Micro BBU (2)

3514

32.0

33

Installation Guide

2 Installation Guide MicroPower Outdoor Battery Cabinet, art 351432.033, v1-2005-10

Information in this document is subject to change without notice and does not represent a commitment on the part of Eltek Energy AS.

No part of this document may be reproduced or transmitted in any form or by any means electronic or mechanical, including photocopying and recording for any purpose without the explicit written permission of ELTEK Energy.

Copyright : Eltek Energy AS, Norway 2006 NS-EN ISO 9001:1994 Certifcate no: 900005Q NS-EN ISO 14001:1996 Certifcate no: 900005E. This product holds a CE mark and satisfies all requirements covering relevant standards and directives.

EMC EN61000-6-2 Industrial Environment EN61000-6-3 Residential, Commercial and Light Industry ETS 300386 v1.3.1 Telecommunication Equipment

LVD LVD73/23/EEC Low Voltage Directive EN60950 Safety of Technology Equipment UL60950,UL1801

Art. No. 351432.033 Issue 1, 2005 December

Published 2005-12-15

ESB.

MicroPower Outdoor Battery Cabinet has part no. 105418

POWER DISTRIBUTION

CENTER FOR

COMMUNICATIONS EQUIPMENT

9N73

Certificate no: 900005E Certificate no: 900005Q

3 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10

TABLE OF CONTENTS

1 DESCRIPTION OF MICROPOWER OUTDOOR BATTERY CABINET 4 IMPORTANT NOTICES 4 OVERVIEW GENERAL ARRANGEMENT 4 BLOCK DIAGRAM 5 DC DISTRIBUTION 5 TORQUE SETTINGS 6 ORDERING INFORMATION 6 SCOPE OF DELIVERY 7

2 INSTALLATION PROCEDURES 8 SAFETY PRECAUTIONS 8 RECOMMENDED TOOLS 8 MECHANICAL INSTALLATION 9

Organize the installation site 9 Lifting the cabinet 9 Position and fasten the cabinet 10 Wind resistance 10 Preventing condensation 10 Mount the batteries on the shelf. 11 Fixing point for temperature sensor 11

ELECTRICAL INSTALLATION 12 Cable access for MicroPower Cabinet 15 Schematic Diagram 16 Installation and maintenance instruction for filter mat in MicroPower Cabinet 17

3 ALARM RELAY OUTPUTS AND SIGNAL CONNECTIONS 19 ALARM RELAY SPECIFICATION 19

About Fail-Safe Operation Mode 20 Connections for Internal system wiring 20


1 Description of MicroPower Outdoor Battery Cabinet

This Installation Guide contains information about how to install the MicroPower Outdoor Battery Cabinet.

Important notices

To be installed only in restricted access areas or the like, in accordance with articles 110-16, 110-17, and 110-18 of the National Electrical Code, ANSI/NFPA 70.

For supply connectors use wires suitable for at least 75C

Type: FEPW, RH, RHW, THHW, THW, THWN, ZHHW, USE, ZX or similar.

Use copper conductors only.

The over voltage protection kit contains a class C protection. This requires an external class B protection on the systems mains feed.

Overview General Arrangement

The MicroPower Outdoor Battery Cabinet is a kit that provides an additional battery string for the MicroPower Outdoor System. The cabinet is identical for both systems so the 3 different kits for mounting the cabinet are the same: Floor Mounting Kit, Pole Mounting Kit and Wall Mounting Kit. The cabinet is designed for cable entry trough cable glands at the cabinet base. The cabinet size is 590x427x775mm, (23.2 x 16.8 x 30.5) (WxDxH). The cabinet fulfils IP 55.

The MicroPower Outdoor Battery Cabinet can be expanded with a second battery string. See the Battery Shelf Kit instruction manual for further details. It is also possible to mount the Heater Kit in this cabinet. However the Heater kit requires the AC Kit for Battery Cabinet in order to operate. See the installation manual for both kits for more information.

Figure 1 Flatpack Power Rack System General Arrangement

Heater Kit

(option)

Battery Shelf

2-pol AC breaker

(option)

FAN

Battery breaker

Analog controller board


E

TRIP

60A

CBI

I

0CURVE U2

10 kA

80V

QY-1(13)-D

Fb1+ - +

Fb1

Fb2*

Analog controller

board

T+

-

FAN Temp.sensor Heater*

F3*

-

+

E

LVBD

+*+

Block Diagram

Figure 2. Block diagram. All items marked with * are options.

