DISCOVER AES RACKMOUNT User manual

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AES RACKMOUNT Battery Cable
Terminal Connector Set Manual
805-0057 REV B
Battery Cable Terminal Connector Set 950-0054
READ AND SAVETHESE INSTRUCTIONS

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INTRODUCTION ........................................................................3
1. AUDIENCE, MESSAGES, WARNINGS, GENERAL SAFETY, PERSONAL PROTECTIVE EQUIPMENT ...3
1.1 Audience.................................................................3
1.2 Warning, Caution, Notice, and Note Messages .................................3
1.3 Warnings and General Safety ................................................4
1.4 Safe Handling Procedures...................................................4
1.5 Personal Protective Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2. ITEMS SHIPPED IN THE BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. SPECIFICATIONS ....................................................................5
3.1 Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.2 Mechanical Specifications...................................................6
3.3 Ingress Protection IP67 .....................................................6
4. HANDLING .........................................................................7
5. THEORY OF OPERATION AND FEATURES ...............................................7
6. TOOLS .............................................................................8
7. ASSEMBLY .........................................................................8
8. CONNECTING TO THE BATTERY MODULE ..............................................9
8.1 Connecting to Battery ModuleTerminals .......................................9
8.2 Disconnecting from Battery ModuleTerminals .................................10
9. ROUTINE INSPECTION .............................................................. 10

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INTRODUCTION
The AES RACKMOUNT Battery Cable Terminator Set consists of a Positive (Red)
Connector and a Negative (Black) Connector. The connectors secure battery cables
to the front terminals on the AES RACKMOUNT Battery Module.
1. AUDIENCE, MESSAGES, WARNINGS, GENERAL SAFETY, PERSONAL
PROTECTIVE EQUIPMENT
1.1 Audience
Configuration, installations, service, and operating tasks should only be performed
by qualified personnel in consultation with local authorities having jurisdiction
and authorized dealers. Qualified personnel should have training, knowledge, and
experience in the:
• Installation of electrical equipment
• Application of electrical codes, safety, and installation standards
• Analysis and reduction of hazards involved in performing electrical work
• Installation and configuration of batteries
1.2 Warning, Caution, Notice, and Note Messages
Messages in this manual are formatted according to this structure.
WARNING
Important information regarding hazardous conditions that may result in personal
injury or death.
CAUTION
Important information regarding hazardous conditions that may result in personal
injury.
NOTICE
Important information regarding conditions that may damage the equipment but
not result in personal injury.
NOTE
Ad hoc information concerning important procedures and features unrelated to
personal injury or equipment damage.

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1.3 Warnings and General Safety
WARNING
ELECTRIC SHOCK AND FIRE HAZARD
Do not lay tools or other metal parts across battery terminals.
Failure to follow these instructions may result in death or serious injury.
CAUTION
ELECTRIC SHOCK HAZARD
• Do not touch the energized surfaces of any electrical component in the Battery
Module Combiner or Battery Module system.
• Before servicing, follow all procedures to fully de-energize the Battery Module
Combiner and Battery Module system.
• Follow “Safe Handling Procedures” when working with the Battery Module Combiner
or Battery Module system.
Failure to follow these instructions may result in injury.
1.4 Safe Handling Procedures
Before using the Battery Cable Terminal Connector Set, read all instructions and
cautionary markings on the units and all appropriate sections of this manual.
• Use personal protective equipment when working with the Battery Cable
Terminal Connector.
• Dispose of or recycle a Battery Cable Terminal Connector following local
regulations.
• Do not modify, re-manufacture, or attempt to insert foreign objects into the
Battery Cable Terminal Connector.
• Do not immerse or expose the Battery Cable Terminal Connector to water or
other liquids, fire, explosion, or other hazards.
• Use the Battery Cable Terminal Connector only with AES RACKMOUNT Battery
Modules or equipment that Discover Energy Systems specifies as compatible.
• Do not lift or carry while in operation.
• Take precautions when handling electrical cables.
• Do not submerge the Battery Cable Terminal Connector.
• Do not install the Positive (Red) Battery Cable Terminal Connector on the
negative battery cable.
• Do not install the Negative (Black) Battery Cable Terminal Connector on the
positive battery cable.
• Do not use the Battery Cable Terminal Connector with Battery Modules or
equipment that exceeds the specifications. Using Battery Modules or equipment
that exceeds Battery Cable Terminal Connector specifications may present a fire
risk or other hazards.

