EG4 Pre Assembled Enclosed Battery Rack User Manual

: September 13, 2024
: Eg4

Table of Contents

EG4 Pre Assembled Enclosed Battery Rack
TECHNICAL SPECIFICATIONS
ABBREVIATIONS
SAFETY
IMPORTANT SAFETY NOTIFICATIONS
BRIEF INTRODUCTION
INSTALLATION
TROUBLESHOOTING AND MAINTENANCE
CONTACT US
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EG4 Pre Assembled Enclosed Battery Rack

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TECHNICAL SPECIFICATIONS

PHYSICAL SPECIFICATIONS

DIMENSIONS OF THE CABINET (W×D×H)| 23.6 × 26.8 × 46.3 in. (59.9 × 68.1 × 117.6 cm)
DIMENSIONS WITH CASTERS (W×D×H)| 23.6 × 26.8 × 49.4 in. (59.9 × 68.1 × 125.5 cm)
TOP CABLE EXIT POINT DIAMETERS| 1.9 in. (47.6 mm)
SIDE CABLE EXIT POINT DIAMETERS| 2.4 in. (62 mm)
CABLE GLANDS SIZE| 4 AWG
MAX. NUMBER OF BATTERIES| 6 EG4 Server Rack Style
BATTERY CABLE BOLTS (IN BUSBAR)| () M6-1.0×15 with a 10mm hex head (and Phillips head)
SYSTEM CABLE BOLTS (IN BUSBAR)| () M8-1.25×15 with a 13mm hex head (and Phillips head)
BATTERY SECURING BOLTS| M5-0.8×10 with an 8mm hex head (and Phillips head)
BUSBAR TORQUE VALUE| 60 in-lbs. (7 Nm)
WEIGHT (INCLUDING CASTERS)| 168.9 lbs. (76.6 kg)
CABINET MATERIAL| Heavy-duty Steel and Welded Joints
FINISH COLOR| Black: Powder-coated
SPECIFICATIONS
MAX. BUSBAR CURRENT| 600A
ENERGY STORAGE CAPACITY| 5.12 – 30.72kWh
BUSBAR COVERS| Yes
BUSBAR HEAT SHRINK PROTECTION| Yes
WARRANTY
STANDARD WARRANTY| 3 years

(*) Always use the proper torque to fasten DC power cable connections. The M6 cable bolts should be torqued to 70 in-lbs. (8 Nm) and the M8 cable bolts should be torqued to 150 in-lbs. (17 Nm).

ABBREVIATIONS

A – Amp(s)
AC – Alternating Current
Ah – Amp hour(s)
AHJ – Authority Having Jurisdiction
ANSI – American National Standards Institute
AWG – American Wire Gauge
BAT – Battery
BMS – Battery Management System
COM – Communication
CT – Current Transformer
DC – Direct Current
DIP – Dual In-line Package
DOD – Depth of Discharge
EG – Equipment Ground
EGS – Equipment Grounding System
EPS – Emergency Power System
ESS – Energy Storage System
E-Stop NO – Emergency Stop Normally Open
FCC – Federal Communication Commission
GE – Grounding Electrode
GEC – Grounding Electrode Conductor
GEN – Generator
GES – Grounding Electrode System
GFCI – Ground Fault Circuit Interrupter
GFDI – Ground Fault Detector/Interrupter
IEEE – Institute of Electrical and Electronic Engineers
Imp – Maximum Power Point Current
In-lbs. – Inch Pounds
IP – Ingress Protection
Isc – Short-Circuit Current
kW – Kilowatt
kWh – Kilowatt-hour
L1 – Line 1
L2 – Line 2
LCD – Liquid Crystal Display
LFP – Lithium Iron Phosphate or LiFePO4
MID – Micro-Grid Interconnection Device
mm – Millimeter(s)
MPPT – Maximum Power Point Tracker
ms – Millisecond(s)
mV – Millivolt(s)
NEC – National Electrical Code
NEMA – National Electrical Manufacturers Association
NFPA – National Fire Prevention Association
Nm – Newton Meters
NOCT – Normal Operating Cell Temperature
PC – Personal Computer
PCB – Printed Circuit Board
PE – Protective Earth (G or Ground)
PPE – Personal Protective Equipment
PV – Photovoltaic
RSD – Rapid Shut Down
SCC – Standards Council of Canada
SOC – State of Charge
STC – Standard Testing Conditions
UL – Underwriters Laboratories
UPS – Uninterrupted Power Supply
V – Volt(s)
Vmp – Voltage Maximum Power
Voc – Open-Circuit Voltage

SAFETY

SAFETY INSTRUCTIONS

Before beginning any work, carefully read all safety instructions, and always observe them when working on or with the cabinet and/or batteries. The installation must follow all applicable national or local standards and regulations. Consult with the local Authority Having Jurisdiction (AHJ) to obtain the proper permits and permissions before installation.

