DISCOVER AES RACKMOUNT User manual

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AES RACKMOUNT Slimline
Enclosure Manual
805-0068 REV C
AES RACKMOUNT Slimline Enclosure 950-0053
READ AND SAVETHESE INSTRUCTIONS

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INTRODUCTION ........................................................................3
1. AUDIENCE, WARNINGS, MESSAGES, 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
1.6 Emergency Procedure ......................................................5
2. ITEMS SHIPPED IN THE BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. SPECIFICATIONS ....................................................................6
3.1 Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.2 Mechanical Specifications...................................................7
3.3 Environmental Specifications ................................................9
3.4 Regulatory ...............................................................9
4. TRANSPORTATION ..................................................................9
5. HANDLING .........................................................................9
6. FEATURES ......................................................................... 10
7. SYSTEM OVERVIEW AND CONFIGURATION ........................................... 11
7.1 Minimum Specifications for AES RACKMOUNT Battery Energy Storage Systems ....12
7.2 Closed-loop Communication with Power Conversion Equipment..................13
7.3 Location ................................................................14
8. TOOLS ............................................................................ 16
9. PREPARING THE ENCLOSURE FOR INSTALLATION...................................... 16
9.1 Moving and Leveling the Enclosure..........................................17
10. INSTALLATION..................................................................... 19
10.1 Mounting the AES RACKMOUNT Battery Modules..............................19
10.2 Connecting the Power Conversion Equipment .................................23
10.3 Attaching the Plexiglass Busbar Protector.....................................24
11. COMMISSIONING .................................................................. 25
12. ROUTINE INSPECTION ............................................................. 26
12.1 External Parts of the Enclosure..............................................26
12.2 De-energize the Enclosure .................................................26
12.3 Internal Part of the Enclosure ...............................................27
13. OPTIONAL ACCESSORIES AND REPLACEMENT PARTS.................................. 28
14. RELATED INFORMATION ............................................................ 28
15. GLOSSARY ........................................................................ 28
APPENDIX ............................................................................ 29
A1. AES RACKMOUNT BESS Commissioning Checklist .............................29
A2. Decommissioning Checklist ................................................32

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INTRODUCTION
The solid casing of the AES RACKMOUNT Slimline Enclosure is designed to
withstand the harshest weather and host up to six AES RACKMOUNT battery
modules for an energy storage system rated up to 30 kWh.
1. AUDIENCE, WARNINGS, MESSAGES, GENERAL SAFETY, PERSONAL
PROTECTIVE EQUIPMENT
1.1 Audience
Configuration, installation, service, and routine inspections 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
ARC FLASH HAZARD
Before installation, service, or routine inspections, review the Arc Flash Warning label
on the product.
Failure to follow these instructions may result in death or serious injury.
WARNING
ELECTRIC SHOCK AND FIRE HAZARD
Do not lay tools or other metal parts across battery terminals or internal components.
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 Enclosure.
• Before servicing the Enclosure, follow all procedures to fully de-energize the battery
energy storage system. Refer to 12.2 De-energize the Enclosure.
• Follow "Safe Handling Procedures" when working with the Enclosure or battery
energy storage system.
Failure to follow these instructions may result in injury.
Do not dispose of the product in a fire or the garbage.
This product is made of recyclable materials and should be recycled.
1.4 Safe Handling Procedures
Before using the Enclosure, read all instructions, cautionary markings on the unit,
and all appropriate sections of this manual.
• Use personal protective equipment when working with the Enclosure.
• Do not wire battery modules or Enclosures in series.
• Dispose of or recycle a used Enclosure following local regulations.
• Do not modify the Enclosure except as specified by Discover Energy Systems.
• Do not immerse the Enclosure in water or other liquids.
• Do not expose the Enclosure to chemicals, fire, explosion, or other hazards.
• Only use the Enclosure with AES RACKMOUNT battery modules.
• Do not move the Enclosure while in operation.
• Lift, move, or mount the Enclosure following local regulations.
• Do not short-circuit the battery modules or busbar or allow metallic conductive
objects to contact cable ends and terminals.

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• Do not drop the Enclosure or battery modules.
• If the Enclosure or a battery module is damaged, take it to a service center for
inspection.
• Do not expose the battery energy storage system (BESS) to high temperatures.
1.5 Personal Protective Equipment
When handling or working near a battery:
• Use Personal Protective Equipment, including clothing, glasses, insulated gloves,
and steel-toe shoes.
• Do not wear metal rings, watches, bracelets, or necklaces.
1.6 Emergency Procedure
Unusual Odor
• If there is a burning smell:
• Turn OFF the power conversion equipment.
• Turn OFF (open the breakers) all the battery modules.
• Call the installer and schedule an immediate inspection.
Fire
• If there is smoke or other signs of fire:
• Call 911 (or the emergency phone number in your area).
• If there is an emergency STOP button, press it to shut down the system.
• Do not open the Enclosure door.
• Do not attempt to put out the fire.
• Do not spray water or other fire retardants.