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• Do not short-circuit or allow metallic conductive objects to contact cable ends
and Battery Cable Terminal connectors.
• If the Battery Cable Terminal Connector is damaged, replace it.
1.5 Personal Protective Equipment
When handling or working near a battery:
• Use Personal Protective Equipment, including clothing, glasses, insulated gloves,
and boots.
• Do not wear rings, watches, bracelets, or necklaces when handling or working
near the battery.
2. ITEMS SHIPPED IN THE BOX
Table 2-1, AES RACKMOUNT Battery Cable Terminal Connector Set
Items Description
1Positive (Red) Amphenol SurLok PlusTM Connector - C10-730186-200
1Negative (Black) Amphenol SurLok PlusTM Connector - C10-730186-100
3. SPECIFICATIONS
3.1 Electrical Specifications
The AES RACKMOUNT Battery Cable Terminal Connector Set is designed for use
with the AES RACKMOUNT Battery Module Combiner and AES RACKMOUNT
Battery Modules.
Table 3-1. AES RACKMOUNT Battery Cable Terminal Connector Electrical
Specifications
Electrical Specifications AES RACKMOUNT Battery Cable Terminal
Connector
Operating Temperature -40°C (-40°F) to 125°C (257°F)
Current Rating (Connector Only) 120 A max for 26.5 mm² / 3 AWG Cable
Operating Voltage 1000 Vdc
Dielectric Withstanding Voltage 3000 Vdc

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3.2 Mechanical Specifications
Table 3-2. AES RACKMOUNT Battery Cable Terminal Connector Mechanical
Specifications
Mechanical Specifications AES RACKMOUNT Battery Cable Terminal
Connector
Height 22.6 mm (0.89 in)
Width 18 mm (0.71 in)
Length 55.1 mm (2.17 in)
Cable Acceptance 26.5 mm² (3 AWG)
IP Rating IP67
55.1 mm (2.17 in)
(0.4 in)
22.6 mm
(0.89 in)
6.6 mm
(0.26 in)
ø10.2 mm
Cable
30 mm (1.18 in)
18 mm
(0.71 in)
ø11.3 mm (0.44 in)
Figure 1. AES RACKMOUNT Battery Cable Terminal Connector Dimensions
3.3 Ingress Protection IP67
Ingress protection rates the degree of protection provided by mechanical casings
and electrical enclosures against intrusion, dust, accidental contact, and water under
specified conditions. The IP67 rating indicates that the product, when connected to
the terminal pin, provides protection against dust and airborne particles as well as
protection against water and liquids up to a depth of 1 meter.
IP codes guide suitability for use under different environmental conditions. IP
ratings do not indicate fitness for purpose or confer a performance guarantee.

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4. HANDLING
Before handling
• Keep the Battery Cable Terminal Connector away from water, heat, and fire.
• De-energize all sources of power before handling a Battery Cable Terminal
Connector.
• De-energize all sources of power before disconnecting a Battery Cable Terminal
Connector.
• Protect the Battery Cable Terminal Connector from short-circuiting and touch.
• Do not lift or carry equipment by the Battery Cable Terminal Connector.
5. THEORY OF OPERATION AND FEATURES
On the Battery CableTerminal Connector, turn the Back Shell counterclockwise to
screw it off and reveal the Grommet inside.The battery cable is passed through the
Back Shell and Grommet, and into the drum, and the cable is secured by crimping
the drum and cable together. Put the Connector, Grommet, and Back Shell back
together by screwing the Back Shell back onto the Connector to encapsulate the
cable after crimping. The assembled Battery Cable Terminal Connector connects to
the male receiving terminal pin on the faceplate of the AES RACKMOUNT Battery
Module when you push the connector onto the receiving pin.
Back Shell
Grommet
Connector
Drum
Figure 2. Battery Cable Terminal Connector parts
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2
Figure 3. Battery Cable Terminal Connectors Mated with
AES RACKMOUNT Battery Module

