Written by Revision No.

Date
Ryan Shin Rev0 21-July-2021
Approved by Description
JS Lee LIB Rack Installation Manual for UPS(LIBS-3W)

M4864P6B Battery Rack Installation Manual

For 3-wire UPS

History of Manual Revision

Date Revision Editor Remarks

1
 Contents
1. Overview................................................................................................................................................................................................. 4

1.1 Battery Rack’s characteristics ................................................................................................................................................ 4

1.2 Important Safety Instructions ............................................................................................................................................... 4

1.3 Validity ............................................................................................................................................................................................. 5

2. Safety Instructions ............................................................................................................................................................................. 5

2.1 General Precautions .................................................................................................................................................................. 5

2.2 Operators Hurt by Battery Related Accidents .............................................................................................................. 7

2.3 Warning Labels and Symbols ............................................................................................................................................... 7

2.4 Battery Pack Drop Case........................................................................................................................................................... 8

3. Exclusion of Product Warranty .................................................................................................................................................... 9

4. Preparation for Rack Installation ............................................................................................................................................. 10

4.1 Major Components and Equipment ............................................................................................................................... 10

4.2 Consumable Tools .................................................................................................................................................................. 14

4.3 Major Tools and Equipment .............................................................................................................................................. 15

4.4 Arrangement of Major Components and Inspection ............................................................................................. 17

4.5 Building Floor Load Capacity ............................................................................................................................................. 18

4.6 Rough Alignment of Junction Rack and Battery Racks ......................................................................................... 18

4.7 Arrangement for Pack Fan Cables................................................................................................................................... 18

5. Installation .......................................................................................................................................................................................... 19

5.1 Precise Alignment of Racks and Cable Duct Installation ..................................................................................... 19

5.2 BPU Mounting .......................................................................................................................................................................... 21

5.3 Cable Connections to BPU ................................................................................................................................................. 22

5.4 Cable Connection between Junction Rack and Battery Rack ............................................................................. 23

5.5 Battery Pack Mounting and Busbar Connection ...................................................................................................... 25

5.6 Communication Cable Connection (RBMS-PBMS and PBMS-PBMS) ............................................................. 27

5.7 BBMS BOX Installation, RBMS-BBMS Connection and DC 24V Cable Connection ................................. 30

5.8 RBMS – RBMS Connection in Separate Battery Racks .......................................................................................... 32

5.9 Attaching Rack Front Door and Rack Side Panel .................................................................................................... 35
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6. Inspection ........................................................................................................................................................................................... 36

6.1 Rack Level Inspection ........................................................................................................................................................... 36

6.2 Bank Level Inspection ........................................................................................................................................................... 38

6.3 System Level Inspection ...................................................................................................................................................... 39

7. Appendix ............................................................................................................................................................................................. 41

7.1 Checklist ....................................................................................................................................................................................... 41

7.2 Battery Rack System Diagram .......................................................................................................................................... 47

7.3 Contact Information .............................................................................................................................................................. 47

Figures

Figure 1. Fan cables ready ---18

Figure 2. Battery Rack ---19
Figure 3. Rack Alignment and Cable Duct Installation ---20
Figure 4. Figure 4. RBMS Mounted onto BPU ---21
Figure 5. BPU Mounting ---22
Figure 6. DC cables drawn down and Fan cables connected to BPU ---23
Figure 7. Cable connection between Junction Rack and Battery Rack ---24
Figure 8. Battery Pack Mounted onto Battery Rack ---25
Figure 9. Battery Mounting and Busbar Connection ---27
Figure 10. BMS Diagram-1 ---28
Figure 11. Battery Pack ---28
Figure 12. Communication Cable Connection (RBMS-PBMS and PBMS-PBMS) ---29
Figure 13. BBMS Box Connection Diagram ---30
Figure 14. BBMS BOX installation, BBMS -RBMS and 24Vdc Cable Connection ---31
Figure 15. BMS Diagram-2 ---32
Figure 16. RBMS-RBMS Connection ---34
Figure 17. Rack Front Door Attached ---35
Figure 18. Rack Side Panel Attached ---35

Tables

Table 1. Major Components and Equipment List ---10

Table 2. Consumable Tools List ---14
Table 3. Major Tools and Equipment List ---15

3
1. Overview

This manual is intended for installation of EON made Battery Rack comprised of LG Energy Solution’s
batteries(M4864P6B). The connection of DC bus on UPS and Batteries is based on 3 wires (negative,
positive and neutral). This installation manual is basically for 10 battery packs in series on each battery
rack.
Any queries regarding this installation manual should be sent to EON Co., Ltd.
Contact information on EON is shown at the end of this manual.