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2. ITEMS SHIPPED IN THE BOX
Table 2-1, AES RACKMOUNT Slimline Enclosure box contents
ITEMS DESCRIPTION
1AES RACKMOUNT Slimline Enclosure
1Accessory kit with the following parts:
• Keys (2)
• Cable Straps (304.8 mm, 12 inch) (24)
• M6 flange nut (2)
• Screws
• M3 round-head screw (2)
• M5 round-head screw (4)
• M6 hexagon-head screw (4)
• M8 hexagon-head screw (2)
• ST5 flat-head screw (4)
• CAT6 Cable (610 mm, 24 inch) (2)
6 pairs Positive and negative battery cables. Length: 0.75 m (2.46 ft)
1Busbar Mounting Assembly (Installed)
1Busbar Plexiglass Protector
4L-bracket
3. SPECIFICATIONS
3.1 Electrical Specifications
Table 3-1, Electrical Specifications
SPECIFICATION VALUE
Nominal Voltage 51.2 Vdc
Charge Voltage (maximum) 55.2 Vdc
Input Current / Output Current (maximum) 500 A
Energy Storage Capacity 5 kWh per battery module
(up to 30 kWh for six battery modules)
Maximum Short Circuit and Duration 3.8 kA / 100 ms per battery module
(up to 22.8 kA / 100 ms for six battery
modules)

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3.2 Mechanical Specifications
Table 3-1, Enclosure Dimensions
DIMENSION VALUE
Height 1721 mm (67.76 inch)
Width 350 mm (13.78 inch)
Depth 680.0 mm (26.77 inch)
Depth (with handles) 715.7 mm (28.18 inch)
Weight 80 kg (176.37 lbs)
Weight (fully loaded with battery modules, battery cables,
busbar, and the LYNK II Gateway)
360 kg (793.66 lbs)
Roof angle 1.87 o
260 mm
(10.24 in)
620 mm
(24.41 in)
620 mm
(24.41 in)
225.54 mm
(8.88 in)
255.5 mm
(10.06 in)
200 mm
(7.87 in)
267 mm
(10.51 in)
Figure 1. Front 230 mm
(9.05 in)
350 mm
(13.78 in)
35 mm
(1.38 in)
Figure 2. Back

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680 mm (26.77 in)
1.87°
1721 mm
(67.76 in)
209.6 mm
(8.25 in)
209.6 mm
(8.25 in)
80 mm
(3.15 in)
80 mm
(3.15 in)
80 mm
(3.15 in)
Figure 3. Side
350 mm
(13.78 in)
Door Handles
715.7 mm
(28.18 in)
680 mm
(26.77 in)
Figure 4. To p
70 mm (2.76 in)
50 mm
(1.97 in)
12 mm
(0.47 in)
18 mm
(1.18 in)
9 mm
(0.35 in)
80 mm (3.15 in)
30 mm
(0.71 in)
To Enclosure
50 mm
(1.97 in)
3 mm
(0.12 in)
Figure 5. L-Bracket (for anchoring the Enclosure)

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3.3 Environmental Specifications
Use the Enclosure and the AES RACKMOUNT battery modules either indoors or
outdoors and away from living quarters.
NOTICE
• Do not install or operate in a location exposed to direct sunlight.
• Do not install or operate near an open flame or heating source.
• Do not install or operate in the living areas of the home or residence.
ENVIRONMENTAL SPECIFICATIONS VALUE
Charge OperatingTemperature 4°C to 52°C (39.2°F to 125.6°F)
Discharge OperatingTemperature -17°C to 52°C (1.4°F to 125.6°F)
StorageTemperature -20°C to 55°C (-4°F to 131°F)
3.4 Regulatory
Regulatory
UL9540A
UL9540
NEMA 3R
4. TRANSPORTATION
Transport the Enclosure on the original pallet and in the original packaging or
equivalent.
NOTICE
Do not transport the AES RACKMOUNT Slimline Enclosure with battery modules
installed. Ship the battery modules separately.
5. HANDLING
Before handling:
• Do not immerse the Enclosure in water or other liquids.
• Keep the Enclosure away from chemicals, heat, and fire.
• Disconnect all cables from battery modules, power conversion equipment, and
other power sources.
• Protect the battery module terminals from short-circuiting and touch.
• Do not lift or transport the Enclosure while in use or operation.
• Do not lift or transport the Enclosure by the attached cables.

