact with the battery system should be aware of the following hazards: WARNING—SHOCK HAZARD Do not contact system connectors or terminals. Do not open the enclosure doors unless proper lock out/tag out procedures and related trainings are followed in accordance with the local codes and regulations.

  • Page 8: Lock Out/Tag Out Guidelines

    ESS. The lock out/tag out procedures must meet or exceed the requirements of all guidelines presented in SAMSUNG SDI safety documentation. Before entering potentially hazardous areas or beginning work on the ESS, complete the following tasks: ...
  • Page 9 Important Safety Instructions WARNING To avoid personal injury or equipment damage caused by equipment 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 English 8/2020. Rev 0.3...

  • Page 11: Table Of Contents

    Table of Contents Table of Contents Important Safety Instructions ......................... i General Instructions ............................... ii Safety Precautions ..............................ii Personnel and Equipment Warnings ........................iii Dangerous Voltages .............................. iii Lock Out/Tag Out Guidelines ..........................iv General Warnings ..............................iv Table of Contents ........................... i Tables ..............................

  • Page 12: Table Of Contents

    Table of Contents 3.10.2 SMU and SMPS Assembly Installation ..................... 33 3.10.3 Battery Module Installation ......................37 3.10.4 Fuse-Busbar Assembly ........................40 3.10.5 Busbar Installation ..........................43 3.10.6 Module and SMU Signal Cable Connection ..................79 3.10.7 SMPS Assembly and SMU Power Cable Connection ..............91 3.10.8 SMPS Assembly and SMU Signal Cable Connection ...............

  • Page 13: Tables

    Table of Contents Tables Table 3-1: Estimated time for installation (based on 136S 3P installation) ..............13 Table 3-2: Parts for 136S 3P Rack ........................... 15 Table 3-3: Ground Wire Specifications ........................... 16 Table 3-4: Ground Wire Fastener Specification ......................16 Table 3-5: Rack Fastener Specifications ..........................

  • Page 14: Figures

    Table of Contents Figures Figure 2-1: Battery Module Type A ........................... 5 Figure 2-2: Battery Module Type B ........................... 6 Figure 2-3: SMU ................................7 Figure 2-4: SMPS Assembly Type A ........................... 8 Figure 2-5: SMPS Assembly Type B ........................... 8 Figure 2-6: Rack Frame ..............................
  • Page 15 Table of Contents Figure 3-49: Connect Battery Module #3 B+ and Module #4 B-..................51 Figure 3-50: Reattach Battery Module #3’s Front Cover ....................52 Figure 3-51: Remove Battery Module #5’s Front Cover....................52 Figure 3-52: Connect Battery Module #4 B+ and Battery Module #5 B-................. 53 Figure 3-53: Reattach Battery Module #4’s Front Cover ....................
  • Page 16 Table of Contents Figure 3-107: Module #14 to Module #15 Signal Cabling ....................86 Figure 3-108: Module #15 to Module #16 Signal Cabling ....................87 Figure 3-109: Module #16 to Module #17 Signal Cabling ....................87 Figure 3-110: Pre-Punched Hole for Signal Cable ......................88 Figure 3-111: Signal Cabling Examples of Left Alignment of SMU ..................
  • Page 17 Table of Contents English 8/2020. Rev 0.3...

  • Page 19: About This Manual

    About this Manual 1. About this Manual To make sure that you understand the proper procedures for safe operation, this section briefly describes the purpose, audience, organization, revision history, and acronyms and abbreviations. 1.1 Purpose The purpose of this manual is to provide information for the safe and successful installation of the product The instructions in this manual are based on assembly of a three-cabinet system.

  • Page 20: Revision History

    About this Manual 1.4 Revision History Rev. Description Author Date First Draft 2019.08.20 Revised module voltage check level. SMU Auxiliary switch and SMPS Status 2019.09.05 auxiliary contact electrical ratings added (Table 2 1, Table 2 11) Updated Table 3-7: Recommended Tools and Instruments Revised Table 3-2: Parts for 136S 3P Rack...