1.1 Battery Rack’s characteristics

1.1.1 Electrical characteristics of battery rack (Model Name: LIBS-3W)

- Main Circuit: 420-581Vdc, 128A (Max Charging),275A(Max Discharging)

- Control Circuit: 220-240Vac, 50Hz/60Hz, 0.8A

- Short circuit current : 4kA

- Earthing system for rack system follows TT, TNCS or TNS according to IEC 60364.

1.1.2 Other Characteristics of Battery Rack

- Protective class : Class 1

- Enclosure rating : IP 20

- Reference to standards : EN 62477-1 and EN 61000-6-2, 61000-6-4

- The connection between DC BUS on UPS and batteries is based on 3 wires.

1.2 Important Safety Instructions

Battery packs and racks should be installed by the third party who are authorized by EON.
The third party above means the person or the company who has been trained for the installation and
safety of battery packs, racks, etc. by EON

4
1.3 Validity

LG Energy Solution’s battery packs and racks are intended and warranted for installation as detailed in
this manual. Any violation of the installation procedures and use of the products for the purposes other
than those here mentioned could damage the products and they would not be warranted in that case.

2. Safety Instructions

All users/operators handling the battery packs and racks should carefully read warning symbols and
precautions attached to the battery packs and racks.

2.1 General Precautions

2.1.1 Handling

Do not place battery packs on flammable materials, in areas where they are stored, in potentially explosive
environments, or in high humid circumstances.

Do not stack any objects on battery packs.

Do not touch or use a battery pack if liquid is spilled on it.

Do not damage battery packs in a way of dropping, deforming, impacting, cutting or penetrating.

Make sure that the battery pack is maintained with its top surface facing upward.

Do not eat, drink, chew or smoke in the area where the battery packs are stored or installed.

2.1.2 Environmental factors and Installation

Ensure the ambient temperature in the place where the battery is placed should range from 0°C to 50°C
and the range of relative humidity should be between 5 and 85% without condensation.
The room should be maintained between 18 to 28℃ and have a relative humidity of between 5 and 85%
without condensation while the batterie are in operation.
This manual can apply to the installation of battery rack system which could only be located 2000 meters
or less above sea level.

5
 2.1.3 Hazardous Situations

The operator/user touching batteries and rack system should be cautious of following hazards.

- Electric shock
Warning – Do not contact any kinds of electrical conductors, connectors and terminals below which are
energized and may cause electric shock.
Positive, negative and neutral terminal of BPU (Battery Protection Unit)
Positive and negative terminals of battery packs
Busbar1(LIBS-BBAR01) and Busbar2(LIBS-BBAR02)
Terminals of AC 230Vac
Incoming and outgoing terminals of DC MCCB on BPU

- Fire
Warning — Place the fire extinguisher near the battery installed.
In the event of battery fire, use NOVEC 1230, FM-200 or CO2 fire extinguisher.
If the fire has not been caused by and not spread to the battery, use ABC fire extinguisher.

- Pinch points
Precaution — There are several pinch points on the rack system. While the workers are doing installation
work of the rack system, they should be wary of getting injured.

- Static
Precaution — Static may damage the electrical equipment. The workers wear static release wristband and
remove the static electricity through touching the earthing system nearby.

- Back injury or physical damage to the worker

Precaution –Battery pack, BPU and rack should be moved in groups of two. Battery pack and BPU should
be lifted by two people to prevent back, wrist or other injuries.

6
 2.2 Operators hurt by Battery related Accidents

Should workers be exposed to chemical materials inside battery cell such as electrolyte, following
procedure should be applied.

2.2.1 Inhalation : Immediately escape from the contaminated area and seek medical attention.

2.2.2 Eye contact: Immediately get the affected eyes flushed with a stream of water for 15 minutes and
seek medical attention.

2.2.3 Ingestion: Immediately induce vomiting and seek medical attention.

2.3 Warning Labels and Symbols

7
 LG ES

2.4 Battery Pack Drop Case

Battery packs should be carefully handled and any impact or mechanical load could cause damage to
them. In case of a battery pack dropped during the installation, storage or moving, the following steps
should be followed.

[Step 1]: Visual inspection

Minimum of 20 minutes of detailed physical inspection should be done whether there is heat generation,
smoke or liquid leakage.
If a faulty condition like smoke, leakage, holes, etc is found, dispose of the damaged batteries as per the

8
waste disposal procedure locally regulated. Should any of damages not be detected, proceed to step 2.

[Step 2]: Voltage check

The battery installer should check the voltage though voltmeter connecting its lead to positive and
negative terminal respectively. The installer should wear protective equipment such as insulation gloves
and must not touch the metal base plate assembly.

[Step 3]: Return

Although a battery pack is in normal condition, it should be sent to HQ of EON in Korea. Batteries that
have failed the voltage check should have a “V” mark on the top of the packaging box.
Only authorized LG Energy Solution engineers could disassemble the battery pack to inspect components
inside.

