805-0094 AES Cabinet Operation + Maintenance Manual
805-0094 AES Cabinet Operation + Maintenance Manual
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TMS Removal and Replacement Procedure

Component: Liquid-Cooled Thermal Management Unit (Chiller)
Model: BTMS-80-ES
System: AES Cabinet
Estimated Time: 1 to 2 hours
Performed By: Qualified Service Provider (QSP)

REQUIRED TOOLS & MATERIALS

  • Hex wrenches (M5, M6, M8)

  • Torque wrench (5 to 11 N·m / 3.69 to 8.1 ft-lb)

  • Socket ratchet (M7)

  • Quick couplers, hose clamps, absorbent pads

  • Electrical test tools, label kit, PPE


STEP 1: Shutdown

  1. Power down the AES Cabinet system.

  2. Engage E-Stop and confirm 0 Vdc on HV terminals.

  3. Disconnect power to the auxiliary 240 Vac input to the cabinet.

  4. Remove all Manual Service Disconnects from the battery modules (MSD).

  5. Tag the system as “De-energized – Maintenance in Progress.”

STEP 2: Disconnect Electrical and Communication Lines

  1. Label and disconnect:

    • AC main power (L-N-PE)

    • CAN communication line

  2. Disconnect the TMS grounding from the cabinet chassis.

  3. Confirm all connectors are clean and protected with caps or covers.

STEP 3: Remove the TMS Unit

  1. Unscrew the M6 mounting bolts that secure the chiller’s brackets.

  2. Remove the water chiller from the rear of the cabinet bottom.

  3. Avoid strain on any coolant lines or harnessing.

  4. Place the unit on a pallet for return/rebuild.

STEP 4: Install Replacement TMS Unit

  1. Slide new chiller into place from the rear of the cabinet.

  2. Align mounting holes and fasten brackets using M6 flange bolts.

    • Torque: 9 to 11 N·m (6.6 to 8.1 ft-lb)

  3. Connect water inlet and outlet hoses.

  4. Confirm directionality of piping (inlet/outlet must not be reversed).

  5. Reconnect:

    • Ground

    • AC power

    • Pump power

    • CAN

STEP 5: Power-up and Functional Verification

  1. Inspect all fittings and lines for leaks.

  2. Wipe down any spilled fluid.

  3. Reapply auxiliary power and restore MSDs.

  4. Power on the inverter and AES Cabinet.

  5. Verify:

    • TMS startup (coolant pump, fan, compressor or heater – based on temperature)

    • No fault codes or alarms

    • Coolant temperatures stabilize at setpoints (Cooling: 20°C / 68°F, Heating: 30°C / 86°F)

  6. Run TMS auto-test or force cooling/heating modes for final validation.

Documentation and Handoff

  • Record:

    • TMS serial number (replaced unit)

    • Coolant batch/lot number

    • Operating pressures at commissioning

    • Time/date of service and technician signature