  • Page 21: Acronyms And Abbreviations

    About this Manual 1.5 Acronyms and Abbreviations The following acronyms and abbreviations are used in this manual. Abbreviations Full Name Automated External Defibrillator Battery Management System Environmental Health and Safety Energy Storage System LOTO LOCK OUT/TAG OUT Overtemperature Overvoltage Protection Power Conversion System String Management Unit SMPS...

  • Page 22: Product Description

    Product Description 2. Product Description Check the components for installation. For more information, please 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) ...

  • Page 23: Battery Module (Type A / Type B)

    Product Description 2.1.1 Battery Module (Type A / Type B) Battery Module is the most basic component of the Battery System and it contains the energy storing battery cells. There is a Module BMS inside each Battery Module. Module BMS checks the status of a Battery Module by measuring its voltage and temperature.

  • Page 24: Figure 2-2: Battery Module Type B

    Product Description Battery Module Type B (Isometric) Battery Module Type B (Front. Front cover removed) Figure 2-2: Battery Module Type B English 8/2020. Rev 0.3...

  • Page 25: Smu (String Management Unit)

    Product Description 2.1.2 SMU (String Management Unit) SMU collects all information about the battery system and controls the battery system by switching the main power line and controls each Battery Module by cell balancing. SMU calculates the state-of-charge (SOC) and state- of-health (SOH) of the battery system.

  • Page 26: Smps Assembly (Type A / Type B)

    Product Description 2.1.3 SMPS Assembly (Type A / Type B) 3-Phase Type A (with System BMS): V044-0006AA 3-Phase Type B (without System BMS): SJ94-00238B 1-Phase Type A (with System BMS): V044-0004AA 1-Phase Type B (without System BMS): V044-0005AA SMPS Assembly houses the System BMS and SMPS, which provides power to the System BMS and SMU. Two options are available for the SMPS depending on the AC input range and cabling: 3 phase and 1 phase.

  • Page 27: Rack Frame

    Product Description 2.1.4 Rack Frame Black: V808-00068A The Rack Frame is used to mount the modules, SMU and 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.

  • Page 28: Installing The Product

    Grounding is required to prevent electric shock hazards and reduce or eliminate damage caused by electrical noise. Ground connections and ground wire routing vary significantly depending on system configuration and equipment layout. Samsung provides grounding strip on top of each rack. See Figure 3-131: Grounding Points (2 EA). English 8/2020. Rev 0.3...

  • Page 29: Arc Flash Calculations

    Installing the Product 3.2 Arc Flash Calculations Arc flash related calculation of the battery system is estimated with the Direct-Current Incident Energy Calculations referenced in Informative Annex D of NFPA 70E Standard for Electrical Safety in the Workplace. The following battery system is assumed to estimate the worst-case scenario Battery configuration: 136S Battery voltage: 571.2V Battery internal resistance (AC IR): 65mohm...

  • Page 30: Installation Procedure

    Installing the Product 3.3 Installation Procedure This product must be installed by following the procedure below: 3. Rack 1. Preparation 2. Rack Anchoring 4. System Installation Stage Stage Installation Stage Stage Figure 3-1: Installation Procedure  Preparation Stage  Procedure ...

  • Page 31: Table 3-1: Estimated Time For Installation (Based On 136S 3P Installation)

    Installing the Product Table 3-1: Estimated time for installation (based on 136S 3P installation) Estimated Time Aggregated Time Step (HH:MM) (HH:MM) Unpacking 00:30 00:30 Inspection 01:00 01:30 Rack Anchoring 04:00 05:30 Battery Module 00:20 05:50 00:10 06:00 SMPS Assembly 00:10 06:10 Rack Fuse Assembly 00:30...

  • Page 32: Preparation Stage-Procedure

    Installing the Product 3.4 Preparation Stage—Procedure For the preparation stage, perform the following steps: 1. Create the installation plan and check the equipment and instruments for installation. 2. Check the arrival schedule of the parts required. 3. Unpack the equipment. 4.