[Step 4]: Storage

The battery pack that is considered damaged one should be kept out of installation place.
Do not let the battery pack face direct sunlight or rain.

3. Exclusion of Product Warranty

If the battery packs and rack system have been damaged by the following reasons, warranty claims and
liability for the damage are denied.

- Damage during storage and transportation

- Incorrect installation

- Operation of the battery rack system in an inappropriate environment

- Improper use or operation

- Insufficient ventilation of the place where battery installed

- Neglecting/ignoring applicable safety warnings and installation manual

- Any attempted repairs or product modifications by unauthorized personnel

- Force majeure such as natural disasters, wars, strikes and riots

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4. Preparation for Rack Installation

4.1 Major Components and Equipment

Major materials are shown below on the template.

Name Material Figure Description

Code
Battery Rack LIBS- 600 x 650 x 2100
BR6521 120kg

Battery Pack LIBS- 445 x 344 x 110

M4864 28kg

BPU LIBS- BPU consists of MCCB, Fuse,

BPU3W Magnetic Contactor, SMPS,
RBMS and others.
35kg

BBMS Box LIBS-BBOX BBMS Box consists of BBMS,

SMPS and power switch

Bolt for LIBS- Self-tapping screw for BBMS

BBMS Box BBSCREW BOX. M5
BBMS LIBS-BBMS BBMS is separately provided

10
RBMS LIBS-RBMS RBMS is separately provided

Cable Duct LIBS-CD DC main and AC cables run

through it

Side Panel LIBS-SP For far left and far right rack

Busbar 1 LIBS- Connecting battery packs in

BBAR01 series
20x4T,80sq

Busbar 2 LIBS- Connection between BPU

BBAR02 Positive and Positive of
Battery #1

Busbar 3 LIBS- Neutral busbar connecting

BBAR03 the upper part of batteries
and lower part of ones

11
Bolt for LIBS- Connecting neutral cable
neutral NBOLT onto neutral busbar
busbar M10*L30
Nut and LIBS-NNW Connecting neutral cable
Washers for onto neutral busbar
neutral
busbar
Blank Panel LIBS- Covering neutral busbar
for neutral BLANK
busbar

DC Cable for LIBS-MDC Connection between BPU

Negative Negative and Negative of the
terminal bottommost battery.
120sq
DC Cable for LIBS-NDC Connection between BPU
Neutral Neutral and Neutral busbar.
terminal 120sq

Comm. LIBS- Connection between each

Cable 1 COM01 PBMS
8Pin- 8Pin
20AWG

Comm. LIBS- Connection between RBMS1

Cable 2 COM02 (12Pins) and PBMS (8Pins)on
Battery Pack#1
UL AWM 2464
20AWG

Comm. LIBS- Connection between RBMS2

Cable 3 COM03 (12pins) and PBMS (8pins)
on Battery pack#6
UL AWM 2464
20AWG

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Comm. LIBS- Connection between
Cable 4 COM04 RBMS1(12pins) and
RBMS2(12pins)
UL AWM 2464
20AWG
Comm. LIBS- Connection between RBMS2
Cable 5 COM05 of Battery Rack#N(12pins)
and RBMS1 of Battery
Rack#N+1(12pins)
UL AWM 2464
20AWG
Comm. LIBS- Connection between
Cable 6 COM06 RBMS(12pins)-BBMS(16pins)
UL AWM 2464
20AWG

Terminal LIBS-TR01 RBMS Terminal Resistor 12Pin

Resistor 1
Terminal LIBS-TR02 RBMS Terminal Resistor 8Pin
Resistor 2

Terminal LIBS-TR03 PBMS Terminal Resistor 8Pin

Resistor 3

DC 24V LIBS- 24Vdc terminal in BPU to

cable 24VDC 24Vdc terminal in BBMS Box

Earthing LIBS-EC01 Between Racks

Cable 1 (25sq)

Earthing LIBS-EC02 For rack front door

Cable 2 (5.5sq)

Fan Cable LIBS-FC Connection between Fan

terminal in BPU and Fan
connector on battery pack

13
 Flange Nuts LIBS-FN Tightening Busbar onto
Battery Pack
M6

M6 Screws LIBS-M6S Mounting Battery Pack,

BBMS Box and BPU onto the
rack
M6

Bolts for LIBS-ABOLT Connection between Racks

alignment for alignment
M10,110mm

Nuts and LIBS-ANW Connection between Racks

Washers for for alignment
alignment

Table 1. Major Components and Equipment List

Junction Rack consists of circuit breakers, etc and is located between UPS and Battery Racks.