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6. FEATURES
Solid steel frame designed to withstand the harshest conditions.
The AES RACKMOUNT Slimline Enclosure can hold up to six AES RACKMOUNT
battery modules in a configuration of 2 columns of 3 batteries. Each module is
supported by the cross brackets of an internal cage and secured to the rack frame
with screws.
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10 1
2
3
4
5
6
7
12
8
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Figure 6. AES RACKMOUNT Slimline Enclosure Components
ITEM DESCRIPTION
1Front Door
2Air Vent (door with integrated fans is optional) (1)
3Door Handles (all with locks)
4Plexiglass Busbar Protector
5Positive and Negative Busbars
6Busbar Mounting Assembly
7Support Feet
8L-brackets (for anchoring the Enclosure)
9Remote Power ON/OFF Key
10 LYNK II Communication Gateway (not included)
11 Internal Cage
12 Enclosure
(1)The door with integrated fans is not required to install and operate the Enclosure.

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NOTE
• Configuration, installation, service, and routine inspections should only be performed
by qualified personnel.
• Size fuses and breakers following established standards and have the system
inspected by the local authority having jurisdiction.
7. SYSTEM OVERVIEW AND CONFIGURATION
The Enclosure can hold up to six AES RACKMOUNT battery modules in 2 columns
of 3.
1
2
3Figure 7. Two Columns of
Three Battery Modules
ITEM DESCRIPTION
1Up to 6 battery modules (not included)
2LYNK II Gateway (not included)
3Busbar Mounting Assembly and Plexiglass Busbar Protector (not shown)

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7.1 Minimum Specifications for AES RACKMOUNT Battery Energy Storage
Systems
To increase system capacity, install AES RACKMOUNT battery modules in a parallel
battery bank configuration. Overall battery energy storage system (BESS) capacity
must be correctly sized to meet the requirements of the load and account for the
following:
• Total Max Charge Current
• Total Peak Discharge Current
• Total Max Discharge Current
The total charging capacity of all charging sources in the system should not exceed
the Max Charge Current operating limit of all the battery modules in the system.
Exceeding this limit will cause the BMS in the battery modules to trigger over-
current protection and disconnect. The charging system’s maximum Continuous
Charge Current must either be below the operating limit of installed battery
modules or curtailed.
The sum of all the Peak Discharge Current values for the attached loads must be less
than the Peak Current value of the BESS, including inrush current values for any
motors and surge values for any inverters.
The sum of all the Max Discharge Current values for the attached loads must be less
than that of the BESS.
For battery modules installed in parallel in a battery bank configuration, the sum of
all battery module capacities provides the overall capacity value for the BESS. Table
7-1 provides DC capacity values for sample systems using the AES RACKMOUNT
battery modules.
NOTICE
• Exceeding the Peak Discharge Current, Max Discharge, or Max Charge values of the
battery modules in the system will either trip the battery module Breaker or trigger
the battery module BMS over-current protection, resulting in the disconnection of all
battery modules in the system.
• Disconnection will result in a voltage spike (Load Dump), which may damage any
component electrically attached to the battery energy storage system.

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Table 7-1, 48-48-5120 / 48-48-5120-H DC Capacity Values for a Sample Battery
Energy Storage System
Specifications @ 25 °C (77 °F)
Part
Number
Parallel
System
Peak
Current
(3 seconds)
Max
Discharge
(1 hour)
Max
Continuous
Discharge
(1)
Max
Charge
(1 hour)
Max
Continuous
Charge (1)
Usable
Capacity
950-0053_1
1 Battery
Module
218 A 95 A 70 A 95 A 70 A 5 kWh
950-0053_2
2 Battery
Modules
436 A 190 A 140 A 190 A 140 A 10 kWh
950-0053_3
3 Battery
Modules
654 A 285 A 210 A 285 A 210 A 15 kWh
950-0053_4
4 Battery
Modules
872 A 380 A 280 A 380 A 280 A 20 kWh
950-0053_5
5 Battery
Modules
1090 A 475 A 350 A 475 A 350 A 25 kWh
950-0053_6
6 Battery
Modules
1308 A 500 A (2) 420 A 500 A (2) 420 A 30 kWh
(1)The maximum continuous charge and discharge values are based on two complete charge and discharge
cycles.
(2) The busbar is rated for 500 A. Do not exceed when charging or discharging the battery modules.
7.2 Closed-loop Communication with Power Conversion Equipment
NOTE
Closed-loop communication is not required in the operation of the Enclosure. Closed-
loop communication is available to improve the performance of batteries and the
power conversion equipment.
Closed-loop communication optimizes the performance and safety of the AES
RACKMOUNT battery modules with Power Conversion equipment (Inverter-charger/
MPPT Controller controller).
For closed-loop communication with the Power Conversion equipment, network the
battery modules to the LYNK II Communication Gateway, then connect the LYNK II
Communication Gateway to the Power Conversion equipment (refer to the 805-0033
LYNK II Installation and Operation Manual).
For instructions on installing and setting up closed-loop communication with Power
Conversion equipment, refer to the specific LYNK II application note for the brand of
Power Conversion equipment in use.