Incorrect installation may cause:

injury or death to the installer, operator or third party
damage to the inverter or other attached equipment

IMPORTANT SAFETY NOTIFICATIONS

DANGER! Hazardous Voltage Circuits!

There are various safety concerns that must be carefully observed before, during, and after the installation, as well as during future operation and maintenance. The following are important safety notifications for the installer and any end users of this product under normal operating conditions.

Do not disassemble the cabinet. Contact the distributor for any issues in need of repair for proper handling instructions. Incorrect servicing or re-assembly may result in a risk ofelectric shock or fire and voiding the warranty.
Never connect AC or PV power directly to the cabinet busbars as they are not meant to be present at the busbar. Doing so can result in serious injury and/or death.
Never short-circuit DC inputs when working with the batteries. Short-circuiting the battery may result in a risk of electric shock or fire and can lead to severe injury or death and/or permanent damage to the unit and/or any connected equipment.
Use caution when working with metal tools on or around the cabinet. The risk of electrical arcs and/or short-circuiting of equipment can lead to severe injury or death and equipment damage.
Beware of high battery current. Please ensure that the battery module breakers and/oron/off switches are in the “open” or “off” position before installing or working on the cabinet. Use a voltmeter to confirm there is no voltage present to avoid electric shock.
Do not make any connections or disconnections to the cabinet while the batteries are operating. Damage to system components or risk of electrical shock may occur if working with energized batteries.
An installer should make sure to be well protected by reasonable and professional insulative equipment [e.g., personal protective equipment (PPE)].
Before installing, operating, or maintaining the system, it is important to inspect all existing wiring to ensure it meets the appropriate specifications and conditions for use.
Ensure that the battery and cabinet connections are secure and proper to prevent damage or injuries caused by improper installation.

WARNING: To reduce the risk of injury, read all instructions

All work on this product (system design, installation, operation, setting, configuration, and maintenance) must be carried out by qualified personnel. To reduce the risk of electric shock, do not perform any servicing other than those specified in the operating instructions unless qualified to do so.

Read all instructions before installing. For electrical work, follow all local and national wiring standards, regulations, and installation instructions.
All wiring and grounding should be in accordance with the National Electrical Code (NEC),ANSI/NFPA 70.
All warning labels and nameplates on this cabinet should be clearly visible and must not beremoved or covered.
The installer should consider the safety of future users when choosing the cabinet’s correctposition and location as specified in this manual.
Please keep children away from touching or misusing the cabinet and relevant systems

DISCLAIMER

EG4 reserves the right to make changes to the material herein at any time without notice. Please refer to www.eg4electronics.com for the most updated version of our manuals/spec sheets

BRIEF INTRODUCTION

PRODUCT DESCRIPTION

The EG4® Welded Indoor Cabinet is a great addition to a new or expanding Energy Storage System (ESS). Made of high-quality steel with welded joints and a durable powder coat finish, this rugged unit is resistant to wear and tear over time and is perfect for housing up to six EG4 rack-mountable batteries. It features a locking door handle to prevent unauthorized access and heavy- duty swivel casters with adjustable feet making it simple to move and easy to level and fix in place. Designed to facilitate efficient installation, maintenance, and troubleshooting, this purpose-built cabinet is ideal for collocating batteries in a compact space. The integrated positive and negative busbars support up to 600 Amps of current for increased energy density and the multiple cable entry/exit knockouts on the top, sides, and bottom of the cabinet provide maximum configuration and installation flexibility.

OVERVIEW OF SYSTEM COMPONENTS

Cabinet Diagrams

NO.	ITEM	DESCRIPTION
1	Cable Exit Points	Two 1.5 in. top entry/exit points for positive/negative

battery

cables

2| Handle with Lock| Depress “Push” button and turn handle clockwise to open

the door

3| Swivel Casters| Four heavy-duty swivel casters with adjustable feet
4| Battery Securing Bolts| 48 M5-0.8×10 Phillips hex head bolts for securing batteries

to the cabinet

5| Horizontal Battery Rails| Six pairs of horizontal rails to house each battery
6| Positive Busbar| 825mm 600A rated busbar with red heat shrink, mounted in

Panduit wiring duct (10xM6 bolts, 6xM8 bolts, 2xM10 holes)

7| Negative Busbar| 825mm 600A busbar with Black heat shrink mounted in

Panduit wiring duct (10xM6 bolts, 6xM8 bolts, 2xM10 holes)

8

|

Cabinet Ground Fastener(s)

| Cabinet Ground Fasteners are two M6-1.0×15 studs with a 10mm nut in the floor of the cabinet (one in the front-right and one in the back-left). There is a 10 AWG yellow/green wire from each stud to the cabinet door and back panel,

respectively.

