Vertiv HPL User manual

Vertiv HPLLithium Ion Energy Storage
System
Service Guide

Vertiv | Vertiv HPLLithium Ion Energy System Installer/Service Guide
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TABLE OF CONTENTS
Important Safety Instructions v
1 Overview 1
1.1 Module Numbering Scheme 1
1.2 Door Sensor 2
1.3 Power Chassis Assembly 2
1.4 Local Interface 4
1.4.1 LCD display 5
1.4.2 Enable and Stop buttons 5
2 Installation 7
2.1 Grounding 11
2.2 Commissioning the Vertiv HPLLithium Ion Energy Storage System 11
2.3 Configuration 15
2.3.1 UPScharger voltage 17
2.3.2 Commissioning Report 17
3 Operation 19
3.0.1 Start up 19
3.0.2 Shut down 19
3.1 LEDs 20
3.1.1 DC-BUS connection/disconnection logic 20
Appendices 23
Appendix A: Technical Specifications 23
Appendix B: Warnings and Faults 25
Appendix C: Cabinet Terminal Block 28
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Vertiv | Vertiv HPLLithium Ion Energy System Installer/Service Guide | iv

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.
Failure to comply with the instructions with this symbol may result in a serious accident, causing death or
a severe injury.
WARNING! Failure to comply with the instructions with this symbol may result in a serious
accident, causing a severe injury.
CAUTION: Failure to comply with the instructions with this symbol may result in minor or
moderate injury.
NOTE: Provides information considered important but not hazard-related. The information relates to
property damage.
IMPORTANT! Indicates valuable tips for optimal installation and operation of the product.
v

DANGER
Indicates a hazardous condition which will result in serious injury or death if not avoided.
WARNING
Indicates a hazardous condition which could result in serious injury or death if not
avoided.
CAUTION
Indicates a hazardous condition which could result in minor or moderate injury if not
avoided.
DANGER
Indicates a hazardous condition which will result in property damage if not avoided.
ENERGY STORAGE DEVICE
Avoid burns or electric shock:
•Service by qualified personnel only.
•Disconnect charger and verify no voltage present before maintenance.
•Turn off battery system and lock out/tag out before maintenance.
ELECTRIC SHOCK HAZARD
Do not remove cover or disassemble.
SHIELD EYES
Wear safety goggles at all times during installation, maintenance or removal. Observe
personal protective equipment (PPE)rules at all times.
ELECTROLYTE HAZARD
Avoid contact with skin, eyes or clothing. If contact happens, immediately flush with
water and seek medical attention immediately.
DO NOT DISPOSE IN TRASH
Transport legally and follow manufacturer's instructions for disposal. Please recycle your
lithium ion battery - do not discard.
GROUND
This symbol indicates a ground point. Ground wires must be connected to a point with
this symbol.
Table 1.1 Safety Symbols
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1 OVERVIEW
The Vertiv HPLLithium Ion Energy Storage System is a high-power DCbattery system for use with Vertiv
Uninterruptible Power Supply (UPS) units, including the Liebert® EXL, EXL/S1, NXL, EXM480V and
NX225-600kVA products. This guide provides information necessary to operate the storage system
correctly.
This guide is for use with storage systems that have been installed by Vertiv service personnel.
For technical specifications, see Appendices on page 23.
CAUTION: Failure to follow safety procedures during use of this product may result in
hazardous operation or damage to the equipment.
WARNING! High Voltage - Electric Shock Hazard. The storage system contains high-voltage
electric shock sources. Do NOTopen any cover of the storage system enclosure, other than
the front door.
1.1 Module Numbering Scheme
The following image shows the module numbering scheme and location of the cabinet terminal block
(CTB).
Figure 2.1 Module Numbering Overview
1