DC Distribution

Under the battery shelf is a DC distribution. This distribution is equipped with 1 battery breaker (Fb1) and a terminal block (+) for DC connection to the battery bank.

In addition there are 2 terminal blocks (+ and -) for 48V DC supply to the Analog Controller Board and a green/yellow terminal block (E) for earth connection to the cabinet chassis.

Figure 3 DC distribution.

MicroPower Outdoor Cabinet

MicroPower Outdoor Battery Cabinet


Torque settings

Screws in 16sqrmm terminal block: 3.0Nm Screws in 6sqrmm terminal block: 1.2Nm Screws in 2.5sqrmm terminal block: 0.6Nm Screws in CBI breaker: 3.0Nm Screws for battery shelf: 5.0Nm

Ordering information

Part number Description Net weight

105418 MicroPower Outdoor Battery Cabinet 29kg


Installation manual

Eltek

Xxx xxxxxxx

Xxx xxxxxxxXxx xxxxxxx

14

Scope of delivery

The MicroPower Outdoor Battery Cabinet consists of the following components:

Part Note Quantity Unit

Basic Outdoor Battery Cabinet 1 1 pcs

Contb WDU 16 Screw terminal 2 2 pcs

End plate WAP 16/35 3 1 pcs

ContbCLmp=4SQ fuse/2p WAGO 4 2 pcs

Fuse cer5x20=T6A3 250V HBC IEC/UL 5 2 pcs

END plate:4SQ fuse/2 pol WAGO 6 2 pcs

Jumper 10-pol WDU 16mm2 7 0,4 pcs

Cable Gland M20 6-12 Black UL 8 5 pcs

Locknut M20 Black 9 5 pcs

Cable Gland M16 2-6 Black UL 10 4 pcs

Locknut M16 Black 11 4 pcs

Deka-fix + 12 3 pcs

Deka-fix - 13 2 pcs

Manual 14 1 pcs

7

3 1

2

8&9

10&11

6

4

5

12 13


2 Installation Procedures

This section describes how to install the MicroPower Outdoor Battery Cabinet. A step-by-step procedure will guide you through the installation.

For installation of the kits for the MicroPower Outdoor Battery Cabinet refer to the installation manual for each kit.

Safety Precautions

Recommended tools

Always use insulated tools suitable for telecom installations.

; The equipment described in this manual must only be installed by authorized personnel, and only operated by persons who have attended a suitable Eltek Energy training course.

; The equipment represents an energy hazard and failure to observe this could cause terminal injury and invalidate our warranty.

; Products into which our components are incorporated have to comply with a number of requirements. Installation is to be in accordance with the recommendations herein.

; Please read the manual carefully before using the equipment.

TOOLS recommended tools needed on the installation of OEM systems Phillips No.3 Battery shelf

Flat screwdriver 3mm

Flat screwdriver 4,5mm

Flat screwdriver 6mm

All terminal clamps, screw or spring clamps

Flat screwdriver < 3mm Spring connections to alarm/controller board

Posidrive No2 (Flat screwdrivers also suited) MCBs

Socket wrench 10mm Common earth and battery poles


Mechanical Installation

Organize the installation site

Begin preparing the installation site, tools, AC supply cables and fuses, etc.

Check that clearances in front and over the cabinet are sufficient for cooling and to facilitate operation and cable entry.

Check that all parts have been received cabinet, batteries (if applicable), documentation, etc. and inspect them for physical or transit damages; contact Eltek Energy otherwise. Protect all the parts.

To facilitate transport standard MicroPower deliveries consist of two strong packages on pallets: one contains batteries, the other the cabinet.

Lifting the cabinet

Open the cabinet door and demount the 2 screws in the front. Take off the roof.

Fix straps to the eye-bolts. Close the door again so the door does not swing during lifting. Lift the cabinet via the straps with lifting equipment to its intended position. Balance the weight.

Remove the straps and remount the roof once the cabinet has been moved and fixed to its installation position.