INSTALLATION

UNPACKING AND INSPECTION

Before installation, please inspect the unit. Be sure that nothing inside the package is damaged.

LOCATION FOR STORAGE

The environment the cabinet is stored in can greatly affect the health of the batteries. For best results, the temperature should remain between -4°F and 113°F (-20°C and 45°C). Keep the cabinet away from locations where it may get wet or locations with high humidity (>55%). Install the cabinet away from combustible materials.

REQUIREMENTS FOR INSTALLATION

WARNING!

Avoid exposing the cabinet to conductive materials, such as water, strong oxidizers, and strong acids.
Avoid putting an operational cabinet in direct sunlight to avoid overheating.
When working with the cabinet, keep all flammable materials out of the working area.
Follow all local requirements for earthquake safety and anchoring.
Before installing the batteries, inspect them for signs of damage. Never usedamaged or puffy batteries. Please contact the distributor if a battery isreceived in this state or experiences this issue.
Use caution when installing the batteries to avoid damaging the battery casing orconnections.
Use caution when installing the batteries to avoid pinching fingers

DANGER!

When adding or removing a battery from any rack, cabinet, or busbar, turn off ALL batteries, and use a voltmeter to confirm there is no DC voltage present. This will prevent users from encountering live (powered) busbars by accident. Failure to do so can result in severe injury and/or death. The 6 AWG red and black cables included with EG4 batteries are intended only for the connection from the battery to the battery cabinet busbars. The busbar is designed to handle a max current rating of 600A. Cable sizing from the battery cabinet to the remainder of the ESS is dependent on multiple factors including the system maximum current draw, distance between the battery cabinet and ESS, location, temperature, etc. Under engineering supervision, conductor ampacities should be calculated to ensure compliance with NEC 310.15(C). Where ambient temperature is above 86°F (30°C), cable size must be increased according to NEC 310.

TOOLS NEEDED FOR INSTALLATION

The following tools are commonly needed to install the casters and the batteries into the battery cabinet. These items are not included with the cabinet.

8mm, 10mm and 13mm sockets and ratchet with extensions
Phillips head screwdriver
Torque wrench capable of 70-150 in-lbs. (8-17 Nm)

INSTALLING THE CASTERS ON THE CABINET

Before installing batteries into the cabinet, carefully remove all items from inside thecabinet and lay it on its back, preferably on a clean surface or a furniture blanket.
Using the sixteen M6-1.0×10 Phillips hex head bolts included with the cabinet, and a 10mmsocket and ratchet, or Phillips head screwdriver, attach the casters to the bottom of thecabinet as shown in following figure
After installing and securing all 4 casters, stand the cabinet upright and roll it into the final location.
Rotate the red gear located on each caster to the right to lower the rubber feet until the weight of the cabinet is supported by the rubber feet and not the wheels. Level the cabinet by making small adjustments to each caster. (See image to the right)

REMINDER: It is strongly advised the caster wheels are only adjusted when relocating the rack. During operation, the caster feet should be extended down to support the full weight of the batteries and the cabinet.

OPENING AND LOCKING THE CABINET

3. Push the door closed and rotate thehandle counterclockwise to the closedposition. Push the handle into the dooruntil it is flush as shown in step 1 above.
4. Insert the key and turn clockwise 180° tolock the door handle.
5. Test the lock by pressing the “PUSH”button. The handle should not fullyextend.
Note: There is play in the handle. When conducting this test, the handle may release slightly, but the door will not open. Simply press the handle back down into the flush position.

CABINET GROUNDING

It is important that the cabinet be properly grounded before installing any batteries. Attach an Equipment Grounding Conductor (EGC) from the cabinet’s grounding fastener to the Equipment Grounding System (EGS). It is important that the Equipment Ground Conductor is sized to the Over-Current Protection of the cabinet. Refer to an NEC approved ampacity chart for specifications. The cabinet Grounding Fastener is an M6-1.0×15 stud with a 10mm nut. The cabinet door and back panel both have a 10 AWG Yellow/Green grounding wire attaching them to the cabinet grounding fasteners. The grounding fasteners should always be torqued to 70 in-lbs. (8 Nm).

CAUTION! Do NOT ground the cabinet or cabinet door to the positive or negative busbars!

BATTERY INSTALLATION

Before installing any batteries into the cabinet, verify the cabinet is properly grounded to the system’s earth ground. Ensure the casters have been raised off the floor and the cabinet is resting on the adjustable rubber feet integrated into the casters (see section 5.3.2). This will prevent the cabinet from moving while the batteries are installed. Also note that the batteries are very heavy. Please use the team lift technique while installing batteries to prevent damage to personnel and/or equipment.