4.2 Consumable Tools

Name Quantity Figure Description

Insulation Tape 1 Set Taping work

Cable Ties 1 Set Tying up cables

Table 2. Consumable Tools List

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4.3 Major Tools and Equipment

Name Qty Figure Description

Forklift 1 Set Moving pallets

Cross-head 1 Set Tightening

Screwdriver screws

Box Cutter 1 Set Cutting

cardboard
boxes

Electric 1 Set Tightening

Screwdriver screws and
bolts

Insulated 1 Set Tightening

Torque nuts and bolts
Wrench

Insulated 1 Set Connecting

Wrench cables to a
Extension terminal
Adapter Rod

Insulated 1 Set Connecting

Socket cables and
Wrench busbar to a
terminal

15
Inclinometer 1 Set Measuring
angles of tilt on
the floor

Battery 1 Set Measuring

Tester battery voltage
and internal
impedance

Insulating 1 Set Preventing

Gloves electric shock

Static 1 Set Static release

Protection
Wrist Strap

Pliers 1 Set Bending

cables/wires

Wire 1 Set Stripping wires

strippers

Electrician's 1 Set Cutting

Scissors wires/cables

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 Insulation 1 Set Testing
Resistor insulation
Tester resistor

Paint Marker 1 Set Marking

Collapsible 1 Set Reaching

Ladder upper part of
the rack

Monkey 1 Set Tightening

Wrench bolts and
screws

Ruler Tape Measuring

length

Table 3. Major Tools and Equipment List

4.4 Arrangement of major components and inspection

- Place battery rack(s), cable duct, battery packs, BPU, RBMS, BBMS, BMS Box, Junction Rack(If there is),
Cables, etc. in the installation area.

As the customer’s request, cable tray or busbar or other material would be used instead of cable duct.

- Before doing installation work, visual inspection on battery rack(s), cable duct, battery packs, BPU, RBMS,
BBMS, BBMS Box, Junction Rack, Cables, etc. should be done. During the inspection, please check whether
there is damage to the important materials and count the number of the major components.

17
4.5 Building Floor Load Capacity

- Consult a building manager or someone who knows the building structure if the building floor where
the battery rack would be installed, could support the weight of battery rack(s) including battery packs,
BPU, etc.

4.6 Rough Alignment of Junction Rack and Battery Racks

- Get the Junction Rack and Battery Racks roughly aligned with each other.
- Remove the rack front door.
- Detach side panels from a battery rack.

4.7 Arrangement for Pack Fan Cables

- Lay fan cables downwards from just below the place where BPU is going to be mounted and get them
ready shown below. They should be arranged considering the number of battery packs. A battery pack
is equipped with a male connector for the fan.

Figure 1. Fan cables ready

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5. Installation

5.1 Precise Alignment of Racks and Cable Duct Installation

5.1.1 Rack Alignment and Earthing

Align the racks side by side with M10 bolts and nuts which could connect the racks’ upper part (2holes)
and lower part (2 holes) shown below. (Figure 2)

Figure 2. Battery Rack

- Get the earthing cable (LIBS-EC01) connected between the battery racks. (Figure 3)

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 5.1.2 Cable Duct

- When the battery rack arrangement is done, put the cable duct (LIBS-CD) on top of the rack.

Figure 3. Rack Alignment and Cable Duct Installation

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 5.2 RBMS Mounted onto BPU and BPU Mounted onto Rack

Figure 4. RBMS Mounted onto BPU

- Open the cover plate of BPU and push RBMS(LIBS-RBMS) towards the rear of the BPU. Get 16 pin
harness connector into the 16 pin port and 24 pin harness connector into the 24 pin port of RBMS.
(Figure 4 and Figure 5)

Put RBMS1 and RBMS2 respectively to the right ports. In order to distinguish RBMS1 from RBMS2, the
harness connectors for RBMS2 have been marked as R2.
And then close the cover plate of BPU.

21
 Figure 5. BPU Mounting

- Two people should lift a BPU (LIBS-BPU3W) onto the rack shelf. BPU has 4 holes that should be fixed
with screws (LIBS-M6S). (Figure 5-①) The torque value for the screws should be 5.0Nm ± 1.0Nm.

5.3 Cable connections to BPU

- Connect fan cable (LIBS-FC) to the fan terminal on BPU.(Figure 6-①)

- Connect one side of DC negative cable (LIBS-MDC) to negative terminal on BPU and the other side of
the cable drawn down to the bottom of the rack.(Figure 6-②)

- Connect one side of the neutral cable (LIBS-NDC) to the neutral terminal on BPU and get the other
side drawn down to the middle of the battery rack. (Figure 6-③)

22
When the bolt is tightened onto the terminal on BPU, the torque value should be 20Nm.
Make sure to have the shrink tube rounding the cable(LIBS-MDC and LIBS-NDC) not interfered by the
connection to the terminal on BPU.