Unscrew these 2 screws and take the roof off.

Eye-bolts.


Position and fasten the cabinet

Flatpack PSB 3kW, 48VDC, Outdoor Power Cabinet has different mounting possibilities; Pole mounting, Wall mounting and Floor mounting options are available. Please refer to the Installation guides for the respective mounting kit.

Pole

Pole mounting kit makes it possible to mount the Micropower Outdoor Cabinet to a pole with minimum diameter 60mm and maximum diameter 115mm.

Floor

The floor mounting kit is intended for mounting the Micropower Outdoor Cabinet to a pad/floor.

Wall

The Micropower Outdoor cabinet can be mounted to a wall with the wall mounting kit.

Wind resistance

Cabinets are tested according to GR 487.

Depending upon the geographic location of a cabinet, exposure to high wind speed wind gusts is often a threat. Unbalanced forces may be applied to pole or wall mounted cabinets resulting in a turning moment. Pole or wall mounted cabinets are capable of resisting the turning moment resulting from a 67m/s wind gust acting on half of the front or rear of the cabinet surface, without damage to the mounting hardware.

Plinth mounted cabinets are capable of resisting the overturning moment resulting from a wind gust of 67m/s perpendicular to the largest vertical surface.

Preventing condensation

Condensation might be a problem in case the cabinet is left unpacked overnight without powering it up. In order to avoid condensation put drying agent next to the system and pull a plastic bag over the cabinet. It is important to cover the roof (air outlet) and the air inlet gills on the door.

The system is packed in a plastic bag at delivery. This bag can be wrapped around the system. Only fresh drying agent should be put inside. Use tape and/or rubber bands to tighten the plastic bag to the cabinet.

Figure 4 Cabinet wrapping.

Adhesive tape

Drying agent


Mount the batteries on the shelf.

Lift and position the batteries on the shelf. Fit the inter-links between the batteries.

Do not terminate the battery cables yet.

Use lifting straps for heavy batteries; Refer to the battery suppliers manual for installation instructions.

Fixing point for temperature sensor

It is recommended to place the temperature sensor in the middle of the battery bank. Fix the sensor with a cable tie to the inter-link between battery number 2 and 3.

Figure 5. The temperature sensor fixed with a cable tie to the inter-link between battery no. 2 and 3.

Electric shock

WARNING: The batteries represent a major energy hazard. To avoid short-circuit of battery poles always remove metallic objects like un-insulated tools, rings, watches, etc. from the vicinity of the batteries.

Temperature sensor


Electrical Installation

Installation Comments OK 1. PREPARATION

To ease access to the DIN rail, located at the bottom of the MicroPower Outdoor Battery Cabinet, it is necessary to remove the factory mounted battery shelf.

Remove four PAN screws minding the nuts for square hole in rack. Pull the battery shelf out. Turn OFF the MicroPower system. Turn OFF the battery breaker. Note! This will disconnect 48V feed

to the load.

2. CABLE ENTRY

Cable entry is from bottom of cabinet. Remove the appropriate size knock-outs to accommodate the supplied cable glands. Refer to the section Cable access for MicroPower Cabinet for an overview of all knock-outs in the cabinet base.

Put a flat screw driver between the 2 tags that support the disc. Give the top of the screw driver a knock with a hammer.

Put the screw driver to the other side between the tags and knock again. Start knocking cautiously and gradually increase the force.

Repeat the knocking until the tags are so fatigued that the disc drops out.


3. CABLE GLANDS Mount cable glands in the opened knock-outs.

Pull the cables through the glands. All cables should be pulled at least 10mm too far inside the cabinet and then be pulled the same distance back again. This will lock the cable in the gland and ensure full IP protection.

4. CONNECTIONS IN THE MICROPOWER OUTDOOR CABINET

First prepare the connections in the MicroPower system. Remove the End stop at the right hand side of the battery

breaker (Fb1). Mount 1 of the 16sqrmm terminal blocks and the End plate on the DIN bar. Lock the terminal block and End plate in place with the End stop. The free cable labelled Ext Bat must have insulation removed and terminated into the top of the terminal block. The 4th terminal block is only required is optional BTS 2 load circuit breaker is fitted. Torque: 3.0Nm.

