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Installing PBC

PBC 05 Cabinet

INSTALLATION INSTRUCTIONS

1/1531-LZA 701 6011 Uen E

Copyright

Ericsson AB 2011-2012. All rights reserved. No part of this document may be reproduced in any form without the written permission of the copyright owner.

Disclaimer

The contents of this document are subject to revision without notice due to continued progress in methodology, design and manufacturing. Ericsson shall have no liability for any error or damage of any kind resulting from the useof this document.

Trademark List

All trademarks mentioned herein are the property of their respective owners. These are shown in the document Trademark Information.

1/1531-LZA 701 6011 Uen E | 2012-12-19Contents

Contents

1Introduction11.1Target Group1

2Prerequisites32.1Documents32.2Conditions32.2.1Before Going to the Site32.2.2Before Starting the Installation32.3Tools42.4Space5

3System Overview73.1PBC 0573.2PBC 05 Solar Hybrid9

4Work Process for Installing13

5Unpacking and Checking Materials15

6Moving the Cabinet into Position176.1Using a Pallet Truck to Move the Cabinet176.2Using a Hand Truck to Move the Cabinet196.3Using a Lifting Device to Move the Cabinet216.4Carrying the Cabinet by Hand22

7Preparing the Cabinet257.1Correct Roof Panel Sealing26

8Installation298.1Installing Cabinet298.1.1Installing Cabinet on a Floor308.1.2Installing the Cabinet on a Wall328.1.3Installing the Cabinet on a Pole368.1.4Installing Cable Inlets418.2Grounding the Cabinet438.3Installing Incoming AC Power448.4Installing the AC Service Outlet (Optional)488.5Connecting Power Distribution to Site Equipment498.5.1Installing Circuit Breakers and Connecting Cables50

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8.5.2Connecting DC Input on Solar Subrack578.5.3Connecting the Incoming Alarm Cable (Optional)598.5.4Connecting Outgoing Alarm Cables618.5.5Connecting DC Supply to Fans in Other BBS 05 Cabinets(Optional)618.5.6Connecting 48 V DC to other Site Equipment628.5.7Connecting the Battery Temperature Sensor638.5.8Connecting the External Battery Temperature Sensor(Optional)658.5.9Handling the Battery Temperature Sensor when no InternalBatteries in the PBC 05 Cabinet668.5.10Installing the Battery String (Optional)688.5.11Connecting the external Battery Backup Systems (Optional)748.5.12Installing the Heater (Optional)758.5.13Connecting the AC Heater Cable External (Optional)768.5.14Installing the Rectifier Units778.5.15Installing the Controller Unit788.5.16Installing the Door Lock788.6Checking and concluding the installation79

9Power Up and Verification83

10Performing Concluding Routines85

Glossary87

Reference List89

1/1531-LZA 701 6011 Uen E | 2012-12-19Introduction

1Introduction

This document describes how to install and verify the functionality of the following systems:

PBC 05 system, which is a Power and Battery Cabinet (PBC) that supplies 48 V Direct Current (DC) power to outdoor Radio Base System (RBS)equipment.

PBC 05 Solar Hybrid system, which is a PBC 05 equipped with a solar subrack and connected to solar panels.

1.1Target Group

This document is for personnel involved in the site installation engineering process and those responsible for the installation and integration of power systems on site.

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Prerequisites

2Prerequisites

This section contains information on the documentation, tools, equipment, and conditions required for the installation procedure.

2.1Documents

Make sure that the following documents have been read and understood:

Personal Health and Safety Information

System Safety Information

See Reference List on page 89 for required documents.

2.2Conditions

The conditions in this section must be fulfilled before starting work.

2.2.1Before Going to the Site

Before going to the site, make sure of the following:

Site access permission has been received.

Documentation stated in Section 2.1 on page 3 is available.

All tools stated in Table 1 are available.

2.2.2Before Starting the Installation

The Site Installation Document (SID) describes what equipment shall be installed and how the equipment shall be installed at the site. Before starting the installation, make sure of the following:

The site is prepared in accordance with the SID, which is prepared and supplied by site engineering.

Ordered hardware is available.

The site grounding system is installed and tested.

Remove all metallic bracelets, rings and watches to prevent short-circuiting during installation.

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2.3Tools

The tools required for the installation of the RBS are shown in Table 1.

Table 1Required Tools

Product NameProduct NumberIncluded in

Personal tool kit, light(case)

Torque set, insulated525 Nm. For battery installation

LTT 601 156/1

LTT 601 157/1

Torque set, 20100 NmLTT 601 141/1

Torque set, 0.54 NmLTT 601 145/1

Torque set, 525 Nm with 3/8 inch socket adapter

Screwdriver bit forSecure TORX T40-TR

Lifting eyes, M8, kit of four pieces.

Electrostatic Discharge(ESD) wrist strap

LTT 601 140/1

NTM- 101 1902/1

LTT 601 136/1

Ear protectionLYB 921 50/1

Eye protectionLYB 921 51/1

One of the following:

Hammer drill 230 V AC

Cordless hammer drill, with 230 V AC charger

Hammer drills for voltages other than230 V AC cannot be ordered from Ericsson

LTT 601 146/1

LTT 601 147/1

Hammer drill bit, 20 mmOne of the following, as appropriate:

LTT 601 146/1

LTT 601 147/1

More information on tools can be found in Implementation Team ProductsOverview in the RBS Site Installation Products library.