  • Page 33: Preparation Stage-Unpacking

    Installing the Product 3.5 Preparation Stage—Unpacking Check the following parts during unpacking: Table 3-2: Parts for 136S 3P Rack Amount Items Part No. Remarks (Unit: EA) RACK FRAME V808-00068A Black BATTERY MODULE Type A EM2031AE003A BATTERY MODULE Type B EM2031AE004A V049-0011AA SMPS ASSEMBLY Type A V044-0004AA (1 Phase)

  • Page 34: Preparation Stage-Ground Wire And Tools

    Installing the Product 3.6 Preparation Stage—Ground Wire and Tools Ground wires for the racks must be provided by the installer. Installer-supplied ground wires must meet the specifications below. Refer to 3.1 Grounding the Battery System for details on grounding. 3.6.1 Ground Wires Use ground wire that is 70 sq mm.

  • Page 35: Preparation Stage-Recommended Tools/Instruments

    Installing the Product 3.7 Preparation Stage—Recommended Tools/Instruments Installers must provide these tools for installing the battery: Table 3-7: Recommended Tools and Instruments Items Usage Appearance To fasten SMU and SMPS assemblies to Power Screwdriver/Drill the rack frames (Max torque: 26Nm/270 kgf/cm) (5.1–6.1Nm/50–60 kgf/cm) Torque Limiter For use with torque wrench...
  • Page 36 Installing the Product Items Usage Appearance Measure battery module’s voltage and internal impedance Hioki BT3554, Fluke BT521 or meters with the same or better voltage and resistance measurement resolution and accuracy is recommended. - Voltage resolution: 1mV - Voltage accuracy: ±0.1% of reading Battery Tester - Resistance resolution: 0.001mΩ...

  • Page 37: Preparation Stage-Visual Inspection

    Installing the Product 3.8 Preparation Stage—Visual Inspection CAUTION  If any defects are found during the inspection, contact the SAMSUNG SDI customer service department. 3.8.1 Inspection of the Rack Frame After transporting the rack frame to the installation location, check for: ...

  • Page 38: Inspecting The Smps Assembly

    Installing the Product 3.8.4 Inspecting the SMPS assembly 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: Rack Anchoring Stage

    Installing the Product 3.9 Rack Anchoring Stage Install the rack frame on a flat, level surface.  To attach the rack and perform the related works CAUTION  Use a proper transportation method considering the weight of the rack frame. ...

  • Page 40: Figure 3-2: Clearance Distance For Single Rack Frame

    Installing the Product Configuration Anchor points per rack Clearance Distance (mm) Side (end) Side (adjacent) Rear Front Multiple Racks 2 (Front) Workable distance (Side-to-Side not rated for seismic event (1000 recommended) and Rear-to- 4 (All) – Telcordia Zone 4 Workable distance Workable distance Workable distance Rear)

  • Page 41: Figure 3-4: Clearance Distance For Multiple Rack Frames Installed Side-By-Side And Rear-To-Rear

    Installing the Product Two anchor points (not rated for seismic event) Four anchor points (Telcordia Zone 4) Figure 3-4: Clearance Distance for Multiple Rack Frames Installed Side-by-Side and Rear-to-Rear 1. After unpacking the rack frame, transport it to its installation location. 2.

  • Page 42: Figure 3-6: Front Panel Hooks (Four)

    Installing the Product Figure 3-6: Front panel hooks (four) Figure 3-7: Side panel screws (six) English 8/2020. Rev 0.3...

  • Page 43: Figure 3-8: Side Panel Hooks (Four)

    Installing the Product Figure 3-8: Side panel hooks (four) Figure 3-9: Rear panel screws (eight) English 8/2020. Rev 0.3...

  • Page 44: Figure 3-10: Rear Panel Hooks (Four)

    Installing the Product Figure 3-10: Rear panel hooks (four) 3. Arrange the rack frame after verifying that the 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.