Remove the End stop at the right hand side of the positive terminal blocks. Also remove the End plate. Mount the 16sqrmm terminal block and the End plate on the DIN bar. Connect the 4 position inter-link in the middle of the terminal blocks. Cut off one position of the inter-link if there are only 3 terminal blocks present.

Put the ceramic fuses into the 2.5sqrmm terminal blocks. Also put the End plates on both 2.5sqrmm terminal blocks before they are mounted on the DIN bar. Connect the 2 cables prepared for these two terminal blocks. These cables are labelled Fext1 +Ve and Fext2 Ve. Lock the new terminal blocks with the End stop removed earlier.

Load

Ext.


5. CABLE CONNECTIONS

Connect cables to the battery cabinet. NOTE! These cables are not delivered with the system because the length of these cables will vary from site to site. Turn OFF the battery breaker(s) in the battery cabinet.

Connect the ground cable to the green/yellow terminal block (E) in the battery cabinet. Maximum earth cable cross sectional area is 6sqrmm. Torque: 1.2Nm.

Connect the battery cables from the terminal blocks in the MicroPower system to the terminal block/battery fuse in the battery cabinet. Maximum length is 10m. Maximum size is 16sqrmm. Torque: 3.0Nm at the terminal blocks and battery fuse.

Connect the DC supply cables from the MicroPower fused terminals to the battery cabinet terminal blocks. Maximum cable cross sectional area is 2.5sqrmm. Torque: 0.5Nm.

TRIP

60A

CBI

I

0CURVE U2

10 kA

80V

QY-1(13)-D

+ +

TRIP

60A

CBI

I

0CURVE U2

10 kA

80V

QY-1(13)-D

Fb1++-

F1Fb1

-+

+ -

TRIP

16A

CBI

I

0CURVE U2

10 kA

80V

QY-2(13)-D

E

Load

Ext. B

att.

6. COMMISIONING Commissioning is performed from the MicroPower Outdoor Cabinet. See the installation manual for this system. When the MicroPower system has been powered up turn on the battery breaker in the MicroPower Outdoor Battery Cabinet. Verify that the batteries are being charged.

7. MAINTENANCE Carefully vacuum clean or remove any accumulation of dust or dirt. Especially notice to clean the grill in front of the filter mat. See Installation and maintenance instruction for filter mat in MicroPower Cabinet.


Cable access for MicroPower Cabinet

In the cabinet base there are several knock-outs for cables to the MicroPower Outdoor Battery Cabinet. Below is an overview of all knock-outs and how to use them.

Cabinet rear

Cabinet front

Figure 6 View on inside of cabinet base

APPLICATION POWER CABINET BATTERY CABINET

AC input KNOCK-OUT E1, CABLE DIA 13.0 TO 20.0mm

FOR 3X4.0mmSQ OR 3X6.0mmSQ

KNOCK-OUT J1, CABLE DIA 9.0 TO 16.0mm

FOR 3X2.5mmSQ

BTS1 KNOCK-OUTS F4 & F5, CABLE DIA 6.0 TO 12.0mm

---

BTS2 KNOCK-OUTS F6 & F7, CABLE DIA 6.0 TO 12.0mm

---

BATTERY KNOCK-OUTS F2 & F3, CABLE DIA 6.0 TO 12.0mm

KNOCK-OUTS F2 & F3, CABLE DIA 6.0 TO 12.0mm

ALARM KNOCK-OUT F8, CABLE DIA 6.0 TO 12.0mm ---

GROUND KNOCK-OUT F1, CABLE DIA 6.0 TO 12.0mm KNOCK-OUT F1, CABLE DIA 6.0 TO 12.0mm

DC CONTROL KNOCK-OUTS G1 & G2, CABLE DIA 2.0 TO 6.0mm

KNOCK-OUTS G1 & G2, CABLE DIA 2.0 TO 6.0mm

SPARE KNOCK-OUTS E2 & E3, CABLE DIA 13.0 TO 20.0mm

KNOCK-OUTS E2 & E3, CABLE DIA 13.0 TO 20.0mm


Schematic Diagram

Con

4

Con

1C

on 6

+FA

N

-FA

N

Figure 7. Schematic diagram of MicroPower Outdoor Battery Cabinet with all options installed.