Figure 6. DC cables drawn down and Fan cables connected to BPU

5.4 Cable Connections between Junction Rack and Battery Rack

If there is Junction Rack which was provided please do the cable work as below. If there is no Junction
Rack, DC main and AC cables would be directly connected to BPU on battery rack from UPS end.

- Run DC cables through cable duct (LIBS-CD) from junction rack to battery rack.(Figure 7-①)

The DC cable with red shrink tube goes to positive terminal and the one with blue shrink tube does to
negative terminal. The neutral cable with black shrink tube goes to the neutral terminal.

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- Place AC cables for SMPS through cable duct (LIBS-CD) from junction to battery rack.(Figure 7-②)

AC cables should be connected to the terminal of BPU in a way that hot, earthing and neutral cable are
placed in order from left to right on the terminal. (Figure 7-④)

The orange coloured cable is a phase and the blue coloured one is a neutral. And the earthing cable is
green.(but if there is a local regulation on colour code for the cables in the country, this should be
followed)

- The earthing cable (LIBS-EC01) between battery rack and junction rack should be connected.
(Figure 7-③)

- The telecommunication supervisor from the end user or the supervisor for telecommunication
installation for this project should prepare for LAN cable routing for ethernet TCP/IP to BBMS in the
battery rack. (Figure 10 and 13)

Figure 7. Cable connection between Junction Rack and Battery Rack

24
 5.5 Battery Pack Mounting and Busbar connection

Figure 8. Battery Pack Mounted onto Battery Rack

- Two people should lift a battery pack (LIBS-M4864) on the rack shelf and push it towards the rear of
the rack.

- Battery pack should be installed from the bottom.

- The battery pack number starts from the top.

- When all of the battery packs are mounted, secure them to the rack frame with screws (LIBS-M6S).
(Figure 8-①)

- One side of the busbar (LIBS-BBAR02) should be connected to the positive terminal on BPU first and

25
then the other side to the positive terminal of the battery pack#1. (Figure 9-①)

Tighten the bolt on the positive terminal on BPU at a torque value, 20Nm and flange nut(LIBS-FN) on
the positive terminal on battery pack#1 at 10.2Nm.- The negative terminal of N’s battery pack should be
connected to the positive terminal of N+1’s battery pack by busbar (LIBS-BBAR01). This should apply to
all the battery packs in series connection. (Figure 9-④)

- Place all the busbars (LIBS-BBAR01) between the battery packs, tighten the flange nuts (LIBS-FN) on
the terminal of the battery pack. (Torque: 9.0Nm ± 1.0Nm)

- Connect the DC negative cable (LIBS-MDC) already laid at bottom to the negative terminal of the
bottommost battery pack and tighten the bolt on the negative terminal of the battery pack at a proper
torque value, 10.2Nm. Make sure the shrink rounding the cable tube should not be interfered by the
connection to the terminal. (Figure 9-②)

- Connect the neutral busbar to the negative terminal of battery Pack#5 and positive terminal of Pack#6
and tighten the flange nuts on both terminals at the torque value, 10.2Nm.

- Connect the neutral DC cable (LIBS-NDC) already in the middle of the rack to the neutral busbar
through tightening the bolt (LIBS-NBOLT) at the torque value,20Nm. Make sure the shrink rounding
the cable tube should not be interfered by the connection to the terminal. (Figure 9-③)

- After all of the nuts have been tightened, draw a I-letter mark on the torqued nuts with a paint pen.
Cover the blank panel (LIBS-BLANK) for the neutral busbar connection and fix it with screws.

- Connect Fan cables’ (LIBS-FC) female connectors already laid downward from BPU to male connectors
from the battery packs. (Figure 9-⑤)

26
 Figure 9. Battery Mounting and Busbar Connection

5.6 Communication Cable Connection (RBMS-PBMS and PBMS-PBMS)

- Connect RBMS1 (X4 port) to PBMS (X1 port) on the battery pack#1 by CAN communication cable
(LIBS -COM02). (Figure 12-①)

- Connect RBMS2 (X4 port) to PBMS (X1 port) on the battery pack#6 by CAN communication cable
(LIBS -COM03). (Figure 12-②)

- Connect X2 port on RBMS1 to X3 port on RBMS2 by CAN communication cable (LIBS -COM04).
(Figure 12-③)

27
Figure 10. BMS Diagram-1

Figure 11. Battery Pack

28
- Place CAN communication cable (LIBS-COM01) between battery packs and connect them in series..
(Figure 12-④)

- Put the terminal resistor (LIBS-TR03) into the X2 port on Battery#5 and Battery#10 respectively.
(Figure 12-⑤)