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1
2 3 4 5
Figure 8. Example of the AES RACKMOUNT Slimline Enclosure in a Closed-Loop
System
ITEM DESCRIPTION
1Battery Modules
2Enclosure
3LYNK II Communication Gateway
4Power Conversion System (Inverter-charger / MPPT Controller)
5Power Conversion System Display
NOTE
One LYNK Network can support up to 36 AES RACKMOUNT battery modules. The
total length of the LYNK network cables must not exceed 36 m (118.11 ft).
7.3 Location
The AES RACKMOUNT Slimline Enclosure can be used indoors (1) or outdoors.
If installed indoors, provide smoke alarms in the vicinity in accordance with
appropriate building, fire, and installation codes.
The installation location should be flat, free from debris, and separate from
habitable and living areas. The location should allow for airflow, and ventilation is
required. The ground of the preferred location should have at least 5 cm (2 inches)
thick concrete to enable the use of concrete screws for anchoring the Enclosure.
Avoid installing in locations exposed to salt spray, humid marine environments, or
condensation.
(1)The Enclosure is intended to be suitable for residential installations per UL 9540 clause 42.14.

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Figure 9. Installation Locations
Consider the following, as well as local fire and building codes, when determining
the installation location:
1. Locate away from habitable and living areas. Install the Enclosure in a shed,
attached or detached garage, or outdoors. Do not install in or within 152.4 cm
(5 ft) of habitable and living spaces, including bathrooms, closets, halls, and
storage spaces.
If installed in a garage, either locate the energy storage system so a vehicle
cannot collide with it or protect the energy storage system with a barrier.
If installed and operated outdoors, do not locate within 1 meter (3 feet) of doors
or windows.
2. Flat Surface. The installation surface should be flat and level with appropriate
drainage. Do not install in locations prone to flooding.
3. Away from direct sunlight. Do not install or operate the Enclosure outdoors in an
area exposed to direct sunlight. Install and operate in shaded areas opposite the
sun’s path.
4. Moderate temperatures. Install and operate in a location with ambient
temperatures between 0°C and 40°C (32°F and 104°F). Ambient temperatures of
15°C to 20°C (59°F to 68°F) are ideal for extending LiFePO4battery life.
If the installation environment experiences cold temperatures, use the battery
model that includes heating.

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5. Ventilated. Do not install the Enclosure in a zero-clearance compartment. Provide
at least 44.45 mm (1.75 in) of clearance space at the top, front, back, and sides.
Add vents to allow airflow to the outdoors from the room that houses the
Enclosure and Battery Modules.
6. No objects on the Enclosure. Do not stack objects, components, or other
Enclosures on top of the Enclosure.
8. TOOLS
• Insulated and settable torque driver with bits matched to the nuts, screws, and
bolts in use
• Insulated screwdriver with bits matched to the screws in use
• Hydraulic knockout punch
• Insulated crimping tool
• RMS voltmeter
• Level
• Personal protective equipment
9. PREPARING THE ENCLOSURE FOR INSTALLATION
If any adjustments are required to the AES RACKMOUNT Slimline Enclosure, they
should be made before installing the battery modules.
• Use a two-person lift to move the Enclosure to its final installation location.
• Punch out holes for DC loads, power conversion equipment, and communication
cables.
• Anchor the Enclosure to the ground.
• Remove the busbar plexiglass protector and the busbar mounting assembly.
Use personal protective equipment, including gloves and appropriate footwear,
when working with the Enclosure and battery modules.
NOTE
• To avoid damage and scratches to the Enclosure and its contents, do not lay the
Enclosure on its side.
• The location of holes for DC loads, power conversion equipment, and
communication should minimize exposure to the elements and minimize the ingress
of moisture due to rain, snow, or flooding.
• Consider knocking out the holes on the sides of the Enclosure, on the bottom third
and closer to the door, to provide access to the Enclosure busbar connectors.
• Use appropriate NEMA or IP-rated conduit fittings around holes to maintain the
Enclosure’s NEMA 3R rating.
• Refer to applicable codes and standards set by the local authority having
jurisdiction for the installation of external power conversion equipment. In North
America, refer to NFPA 70 and C22.1.