Installation and maintenance instruction for filter mat in MicroPower Cabinet

1. Open the front door of the cabinet by operating the swing handle.

Figure 8. Door with filter

2. Pull the filter mat out of the rectangular aperture at the inside of the front door.

Figure 9. Pull out the filter

3. Fit the filter mat into the aperture in the opposite way of item 2.

Figure 10. Fit the new filter

) Please consider the right direction of the filter. The side with the higher density (harder surface) is to fit towards the door side and is not visible to the user.

Figure 11. Direction of filter.

Wrinkled surface towards the door.

Smooth surface visible from inside of door.


)Make sure that the grill in front of the filter is free from damage, carefully vacuum clean or remove any accumulation of dust and dirt.

)The filter should be replaced by a new one with same density and material quality (EU5 grade acc. to EN 779, Eltek part nr. 200892).

Under normal operational conditions (normal industrial pollution) we recommend to change the filter on a yearly period.

Under ambient conditions with high pollution and near the coast we recommend to change the filter twice a year or shorter.

The pollution of the filter can be detected by an increase of the internal cabinet temperature without any failure of the fan or/and the change of the colour of the mat from white to grey.


3 Alarm Relay Outputs and Signal Connections

The analog alarm interface board inside the MicroPower Outdoor Battery Cabinet is the same as in the MicroPower system. However these 2 boards are separate alarm boards monitoring and controlling each cabinet. The alarms in the battery cabinet are not the same as in the system cabinet. The alarm relays are operated in fail-safe, i.e. the relays are energized when there is no alarm. If several external devices are going to the same digital input, they must be connected in series. The description below describes the pin out in normal state, i.e. the NO output is open in normal operation and shorts to the COM output in the alarm-state.

Alarm relay specification

Figure 12. Alarm relay outputs

CON 4 Pin Assignments For Analog Controller board- Micro Power

Pin Signal Function Pin Signal Function

1

2

3

NO

Com

NC

Relay 1:

Low Voltage Alarm

420,5Vdc

10

11

12

NO

Com

NC

Relay 4:

Low Temp Alarm

Below -5C 1-2C 4

5

6

NO

Com

NC

Relay 2:

Not operating

(Module Fail Alarm)

13

14

15

NO

Com

NC

Relay 5:

Mains abnormal alarm (Only operating when the AC kit for Battery Cabinet Heater is installed)

Below 85Vac or above 300Vac

7

8

9

NO

Com

NC

Relay 3:

High Temp Alarm

Over 40C 1-2C

16

17

NO

Com

Relay 6:

Not operating (LVBD Control

Disconnect at 390,5Vdc)

18

19

NO

Com

Relay 7:

Fan Control

Fan ON: +25C 1-2C Fan OFF: +18C1-2C

Nominal switching capacity 2A/30V DC

Maximum switching power 60W (resistive load)

Maximum switching voltage 220V DC

Maximum switching current 2A DC

CON 4 1-15 alarm relays 16-19 Control relays


About Fail-Safe Operation Mode

All Flatpack PSS alarm outputs use the Fail-Safe Operation Mode (relay coils energized in the systems normal operation mode). In order to implement fail-safe digital inputs circuits, the external relay coil must be energized and the contact closed in the systems normal mode of operation.

Figure 13

Connections for Internal system wiring

Figure 14

Correct Use of Alarm Outputs (example)

+-

NO

Relay X(De-energized coil)

Alarm

CON 6 Pin Assignments

For Analog Controller board- MicroPower

Pin Signal Function

1

2

+

-

Temperature Probe

Red

Blue

3

4

+

-

System Voltage input

Red

Blue

CON 1 Pin Assignments

For Analog Controller board- MicroPower

Pin Signal Function

1

2

L

N

AC Mains input

3

4

N

L

Heater Control

Heater ON: +5C

Heater OFF: +15C

NC

COM

+-

NO

Relay X(Energized coil)

Normal NC

COM

Main Office:

Eltek Energy AS P.O. Box 2340 Strms N-3003 DRAMMEN Norway Phone: 47 32 20 32 00 Fax: 47 32 20 32 10 E-Mail: mailto:[email protected] [email protected] Internet: www.eltekenergy.com

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