Figure 12. Communication Cable Connection (RBMS-PBMS and PBMS-PBMS)

29
 5.7 BBMS BOX Installation, RBMS-BBMS Connection and DC 24V Cable Connection

Figure 13. BBMS Box Connection Diagram

- There are 4 ports in BBMS; X1 is for maintenance by the manufacturer, B1 is RJ45 LAN port for
ethernet TCP/IP communication to the server where EON made HMI software called LBM is installed,
X2 is for communication with RBMS on BPU, and X3 is for DC power source from SMPS. (Figure 10,
13 and 14)

- Open the cover plate of BBMS Box (LIBS-BBOX) and put BBMS and then fix 4 parts of BBMS with
screws.

Put 16 pin harness connector connected to the CAN communication cable (LIBS-COM06, Figure 14-①)
from X3 on RBMS1 into BBMS Box. Get this 16pin harness connector into X2 port on BBMS and 8pin
harness connector already fixed in BBMS box inside into X3 port on BBMS. (Figure 13)

30
Close the cover plate of BBMS Box and tighten it with screws.

The battery rack number starts from the rack which is most adjacent to junction rack.

The numbering system for RBMS follows battery rack’s ordinal number.

- The outgoing terminal of 24Vdc on BPU should be connected to the 24Vdc terminal in BBMS Box by
24Vdc cable (LIBS-24VDC). (Figure 14-②, 14-③, and14-④ )

Connect 24Vdc cables(LIBS-24VDC) to the terminal of BPU and BBMS Box in a way that positive and
earthing and negative cable are placed in order from left to right on the terminal.

- BBMS box should be put into the bottom of the battery rack closest to junction rack and then it would
be fixed by screws (LIBS-BBSCREW). (Figure 14-⑤ )

Figure 14. BBMS BOX installation, BBMS -RBMS and 24Vdc Cable Connection

31
5.8 RBMS – RBMS Connection in Separate Battery Racks

- Connect X2 port of N’s RBMS2 to X3 port of N+1’s RBMS1 by communication cables (LIBS-COM05).
CAN communication cable should not be laid together with DC/AC power cables. (Figure 16-①)

32
 Figure 15. BMS Diagram-2

Put the terminal resistor (LIBS-TR01) into X2 port of the RBMS2 on the last battery rack in the bank.

Put the terminal resistor (LIBS-TR02) into X1 port of every RBMS.

33
Figure 16. RBMS-RBMS Connection

34
5.9 Attaching Rack Front Door and Rack Side Panel

- Mount the rack front door and connect the earthing cable (LIBS-EC02) to the rack door, then fix it with
a screw.

Figure 17. Rack Front Door Attached

- Put the side panel (LIBS-SP) onto the rightmost and leftmost battery rack among the aligned battery
racks.

Figure 18. Rack Side Panel Attached

35
6. Inspection

6.1 Rack Level Inspection

6.1.1 BPU MCCB Check

Make sure that MCCB has been off.

Refer to Check Item No. 1 in an attachment.

6.1.2 Torque value for Pack and BPU

Check the torque value for the bolts to secure the all the battery packs and BPU to the rack frame to see
if they have acceptable ones (Torque: 5.0Nm ± 1.0Nm)
Markings on the torqued bolts whether they have been done or not. Check the torque value for the bolts
to secure the all the battery packs into the rack frame to see if they have acceptable ones (Torque: 5.0Nm
± 1.0Nm)
Refer to Check Item No. 2 in an attachment

6.1.3 Series Connection of BPU and Battery

- Check whether markings on the torqued flange nuts have been done or not.

- Check the DC negative cable (LIBS-MDC) if it has been well connected to the negative terminal of BPU
and bottommost battery pack. Check whether the colour of the shrink tube for the DC negative cable
(LIBS-MDC) is blue or not.

- Check the busbar (LIBS-BBAR02) if it has been well connected to the positive terminal of BPU and
battery pack#1.

- Check the connection between the neutral terminal of BPU and the neutral busbar (LIBS-BBAR03) by
the neutral DC cable (LIBS-NDC). Check whether the colour of the shrink tube for the DC cable (LIBS-
NDC) is black or not.

Refer to Check Item No. 3 in an attachment

36
 6.1.4 Connection between Battery Packs

- Check to see if flange nuts (LIBS-FN) have been tightened at the acceptable torque value (Torque:
9.0Nm ± 1.0Nm) for every connection between busbar and battery pack (LIBS-BBAR01)

- Check whether markings on the torqued flange nuts have been done or not.

- Check whether the terminal cover has been closed.

Refer to Check Item No. 4 in an attachment

6.1.5 Communication Cable Check

- Check for the communication cables (LIBS-COM02) that have well connection between X4 port on
RBMS1 and PBMS on battery pack #1.