  • Page 45: Figure 3-12: Holes On The Sides Of The Rack (Six)

    Installing the Product 5. Connect the racks together using M10 hardware through holes in the sides (“SCREW M10 X 25,” “M10 FLAT WASHER” and “NUT M10”). Torque the bolts to 30Nm (300kgf cm). Figure 3-12: Holes on the sides of the rack (six) 6.

  • Page 46: Figure 3-13: Reattaching The Side Panels (Four Hooks And Six Screws For Each Panel)

    Installing the Product Figure 3-13: Reattaching the Side Panels (four 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: Figure 3-14: Reattaching The Rear Panels

    Installing the Product Figure 3-14: Reattaching the Rear Panels 8. Front panels will be reattached after all the components are installed. English 8/2020. Rev 0.3...

  • Page 48: Rack Installation Stage

    Installing the Product 3.10 Rack Installation Stage WARNING Arc Flash and Shock Hazard Insulated tools are required for any 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.

  • Page 49: Front Door Removal

    Installing the Product 3.10.1 Front Door Removal 1. Open the front 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.

  • Page 50: Figure 3-17: Removing The Front Door

    Installing the Product 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. English 8/2020. Rev 0.3...

  • Page 51: Smu And Smps Assembly Installation

    Installing the Product 3.10.2 SMU and SMPS Assembly Installation Important  Attach each SMU to its rack frame with four M5 x 10L screws. (Torque: 5.1–6.1 Nm [50–60 kgf cm])  Verify 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.

  • Page 52: Figure 3-21: Ground Cable Connection To The Smu

    Installing the Product 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 English 8/2020.

  • Page 53: Figure 3-22: Inserting Smps Assembly

    Installing the Product 4. Insert SMPS Assembly into the rack frames designated for SMPS Assembly as shown in Figure 3-22: Inserting SMPS Assembly Important  Attach the inserted SMPS Assemblies to the rack frames by fastening each with four M5 x 10Lscrews ...

  • Page 54: Figure 3-24: Ground Cable Connection To The Smps Assembly

    Installing the Product 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 English 8/2020.

  • Page 55: Battery Module Installation

    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.) ...

  • Page 56: Figure 3-26: Battery Module Arrangement On The Eighth Shelf

    Installing the Product Two Type A Battery Modules Figure 3-26: Battery Module Arrangement on the Eighth Shelf 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: Figure 3-28 : Module Number

    Module #9 Figure 3-28 : Module Number Important  Samsung recommends installing modules from top to bottom.  The bottom shelf (1 shelf) has one Type B module in the left slot, as shown in Figure 3-29. Figure 3-29: Insertion of modules on 1st shelf...

  • Page 58: Fuse-Busbar Assembly

    Installing the Product 3.10.4 Fuse-Busbar Assembly Three types of fuse-busbar assemblies must be assembled before installing them to the Battery Modules. NOTICE  Rack Fuse Busbar Assembly is assembled at the installation location.  M12 X 16L screws are used to assemble the busbars and fuse. ...

  • Page 59: Figure 3-32: Fuse Busbar Left Assembly

    Installing the Product 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 Figure 3-33: Fuse Busbar Left Assembly (Fuse Cover) English 8/2020.

  • Page 60: Figure 3-34: Fuse Busbar Right Assembly

    Installing the Product 3. Assemble the 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) English 8/2020.

  • Page 61: Busbar Installation

    Installing the Product 3.10.5 Busbar Installation Connect the power busbars between modules Verify with a voltmeter that no power is present on the system. Use lock out/tag out procedures to secure the UPS and batteries. CAUTION  Please follow the instructions to protect the module BMS against damage. ...

  • Page 62: Figure 3-36: Copper Busbar Appearance

    Clean the surface with a dry cloth before assembling the busbar to the terminal. NOTICE  As a reference, grease used by Samsung SDI for internal testing is “Ox-Gard Anti-Oxidant Compound OX-400N”. Electrical conductivity, thermal and chemical characteristics of the grease must be properly checked and tested before use.