ITEM DESCRIPTION ITEM DESCRIPTION
1 Module 1 5 Module 5
2 Module 2 6 Module 6
3 Module 3 7 Power Chassis Assembly (PCA)
4 Module 4 8 Cabinet Terminal Block (CTB)
Table 2.1 Module Descriptions
Refer to Vertiv submittal drawings for signal wiring requirements and interconnection assignments, based
on UPS type. The following table lists which drawings to refer to for each UPS.
UPSTYPE SUBMITTAL DRAWING
EXL-S1
EXL
NXL
NX225-600
HPL-19-S001
HPL-19-S005
HPL-19-S006
EXM480V
HPL-19-S002
HPL-19-S004
HPL-19-S005
HPL-19-S006
Cabinet with Conduit Box HPL-05-S001
Cabinet without Conduit Box HPL-05-S002
Table 2.2 UPS Submittal Drawings
1.2 Door Sensor
Inside the enclosure at the upper right is a door sensor to indicate when the door is open or closed. If the
door is open for more than 60 seconds, a fault is indicated and the enclosure is disconnected from the DC-
BUS.
1.3 Power Chassis Assembly
The power chassis assembly (PCA)is a 4Uenclosure that controls the connection of the battery
enclosure to the DCbus. The PCAmonitors each battery module's voltage and temperature to ensure
operation within the manufacturer's specified limits throughout the life of the product.
IMPORTANT! Operation of the Vertiv HPLLithium Ion Energy Storage System outside of its
recommended environmental or power limits may void the warranty.
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Figure 2.2 Power Chassis Assembly
ITEM NAME DESCRIPTION
1S1 maintenance disconnect with
lock-out tag-out feature
Used to isolate the battery rack from the DC bus.
Warning!:Do not operate when the CTL PWRBREAKER is closed, except as
specifically directed when logged into the service console.
2Service power input jack (90-
208VAC 50/60Hz)
For use by Vertiv service personnel only. Provides control power for servicing the unit
when battery and DC bus power are unavailable.
3 RUN/SERVICE key switch For use by Vertiv service personnel under guidance from tech support only.
4Control power breaker (CTLPWR)
and shunt trip Interrupts control power from the battery.
5 Battery (BATT)interface Communications connection to battery modules.
6 100BT interface Ethernet interface for Modbus/TCP.
7 USBinterface Connection for retrieving data logs and commissioning information.
8 CONSOLE interface RS-232 interface for Vertiv service personnel use only.
9 SD card interface Contains the BMS firmware and data logs.
Important:Never remove the SDcard from the SDslot on the PCA.
Table 2.3 Power Chassis Assembly Descriptions
CAUTION: ALWAYSperform the following procedure before opening or closing the S1
maintenance disconnect. Failure to follow this procedure may result in damage to your
equipment.
When the Vertiv HPLLithium Ion Energy Storage System is online, the S1 maintenance disconnect may
be opened.
To open the S1 maintenance disconnect:
1. Verify the RUN/SERVICE key switch is in the RUN position.
1 Overview 3