- Check for the communication cables (LIBS-COM03) that have well connection between X4 port on
RBMS2 and PBMS on battery pack #6.

- Check for the communication cables (LIBS-COM04) that have well connection between X2 port on
RBMS1 and X3 port on RBMS2.

- The communication cables (LIBS-COM01) should be checked to see if they have proper connection
between battery packs.

- Check whether the terminal resistor (LIBS-TR03) at the bottommost battery pack has been placed or
not.

- Check whether the terminal resistor (LIBS-TR02) at the X1 port of RBMS has been placed or not.

Refer to Check Item No. 5 in an attachment

37
 6.1.6 Rack Voltage Check

Check for the voltage between the negative and the positive on BPU.

Refer to Check Item No. 6 in an attachment

6.1.7 Insulation Resistor Check

- Set the voltage level at 1000V of the insulation resistor tester.

- Contact the positive probe onto the battery terminal (either negative or positive) and the negative
probe to the rack frame.

- Hold the positive probe button for 10 seconds and record the measured value.

Refer to Check Item No. 7 in an attachment

6.2 Bank Level Inspection

6.2.1 Visual Inspection on Communication Cables

Check for the communication cable connection between RBMS and RBMS, and RBMS and BBMS.
Look into whether the terminal resistor (LIBS-TR01) has been placed into X2 port of the RBMS2 of the
last battery rack.
Refer to Check Item No. 8 in an attachment

6.2.2 Power Cable Connection Check

Check whether AC cables from AC MCCB on junction rack to each battery rack have been properly
connected and have the right colour’s shrink tube; the neutral is blue and the hot is orange and the
earthing is green(If there is a different colour code for the cables in the country, this local regulation
should be followed).

Check for DC cables from main DC MCCB on junction rack to each battery rack that have been
appropriately connected and have the right colour’s shrink tube; positive one is red, negative one is blue

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and neutral one is black.

Check to see whether 24V DC cables (LIBS-24VDC) have been well connected from SMPS on BPU to
SMPS in BBMS box.
24Vdc cables have two types of colors ; red for positive, green for earthing and black for negative.
Refer to Check Item No. 9 in an attachment

6.3 System Level Inspection

6.3.1 Battery Voltage and Polarity Check in each Rack

- Ensure that DC MCCB (or DS+Fuse) on junction rack has been off, if not shut it off.

- Close DC MCCB on BPU of the battery rack #1.

- Check the voltage and polarity on the secondary side of DC MCCB (or DS+fuse) on junction rack.

- Turn off the DC MCCB on BPU of the battery rack #1 when there is no error on the voltage and
polarity.

- The above steps should apply to check other battery rack’s (#2,#3…#N) voltage and polarity.

6.3.2 LBM HMI Starting

- Make sure that AC power circuit to SMPS on BPU has been energized.

- Switch on the power for SMPS on BPU in each battery rack.

- Close the main and branch circuit of MCCB for AC power in junction rack.

- Connect LAN Port in BBMS to the server where LBM HMI has been installed by LAN cable.

(cf. The RJ45 LAN Port on the front of BBMS is for TCP/IP communication between LBM and BBMS)

- After IP setting and network connectivity are checked, run LBM program.

- Turn on DC MCCB on BPU in each battery rack.

Refer to Check Item No. 10 in an attachment

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 6.3.3 Battery Status Check

After the BBMS has been connected to the server with LBM HMI installed as per the above procedure,
run LBM and check for data in the level of battery bank, rack and battery pack.
Check for the following information through the same server with each BBMS.
Check to see whether SoH, SoC, V, A, Power, Backup time, Ah, and Temperature are shown in the level of
BBMS (Bank BMS).
Check that SoC, SoH, V, A, and Temperature are seen in the level of RBMS (Rank BMS).
Look into whether V and Temperature are displayed in the level of PBMS (Pack BMS).
Refer to Check Item No. 11 in an attachment

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7. Appendix

7.1 Checklist

Check Item No. 1 - BPU Status

Date: Inspector: Signature:

Description Criteria Check Remarks

BPU CB open Off
As check done, put V mark in the blank of the column of Check.

Check Item No. 2- Pack and BPU Mounting Torque

Date: Inspector: Signature:

Description Criteria (Torque) Check Remarks

Pack No. 1 5.0 ± 1.0 Nm
Pack No. 2
Pack No. 3
Pack No. 4
Pack No. 5
Pack No. 6
Pack No. 7
Pack No. 8
Pack No. 9
Pack No. 10
BPU
As check done, put V mark in the blank of the column of Check.

The battery pack number starts from the top.