  • Page 63: Figure 3-38: Contact Resistance Probe Points (Battery Module Terminal To Busbar)

    Installing the Product NOTICE  After connecting the busbar to the terminals (battery module, SMU, fuse), measure the contact resistance between the terminals and the busbars using a low resistance meter. Refer to Figure 3-38: Contact Resistance Probe Points (Battery Module Terminal to Busbar) for location of the measurement.

  • Page 64: Figure 3-39: Removing The Module #1'S Cover And Smu B- Terminal Cover

    Installing the Product 1. Remove Battery Module #1’s front cover and the SMU B- terminal cover. Figure 3-39: 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.

  • Page 65: Figure 3-41: Restore Smu's B- Terminal

    Installing the Product 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 English 8/2020. Rev 0.3...

  • Page 66: Figure 3-43: Connect Battery Module #1 B+ And Battery Module #2 B

    Installing the Product 5. Connect Battery Module #1 B+ and Module #2 B- using “BUS-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.

  • Page 67: Figure 3-45: Remove Battery Module #2'S Front Cover

    Installing the Product Figure 3-45: 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 68: Figure 3-47: Reattach Battery Module #2'S Front Cover

    Installing the Product 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 English 8/2020. Rev 0.3...
  • Page 69 Installing the Product 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-. English 8/2020.
  • Page 70 Installing the Product 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 English 8/2020. Rev 0.3...
  • Page 71 Installing the Product 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-. English 8/2020.
  • Page 72 Installing the Product 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 English 8/2020. Rev 0.3...
  • Page 73 Installing the Product 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-. English 8/2020.
  • Page 74 Installing the Product 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 English 8/2020. Rev 0.3...
  • Page 75 Installing the Product 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- English 8/2020.
  • Page 76 Installing the Product 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 English 8/2020. Rev 0.3...
  • Page 77 Installing the Product 17. Connect Battery Module #7 B+ and Battery Module #8 B- using “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.
  • Page 78 Installing the Product Figure 3-63: Remove Battery Modules #9’s Front Cover English 8/2020. Rev 0.3...
  • Page 79 Installing the Product 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.
  • Page 80 Installing the Product Figure 3-66: Remove Battery Modules #10’s Front Cover 21. Connect 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-.
  • Page 81 Installing the Product Figure 3-68: Reattach Battery Module #9’s Front Cover Figure 3-69: Remove Battery Module #11’s Front Cover English 8/2020. Rev 0.3...
  • Page 82 Installing the Product 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-. English 8/2020.
  • Page 83 Installing the Product 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 English 8/2020. Rev 0.3...
  • Page 84 Installing the Product 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-. English 8/2020.
  • Page 85 Installing the Product 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 English 8/2020. Rev 0.3...
  • Page 86 Installing the Product 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-. English 8/2020.
  • Page 87 Installing the Product 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 English 8/2020. Rev 0.3...
  • Page 88 Installing the Product 29. Connect Battery Module #13 B+ and Battery Module #14 B- using “BUS-BAR MAIN.” 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-. English 8/2020.
  • Page 89 Installing the Product 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 English 8/2020. Rev 0.3...
  • Page 90 Installing the Product 31. Connect Battery Module #14 B+ and Battery Module #15 B- using “FUSE BUSBAR LEFT ASSEMBLY.” 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-. English 8/2020.
  • Page 91 Installing the Product 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 English 8/2020. Rev 0.3...
  • Page 92 Installing the Product 33. Connect Battery Module #15 B+ and Battery Module #16 B- using “BUS-BAR MAIN.” Connect using an 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-. English 8/2020.
  • Page 93 Installing the Product 34. Reattach Battery Module #15’s front cover and remove Battery Module #17’s front cover. Figure 3-86: Reattach Battery Module #15’s Front Cover Figure 3-87: Remove Battery Module #17’s Front Cover English 8/2020. Rev 0.3...
  • Page 94 Installing the Product 35. Connect Battery Module #16 B+ and Battery Module #17 B- using “BUS-BAR MAIN”. Connect using M8 screw. Measure the contact resistance between the terminal and the bus bar. Figure 3-88: Connect Battery Module #16 B+ and Battery Module #17 B-. English 8/2020.
  • Page 95 Installing the Product 36. Reattach Battery Module #16’s front cover and remove SMU’s B+ terminal cover. Figure 3-89: Reattach Battery Module #15’s Front Cover Figure 3-90: Remove SMU B+ Terminal Cover English 8/2020. Rev 0.3...
  • Page 96 Installing the Product 37. Connect SMU B+ and Battery Module #17 B+ using “BUSBAR M TO SMU.” SMU B+ terminal is connected using an M12xL25 screw and Module #17 B+ terminal is connected using an M8 screw. Measure the contact resistance between the terminal and the bus bar.