2. Press and hold the STOPbutton for five to 10 seconds or until the STOP and ENABLELEDs
turn red.
3. After 45 seconds, the CTLPWR BREAKER opens, indicating it is safe to open the S1.
To close the S1 maintenance disconnect:
1. Verify the CTLPWRBREAKERis open.
2. Verify the RUN/SERVICEkey switch is in the RUNposition.
3. Close the S1.
4. Close the CTLPWRBREAKER.
1.4 Local Interface
On the front door of the Vertiv HPLLithium Ion Energy Storage System is an LCD display and push
buttons that provide information on the status of the storage system.
Figure 2.3 Local Interface
ITEM DESCRIPTION
1 LCDdisplay
2 ENABLE button
3 STOP RESET button
Table 2.4 Local Interface Descriptions
Along with the Modbus/TCP interface, the local interface is the primary means of interacting with the
storage system.
For more information about the Modbus interface, see the Vertiv HPLLithium Ion Energy Storage System
Operations Guide.
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1.4.1 LCD display
Figure 2.4 LCDLayout
ITEM NAME DESCRIPTION
1Rack status
(ENABLED/DISABLED)
ENABLED means the rack is connected to the DC-BUS. DISABLED means the rack is not
connected to the DC-BUS.
2 Rack mode Displays the mode of the rack - ONLINE, SHUTDOWN, FAULT, SERVICE or WAITING.
3 Battery status Displays whether the battery is Charging, Discharging or Floating at the top of a charge.
4 Seconds Remaining Displays the number of seconds remaining until the battery is exhausted. When not discharging,
this is an estimate based on the last observed discharge.
5 KW Displays the actual power charge/discharge in kilowatts. This reading is always positive.
6 Fault/Warning display Rotates between displaying faults and warnings.
7 Voltage and Current Displays actual battery voltage and actual current charge/discharge. This reading is always
positive.
8 State of Charge (SOC) Displays the percentage charge of the battery.
9 Rack number Displays the number of the rack in the system.
Table 2.5 LCD Layout Descriptions
For warning and fault descriptions, see Warnings and Faults on page 25.
1.4.2 Enable and Stop buttons
At the right of the local interface is the ENABLE button. This button enables the storage system to join
the DC bus when conditions are right. Until that time, the rack will be in WAITING mode, as evidenced by
the FLASHING LED (color dependent on the rack status) around the ENABLE button.
At left of the local interface is the STOP RESET button. This push button disconnects the rack from the
DC bus when it is online or, if a fault exists, resets the fault indication.
1 Overview 5

NOTE: If a fault still exists after pressing the button, pressing RESET a second time resets the fault
indication if the condition has cleared.
For more information on the Enable and Stop buttons, see LEDs on page 20.
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2 INSTALLATION
This section provides information to help you physically install the Vertiv HPLLithium Ion Energy Storage
System at the customer site. Installation must be performed by installers familiar with rigging heavy
equipment and connecting high-power electrical devices and control wiring.
CAUTION: Failure to follow safety procedures during unpacking and installation may result in
severe injury.
WARNING! HIGH VOLTAGE – ELECTRIC SHOCK HAZARD. Battery modules and wires may be
exposed, increasing the probability of electric shock. The energy storage system contains
high-voltage electric shock sources. Do NOT open any cover of the battery module or power
chassis assembly.
To install the storage system:
1. Unpack the rack and remove the bolts holding the bolt-down brackets at the base of the
storage system to the shipping pallet. Do not remove the bolts holding the brackets to the
storage system.
NOTE: If you are installing the cabinets back-to-back, you must use the conduit box for the power
cables. If you are installing the cabinets side-by-side, use of the conduit box is optional. If you are not
using the conduit box, power cables must be installed from the rear of the cabinet before the cabinet is
placed in its final position. Do not loop the cables behind the cabinet as this may impede installation of
the power chassis.
2. Using a lifting device rated for at least one ton (1T), hoist the storage system to the desired
position, utilizing the four eye bolts installed at the top of the unit. When the storage system is
in place and level, remove the four eye bolts and retain for future use.
WARNING! Failure to follow the safety procedures or use of insufficient equipment for the
weight rating of the storage system may result in injury or death.
Figure 3.1 Hoisting the Storage System
7

3. On the top of the rear access panel, loosen the panel hardware with a T-30 star bit or wrench.
4. Slide the rear access panel up and off.
5. Remove the rear interior insulation barrier.
Figure 3.2 Removing the Top and Rear Access Panel
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ITEM DESCRIPTION TOOL NEEDED
1 Front of rack T-30 star drive bit
2 Rear of rack T-30 star drive bit
3 Top panel T-30 star drive bit
4 Rear interior insulation barrier 10mm
5 Rear access panel T-30 star drive bit
Table 3.1 Removing the Top and Rear Access
Panel Descriptions
6. Connect the storage system to a DC-BUS. Torque DC-BUS connections to 9Nm/80 in-lbs. Use
an appropriate-sized cable to safely ensure less than 2VDC drop at 600A from the cable to the
UPS.
7. Re-attach the rear insulation barrier, then re-attach the rear access and top panel. Pass the
cables through the U-shaped cutout on the top panel.
Figure 3.3 Reattaching the Roof and Rear Access Panel
NOTE: Connect the DC-BUS and re-attach the rear access and top panel before placing and bolting the
rack in its final position.
8. Bolt the storage system to the floor by using appropriate flooring bolts to secure the four
brackets at the base of the storage system to the floor.
NOTE: For raised-floor applications, a solid-top floor stand or pedestal should be installed under the
Vertiv HPLLithium Ion Energy Storage System to avoid forcing air into the cabinet.
2 Installation 9