Beginning with the bottom cabinet slot and progressing upward, insert the batteries into thecabinet one at a time. Slide each battery into the cabinet until the battery is firmly seated inthe slot before progressing to the next battery. Secure each battery to the cabinet rails withfour of the M5-0.8×10 Phillips hex head bolts included with the cabinet. These bolts requirean 8mm socket or Phillips head screwdriver.
Use the M6-1.0×15 Phillips hex head bolts included in the cabinet busbars and the 6 AWG redand black DC power cables included with the EG4 batteries to connect each battery to theinternal positive and negative busbars, respectively. These bolts require a 10mm socket andshould be torqued to 70 in-lbs. (8 Nm). Always use the proper torque to fasten DC powercable connections.
DO NOT simply finger tighten the battery or busbar terminal bolts. Both require a specifictorque to ensure they do not come loose during operation. The M6 cable bolts should betorqued to 70 in-lbs. (8 Nm) and the M8 cable bolts should be torqued to 150 in-lbs. (17 Nm).Failure to properly torque the terminal bolts can result in serious damage and will void thewarranty.
If the battery came with a ground stud on the front panel and a 10AWG Yellow/Green groundwire, install the ground wire between the battery ground stud and the cabinet ground stud onthe left or right of each battery slot (see image below). The ground studs on the left and rightof each battery slot are M6-1.0×15 with a 10mm nut. Always torque the 10mm nut to 70 in-lbs.(8 Nm) for a secure connection.
To ensure no connection errors, clearly identify the location of the Energy Storage System’s(ESS) positive and negative terminals—normally on the system’s inverter. Once sure of thesystem polarity, connect the main cabinet positive (red) and negative (black) cables to the ESSusing a properly sized fuse/breaker between the battery cabinet and the system. Attach themain DC power cables to the cabinet busbars using the M8-1.25×15 Phillips hex head boltsincluded in the busbars. These bolts require a 13mm socket and should be torqued to 150 in-lbs. (17 Nm). Always use the proper torque to fasten DC power cable connections

CABINET CABLING OPTIONS

This battery cabinet comes with several knockouts on the sides and top to facilitate cabling from the battery cabinet to the remainder of the ESS. For demonstrative purposes, the figure to the right includes conduit stubs installed in six of the 10 available knockouts. These knockouts provide maximum flexibility to install the cabinet in the location and orientation of choice while minimizing cable runs. There are also 4 small 23mm (0.9 in.) holes in the floor of the cabinet (reference item 10 in the callouts of section 4.2). The four glands provided with the cabinet can be installed in these holes to protect wires up to 4 AWG from abrasion. If no wires or cables are fed through the holes in the bottom of the cabinet, it is highly recommended that the glands be installed to better prevent accumulation of dust particles and/or other foreign objects & materials.

EXAMPLE CABINET CONFIGURATION

For demonstration purposes, the image below shows a fully populated EG4® Welded Indoor Cabinet with six EG4 48V batteries.

Batteries:

There are four EG4-LLV2 48V/100Ah batteries (top 4), one EG4-LLV1 48V/100Ah battery, and one EG4 LifePower4 48V/100Ah battery (bottom). These batteries have been connected in parallel using the integrated busbars. This maintains the appropriate 48V system voltage while increasing the discharge rating of this battery bank to 600Ah. In addition, the potential DC output amperage of the rack now approaches 600 Amps, ~100 Amps per battery.

Battery Power Cables:

The 6 AWG power cables required to connect each battery to the internal positive and negative busbars are included with the EG4 batteries. Be sure to choose the correct size cables to connect the cabinet busbars to the remainder of the ESS. Refer to an NEC approved ampacity chart for specifications. Always use the proper torque to fasten DC power cable connections!

Battery Grounding Wires

The LLV1 and LLV2 batteries come with a ground stud on the front panel and a 10AWG Yellow/Green ground wire. These wires are Installed between the battery ground stud and the cabinet ground stud on the left or right of each battery slot.

DIP Switches:

The DIP switches are set according to each battery’s individual requirements. In this example, the top battery acts as master to the bottom five slave batteries.

Communications Cables:

The blue communications cables are daisy-chained to allow all six batteries to share information with the ESS Inverter. In this example, the top Master battery connects to the ESS and is daisy-chained to the remainder of the slave batteries below it.

TROUBLESHOOTING AND MAINTENANCE

Regular cleaning is essential since collected dust and debris can block battery fan filters and cause overheating. Check cable connections to avoid loose or damaged cables from interfering with network connectivity. Always use the proper torque to fasten DC power cable connections. Inspect the cabinet for physical damage such as dents or scratches that may require repairs to maintain structural integrity. In addition, power cords and surge protectors should also be inspected because they can fray over time, resulting in power outages or electrical problems.