  • Page 97: Module And Smu Signal Cable Connection

    Installing the Product 3.10.6 Module and SMU Signal Cable Connection Connect the signal cables for SMU and Module BMS’s for each module. NOTICE  Use the proper 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.
  • Page 98 Installing the Product Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #1 “Left Connector” to Module #2 “Right Connector.” Figure 3-94: Module #1 to Module #2 Signal Cabling Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #2 “Left Connector” to Module #3 “Right Connector.”...
  • Page 99 Installing the Product Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #3 “Left Connector” to Module #4 “Right Connector.” Figure 3-96: Module #3 to Module #4 Signal Cabling Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #4 “Left Connector” to Module #5 “Right Connector.”...
  • Page 100 Installing the Product Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #5 “Left Connector” to Module #6“Right Connector”. Figure 3-98: Module #5 to Module #6 Signal Cabling Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #6 “Left Connector” to Module #7 “Right Connector.”...
  • Page 101 Installing the Product Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #7 “Left connector” to Module #8 “Right connector”. Figure 3-100: Module #7 to Module #8 Signal Cabling Connect the signal cable “WIRE ASSY MODULE TO MODULE #2" from Module #8 “Left Connector” to Module #9 “Right Connector.”...
  • Page 102 Installing the Product Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #9 “Left Connector” to Module #10 “Right Connector.” Figure 3-102: Module #9 to Module #10 Signal Cabling Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #10 “Left Connector” to Module #11 “Right Connector.”...
  • Page 103 Installing the Product Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #11 “Left Connector” to Module #12 “Right Connector.” Figure 3-104: Module #11 to Module #12 Signal Cabling Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #12 “Left Connector” to Module #13 “Right Connector.”...
  • Page 104 Installing the Product Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #13 “Left Connector” to Module #14 “Right Connector.” Figure 3-106: Module #13 to Module #14 Signal Cabling Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #14 “Left Connector” to Module #15 “Right Connector.”...
  • Page 105 Installing the Product Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #15 “Left Connector” to Module #16 “Right Connector.” Figure 3-108: Module #15 to Module #16 Signal Cabling Connect the signal cable “WIRE ASSY MODULE TO MODULE #1" from Module #16 “Left Connector” to Module #17 “Right Connector”.
  • Page 106 Installing the Product For a multiple rack system, connect the signal cables “WIRE ASSY RACK TO RACK #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.
  • Page 107 Installing the Product Signal Cabling Examples of Left Alignment of Trays (System BMS on the left) Figure 3-111: Signal Cabling Examples of Left Alignment of SMU Turn the termination resistor switch on for the last SMU in the CANbus loop. English 8/2020.
  • Page 108 Installing the Product Figure 3-112: 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. English 8/2020. Rev 0.3...

  • Page 109: Smps Assembly And Smu Power Cable Connection

    Installing the Product 3.10.7 SMPS Assembly and SMU Power Cable Connection Connect the SMU DC power cables. Figure 3-113: DC Power Cables from SMPS Assembly 3 Phase Type A to SMU Figure 3-114: DC Power Cables from SMPS Assembly 3 Phase Type B to SMU English 8/2020.