Figure 3.4 Bolting the Storage System to the Floor
NOTE: DC- and DC+ cable pairs must be run together in the same conduit.
NOTE: For side-to-side installation, do NOT remove the side panels. Use the brackets from the
supplied accessory bag to bolt the racks together.
NOTE: The torque specification is 9Nm/80 in-lbs.
Figure 3.5 Installing Baying Brackets for Side-to-Side Installation
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2.1 Grounding
Each rack must be grounded using one of the available eyebolt locations at the top of the frame. Sizing of
the equipment-grounding conductor is based on applicable building codes. The following figure shows
the location of the grounding points.”
Figure 3.6 Grounding Points
2.2 Commissioning the Vertiv HPLLithium Ion Energy Storage System
WARNING! High Voltage - Electric Shock Hazard.
WARNING! Personal Protective Equipment (PPE) is required for step 4.
To commission the storage system:
1. Remove the plexiglass at the front of the rack. Keep the plexiglass to reinstall it prior to UPS
start-up.
2 Installation 11

Figure 3.7 Removing the Plexiglass
2. Run the control wiring through the hole in the conduit and drop it straight down into the
vertical cavity of the rack. Grab the wire from the back, pull it out and connect to the cabinet
terminal block.
Figure 3.8 Running the Control Wiring
3. Connect the UPSand Rack CANsignaling connections on the cabinet terminal block at the
top right of module 6.
4. If applicable, connect the network cable. DHCPis the default mode of operation.
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The power jumpers and negative terminal insulators are hanging through the bushings between shelves
with a protective cover. The positive busbars are fastened to the right-hand threaded inserts, which are
not energized. See the following figure.
Figure 3.9 Connecting Each Battery in the Rack
ITEM DESCRIPTION ITEM DESCRIPTION
1 Cable from the module above 4 Positive busbar
2 Negative insulator 5 Cable to the module below
3 Red positive insulator 6 Negative busbar
Table 3.2 Connecting Each Battery in the Rack Descriptions
NOTE: Ensure each connection is torqued to 9NM/80 pounds.
NOTE: The right terminal is not electrically connected to the battery.
NOTE: Verify S1 is in the open position before connecting the battery modules.
5. The batteries must be connected in the following order:
a. M1 (bottom shelf) POS to M2 NEG.
b. M2 POS to M3 NEG.
c. Skip M3 POS to M4 NEG.
d. M4 POS to M5 NEG.
e. M5 POS to M6 NEG.
f. If not connected, connect M6 POS to the RACK POS cable.
g. Verify at least 1 MΩresistance between M3 POSto M4 NEGwith an ohm meter.
h. M3 POS to M4 NEG.
2 Installation 13

6. Perform the following steps to connect each battery in the rack.
a. Remove the positive insulator from the left (POS)terminal and set aside for later use.
b. Move the busbar from the right-hand (INERT)terminal to the left (POS) terminal.
c. Push the insulated sleeving up the NEG cable. Connect the NEGcable to the POSbusbar.
Push the insulated sleeving over the cable connection and the bus connection.
d. Install the positive insulator in the right-hand (INERT)terminal for later use if the module
must be replaced.
e. Reinstall the plexiglass insulating the front panel.
Figure 3.10 Connecting the Batteries
ITEM DESCRIPTION ITEM DESCRIPTION
1 Positive terminal busbar on module 6 4 JA2 negative
2 Negative terminal busbar on module 1 5 JA2 positive
3 Power Chassis Assembly (PCA)
Table 3.3 Connecting the Batteries Descriptions
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