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6. TOOLS
• Cable cutting tool
• Manual hydraulic crimping tool with 25 mm
2
die (suitable for 26.5 mm
2
, 3 AWG cable)
• RMS type Voltmeter
• Post cleaner and wire brush
• Personal protective equipment
7. ASSEMBLY
The AES RACKMOUNT Battery Cable Terminal Connector consists of three pieces:
Connector, Grommet, and Back Shell.
A 26.5 mm² (3 AWG) battery cable is passed through the Back Shell and Grommet,
and into the Drum, and the cable is secured by crimping the drum and cable
together. Put the Connector, Grommet, and Back Shell together by screwing the
Back Shell back onto the Connector to encapsulate the cable after crimping.
Back Shell
Grommet
Connector 26.5 mm
2
(3 AWG) Wire
18 mm ±1 mm
(0.71 in ±0.04 in)
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2
3
Drum
Figure 4. AES RACKMOUNT Battery Cable Terminal Connector Assembly
1. Cut the 26.5 mm² (3 AWG) battery cable to the length required and strip 18.0 mm
±1.0 mm (0.71 in ±0.04 in) of insulation off the end of the cable.
2. Pass the cable through the Back Shell and Grommet, and insert the bare cable
into the drum of the Connector.
a. Ensure the chamfer of the Grommet is pointed towards the Back Shell.
b. Line the cable up so the insulation is right beside the drum of the Connector.
3. Using a manual hydraulic crimping tool, crimp the drum of the Connector to the
battery cable.

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a. Compress the crimp height to 7.5 mm +/- 0.2 mm (0.295 in ±0.008 in) and a
minimum cable pullout force of 1200 N (270 lb).
4. Push the Grommet and Back Shell up against the Connector, and twist to screw
the Back Shell onto the Connector.
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Figure 5. AES RACKMOUNT Battery Cable Terminal Connector
8. CONNECTING TO THE BATTERY MODULE
WARNING
ELECTRIC SHOCK AND FIRE HAZARD
• Always assume the AES RACKMOUNT Battery Module Combiner is energized, even
if the At-a-glance LED shows that the AES RACKMOUNT Battery Modules are OFF.
• Even if the AES RACKMOUNT Battery Module Combiner LED is OFF, the combiner
may be energized by power from the Power Conversion System (inverter-charger /
MPPT controller).
• Verify the terminal voltage with a voltmeter before handling any components in the
Energy Storage System.
Failure to follow these instructions may result in death or serious injury.
8.1 Connecting to Battery Module Terminals
The AES RACKMOUNT Battery Cable Terminal Connector mates with the receiving
pin of the male terminal on the faceplate of the AES RACKMOUNT Battery Module.
1. De-energize all AES RACKMOUNT Battery Modules and the AES RACKMOUNT
Battery Module Combiner.
2. Attach the red, positive (+) connector to the red, positive (+) terminal on the
Battery Module and push to lock the Connector to the terminal.
3. Attach the black, negative (-) connector to the black, negative (-) terminal on the
Battery Module and push to lock the Connector to the terminal.
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2
Figure 6. Connection with the Battery Module

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8.2 Disconnecting from Battery Module Terminals
1. De-energize all AES RACKMOUNT Battery Modules and the AES
RACKMOUNT Battery Module Combiner.
2. Detach the red, positive (+) connector from the positive (+) terminals
on the Battery Module by holding down the button on the side of the
Connector and pulling it away from the Battery Module.
Button
Figure 7. AES RACKMOUNT Battery Cable Terminal Connector
Disconnection
3. Detach the black, negative (-) connector from the black, negative (-)
terminal on the Battery Module by holding down the button on the side of
the Connector and pulling it away from the Battery Module.
9. ROUTINE INSPECTION
Periodically inspect the Battery Cable Terminal Connector:
1. Ensure that all terminal connections are secure and tight.
2. Ensure that the contact location is clean and free of debris.
3. Inspect the Battery Cable Terminal Connector covers for cracks.
4. Replace any damaged Battery Cable Terminal Connectors.
5. Replace any cracked, frayed, or damaged cables.