  • Page 110: Smps Assembly And Smu Signal Cable Connection

    Installing the Product 3.10.8 SMPS Assembly and SMU Signal Cable Connection The following steps are only for an SMPS Assembly Type A. 1. Connect the signal cable from the SMPS Assembly to SMU “WIRE ASSY RACK TO SYSTEM.” Figure 3-115: CAN Signal Cable Connection from SMPS Assembly 3 Phase Type A to SMU 2.
  • Page 111 Installing the Product Figure 3-117: Dry Contact Cable Connection to SMPS Assembly 4. Optional: Connect the SMU MCCB Cable. Figure 3-118: MCCB Extra Auxiliary Connection English 8/2020. Rev 0.3...

  • Page 112: Smps Assembly Ac Input Connection

    Installing the Product 3.10.9 SMPS Assembly AC Input Connection 1. Remove the protective covers from the AC input terminals. Figure 3-119: AC Input Terminals of SMPS Assembly 3 Phase Type A Figure 3-120: AC Input Terminals of SMPS Assembly 3 Phase Type B English 8/2020.
  • Page 113 Installing the Product Figure 3-121: AC Input Terminals of SMPS Assembly 1 Phase Type A Figure 3-122: AC Input Terminals of SMPS Assembly 1 Phase Type B English 8/2020. Rev 0.3...
  • Page 114 Installing the Product 2. Connect each AC input in the SMPS Assembly. Make sure the AC cables are not energized. Figure 3-123: SMPS Assembly 3 Phase Type A - AC Input Terminals with Cables Attached Figure 3-124: SMPS Assembly 3 Phase Type B - AC Input Terminals with Cables Attached AC Cables are not factory-provided.
  • Page 115 Installing the Product Figure 3-125: SMPS Assembly 1 Phase Type A - AC Input Terminals with Cables Attached Figure 3-126: SMPS Assembly 1 Phase Type B - AC Input Terminals with Cables Attached 3. Reattach the protective covers to the AC input. Figure 3-127: AC Input Terminals of SMPS Assembly 3 Phase Type A English 8/2020.
  • Page 116 Installing the Product Figure 3-128: AC Input Terminals of SMPS Assembly 3 Phase Type B Figure 3-129: AC Input Terminals of SMPS Assembly 1 Phase Type A English 8/2020. Rev 0.3...
  • Page 117 Installing the Product Figure 3-130: AC Input Terminals of SMPS Assembly 1 Phase Type B English 8/2020. Rev 0.3...

  • Page 118: Dc Link Cable Connection

    Installing the Product 3.10.10 DC Link Cable Connection 1. Connect the ground cables. 45 mm Pitch Between Holes Figure 3-131: 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.
  • Page 119 Installing the Product 2. Connect the DC link high-voltage terminals from the UPS. CAUTION  Verify with a voltmeter that no power is present on the system. Disconnect all input power supplies. Use lock out/tag out procedures to secure the UPS and battery system before beginning this step.
  • Page 120 Installing the Product After installation is complete, check the following:  Bolt fastening condition  Screw fastening torque by sampling  High-voltage cable connection  Module connections  SMU connections English 8/2020. Rev 0.3...

  • Page 121: Ac Input Commissioning

    Installing the Product 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. English 8/2020. Rev 0.3...

  • Page 122: Bms Configuration

    Installing the Product 3.10.12 BMS Configuration NOTICE  It is recommended that the configuration of the Rack BMS and 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.

  • Page 123: Reinstall The Front Door

    Installing the Product 3.10.14 Reinstall the Front Door 1. Reinstall the front door to cover the battery rack and prevent further 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 3-133: Reattaching the Front Door 3.

  • Page 124: Reinstall The Front Panel

    Installing the Product 3.10.15 Reinstall the Front Panel 1. Reinstall the front panel to cover the battery rack and prevent further access to high voltage parts of the battery modules. 2. Locate the 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.

  • Page 125: Switching On The Mccb

    Installing the Product 3.10.16 Switching on the MCCB After powering on the battery system’s SMPS Assembly and SMU, and configuring the System BMS and the Rack BMS according to the installation, check the indicator LED to determine whether the system status is normal. Refer to the “Product Specification”...
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  • Page 129 www.SamsungSDI.com...

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