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9.1 Moving and Leveling the Enclosure
CAUTION
HEAVY OBJECT
The Enclosure is very heavy once fully loaded. Do not move it after it is loaded.
Failure to follow these instructions may result in injury.
1. Turn all the handles to their horizontal position (open) and remove the Enclosure
door. Be careful not to loosen the bonding wire between the door and the
internal rack frame.
2. Inside the Enclosure, find the plexiglass busbar protector and accessory kit.
3. Remove the accessory kit and place the items to the side.
4. Attached to the internal cage is the busbar mounting assembly. Using a Phillips
screwdriver, remove the screws securing the busbar mounting assembly to the
internal cage, and place the busbar assembly and screws to the side.
5. Lift the Enclosure upright.
6. Use a hydraulic knockout punch to punch holes for DC loads, power conversion
equipment, and communication cables.
185 mm
(7.3 in)
85 mm
(3.35 in)
110 mm
(4.3 in)
530 mm
(20.87 in)
Figure 10. Dimensions of Area for Knockouts

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To avoid damage to the internal frame, knock out the holes on the sides of the
Enclosure 85 to 185 mm (3.35 to 7.3 in) from the front opening, and 110 to 530
mm (4.3 to 20.87 in) from the bottom of the Enclosure body. The location of
holes should minimize exposure to the elements and minimize the ingress of
moisture due to rain, snow, or flooding.
7. Carefully move the Enclosure to its final installation location using a two-person
lift.
8. Ensure the Enclosure is level and balanced. Use shims if required.
Level
Figure 11. Level the Enclosure
9. Drill holes into the concrete for anchoring the Enclosure.
10. Attach the four L-brackets to the feet of the Enclosure, then anchor the Enclosure
to the ground with 3/8 inch (9.5 mm) concrete screws.
Figure 12. Anchor with Concrete Screws

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NOTICE
• Do not put heavy objects on top of the Enclosure, as extra weight can damage the
Enclosure, rack, or support feet. If damage occurs, unload the Enclosure and replace
the damaged components.
• The AES RACKMOUNT Slimline Enclosure is very heavy when loaded with battery
modules. It is, therefore, advisable to punch holes for home runs, and position,
balance, and anchor the Enclosure before loading it with battery modules.
• If installing and operating multiple Enclosures, maintain a minimum space of 44.45
mm (1.75 in) between the sides and backs of each enclosure. More space may be
required depending on the location of wires and grommets in the installation.
NOTE
The roof of the Enclosure slopes down 1.87 ofrom front to back to reduce pooling of
water and snow.
10.INSTALLATION
10.1 Mounting the AES RACKMOUNT Battery Modules
CAUTION
HEAVY OBJECT
• The Enclosure is very heavy once fully loaded. Do not move it after it is loaded.
• A two-person lift is recommended when installing the battery module into the
Enclosure. A two-person lift reduces the likelihood of pinching fingers and skin
between the battery module and the Enclosure.
Failure to follow these instructions may result in injury.
CAUTION
ELECTRICAL HAZARD
• Configuration, installation, service, and routine inspections should only be performed
by qualified personnel.
• When installing the battery modules, orient the end with the breakers towards the
bottom.
• Do not install in wet conditions.
• When connecting battery cables to the Enclosure's busbar, use only the busbar
terminal screws. Do not connect the battery cables with screws intended to hold the
busbar mounting assembly to the Enclosure's internal cage.
Failure to follow these instructions may result in injury.
In the order shown below, install the AES RACKMOUNT battery modules into the
Enclosure with their breakers oriented toward the bottom. For detailed instructions,
refer to the AES RACKMOUNT Installation and Operation Manual (805-0043).

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1. Ensure the Enclosure is in its final position.
Moving the Enclosure after it is loaded with battery modules is dangerous. You
may damage parts of the Enclosure, including its base, screws, internal cage,
and Enclosure walls.
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34
56
Figure 13. Order of Installation
2. Starting from the bottom, install the battery modules in the order indicated. The
position of the breakers should be at the bottom.
a. Holding the front end of the battery module higher, carry the battery module
into the Enclosure using a two-person lift.
b. Carry the battery module as deep as you can into the Enclosure, then lower
the back end of the body onto the edge of the internal cage.
Figure 14. Inserting the Battery
Module into the Enclosure