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Check Item No. 3- Connection between Positive, Negative and Neutral of BPU and Battery Packs

Date: Inspector: Signature:

Description Criteria (Torque and Check Remarks

I-letter mark)
BPU Positive Terminal 20Nm
BPU Negative Terminal 20Nm
BPU Neutral Terminal 20Nm
Positive Terminal on Battery Pack#1 10.2Nm
Negative Terminal on Battery 10.2 Nm
Pack#10

Connecting point on Neutral Cable 20Nm

and Neutral Busbar
As check done, put V mark in the blank of the column of Check.

Check Item No. 4-Busbar Connection

Date: Inspector: Signature:

Description Criteria + Terminal - Terminal Check Remarks

(Torque)) Cover
closed
Pack No. 1 9.0 ± NA
Pack No. 2 1.0 Nm
Pack No. 3
Pack No. 4
Pack No. 5
Pack No. 6
Pack No. 7
Pack No. 8
Pack No. 9
Pack No. 10 NA
As check done, put V mark in the blank of the column of Check.

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Check Item No. 5- Communication cable connection (Rack Level)

Date: Inspector: Signature:

Description Criteria (Properly connected) Check Remarks

RBMS1 -Pack #1
RBMS2 -Pack #6
Pack #1 - Pack #2
Pack #2 - Pack #3
Pack #3 - Pack #4
Pack #4 - Pack #5
Pack #5 - Pack #6
Pack #6 - Pack #7
Pack #7 - Pack #8
Pack #8 - Pack #9
Pack #9- Pack #10
Terminal Resistor on
RBMS1 X1
Terminal Resistor on
RBMS2 X1
Terminal Resistor on
Pack #5
Terminal Resistor on
Pack #10
As check done, put V mark in the blank of the column of Check.

Check Item No. 6- Rack Voltage

Date: Inspector: Signature:

Description Criteria (250~254V) Check Remarks

Pack#1 Positive to
Pack#5 Negative
Pack#6 Positive to
Pack#10 Negative
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As check done, put V mark in the blank of the column of Check.

The criteria would be dependent on the number of packs.

Check Item No. 7 – Insulation Resistor

Date: Inspector: Signature:

Voltage Input (+) Ground(-) Criteria Insulation Remarks

Resistor
Pack#1 Positive Rack frame 10MΩ or more
Pack#10 Negative Rack frame 10MΩ or more
As check done, put V mark in the blank of the column of Check.

Check Item No. 8 – Communication cable connection (Bank Level)

Date: Inspector: Signature:

Description Criteria (Properly connected) Check Remarks

RBMS to RBMS X2 on RBMS2 of Battery Rack#n-
X3 on RBMS1 of Battery Rack#n+1
BBMS to RBMS X2 on BBMS- X3 on RBMS1 of
Battery Rack #1
Terminal Resistor X2 on RBMS2 of the last Battery
Rack
As check done, put V mark in the blank of the column of Check.

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Check Item No. 9 – Power cable connection

Date: Inspector: Signature:

Description Criteria (Properly connected) Check Remarks

Junction Rack to AC cables(Blue for neutral, Orange
Battery Rack(s) for hot and Green for earthingl, Local
rules could be followed) and DC
cables (red for positive, blue for
negative and black for neutral)

24Vdc terminal in BPU DC 24V cables

to 24Vdc terminal in (red for positive, green for earthing,
BBMS Box and black for negative)
As check done, put V mark in the blank of the column of Check.

Check Item No. 10 – BPU Startup

Date: Inspector: Signature:

Criteria Check Remarks

DC MCCB in junction rack to be off
DC MCCB in battery rack #1 to be on
Voltage and polarity to be checked
DC MCCB in battery rack #1 to be off
Other battery racks (#2,#3,#4…#n) to be checked in the
same steps above indicated
Power source for SMPS in BPU to be on
All Switches for SMPS in each battery rack to be on
AC MCCB for main and branch circuit in Junction Rack to
be on
BBMS to be connected to LBM server with LBM program
installed
LBM program to be run right after IP setting and network
connectivity check
DC MCCB in each battery rack to be on
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Check Item No. 11 – BBMS, RBMS and PBMS information

Date: Inspector: Signature:

Description Criteria (Information below is Check Remarks

shown or not)
BBMS # SoH, SoC, V, A, Power, Backup time,
Ah, Temperature
RBMS SoC, SoH, V, A, Temperature
(or all of the RBMS)
PBMS V, Temperature

As check done, put V mark in the blank of the column of Check. If there is more than 1 set

of BBMS, use this sheet and put the number of BBMS.

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7.2 Battery Rack System Diagram

7.3 Contact Information

Technical Director : Ryan Shin , shin@eonworld.com , +82 31 548 4801

Sales Manager : Jay Lee, jaysale@eonworld.com , +82 70 7511 0232

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