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Prerequisites

In addition to the tools mentioned above, the following material will be required:

Electrical insulation tape

Plastic wire strappers in different dimensions and lengths

Lubrication for sealing

2.4Space

Each cabinet has space requirements both for working condition and airflow. Figure 1. shows recommended dimensions.

The minimum distance to nearest object above the cabinet is 500 mm. The minimum distance to nearest object beside the cabinet is 100 mm. The minimum distance to nearest object behind the cabinet is 80 mm.Note:It is recommended to have more space in front of the cabinet, for a more comfortable working condition.

A

B

C

D

Figure 1Space Around Cabinet

Table 2Installation Space Dimensions

MeasurementDimension in mm

A800

B660C700

D1050

P022458A

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System Overview

3System Overview

3.1PBC 05

The system consists of the main PBC 05 Cabinet, which provides 48 V DC power to all other RBS equipment on the outdoor site. The cabinet has the option to include one string of back-up batteries. An additional option to install up to two more battery back-up systems exists. The BBS 05 is a battery back-up system, and is designed to work with the main cabinet, but it is also possible to connect the main cabinet to other battery back up systems. Alternative battery backup cabinets may be the BBS 6301, BBS 6101 and the BBS 6102.

The main connectivity from the PBC 05 Cabinet is shown in Figure 2 and can be summarized follows:

AC main power supply

48 V DC supply to site equipment.

48 V DC to external battery backup system.

Alarm signal inputs from internal and external sources.

Alarm signal outputs.

PBC 05

BBS 05BBS 05

AC/DCpower

BBBB

BBBB

BBBB

BBBB

BBBB

AC power input

48V DC

48V DC power out

Figure 2PBC 05 System Connectivity

P022425B

Figure 3 shows the main features of the cabinet and Table 3 provides a brief description.

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ABC

Q

DP

E N

F

G M

LKHJH

Figure 3PBC 05 Cabinet

P022422A

Table 3Cabinet Key Modules

Position Function

A Cabinet roof panel

BPanel behind which are cable connections, fans and fan control board

C Door switch

D Controller unit

EConnector blocks on inside wall for Interface Board (IB2), alarms and cable shields

F AC circuit breakers

G Compartment for optional battery string H Cable inlets with environmental sealing J Heater (optional)KMain Earth Terminal (MET) LFilter for incoming airM Cabinet door

N AC main power terminal behind panel

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System Overview

PositionFunction

PRectifiers

QDC Multifunction unit with circuit breakers

3.2PBC 05 Solar Hybrid

The system consists of the main PBC 05 cabinet, which is equipped with a solar subrack and connected to solar panels. The solar subrack is a power device providing electricity for load by using solar energy. It needs to be used together with other power systems. The solar subrack contains the solar connection point and the wind connection point. The cabinet can install up to two BBS 6102, which is a battery back-up system designed to work with the main cabinet. Two BBS cabinets will secure up to two days of battery backup.

The main connectivity from the PBC 05 cabinet is shown in Figure 4 and can be summarized follows:

AC main power supply

48 V DC supply to site equipment.

48 V DC to external battery backup system.

DC input cables from solar panels.

DC input cables from wind generator.

Alarm signal inputs from internal and external sources.

Alarm signal outputs.

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Wind

PBC 05

BBS 6102BBS 6102

AC/DCpower

B B B B B B B B

B B B B B B B B

Junction Box

Solar Subrack

ESC EPP

B B B B B B B B

B B B B B B B B

B B B B B B B B

B B B B B B B B

Diesel

ATC

AC

AC power input

-48V DC

Generator

-48V DC power out

RBS

Figure 4PBC 05 System Connectivity

P023411B

Figure 5 shows the main features of the cabinet and Table 3 provides a brief description.

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System Overview

ABC

N

MD

L

E

F K

JGHG

Figure 5PBC 05 Solar Hybrid Cabinet

P023392A

Table 4Cabinet Key Modules

PositionFunction

ACabinet roof panel

BPanel behind which are cable connections, fans and fan control board

CDoor switch

DAdvanced Controller Unit (ACU+)

Connector blocks on inside wall for Interface Board (IB2), alarms and cable shields

EAC circuit breakers

FSolar Converter with Solar system and Wind generator connection points

4 U space for 19-inch equipment

2 U can be used for Ericsson Site Controller (ESC) and ESC Patch Panel (EPP)

GCable inlets with environmental sealing

HHeater (optional)

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PositionFunction

JFilter for incoming air

KCabinet door

LMain Earth Terminal (MET)

MAC main power terminal behind panel

NRectifiers

DC Multifunction unit with circuit breakers

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Work Process for Installing

4Work Process for Installing

This section provides a process flowchart for installing the cabinet. Figure 6 shows the work process for installing the PBC 05.

Introduction

Material check and unpacking

Preparing and moving cabinet

Cabinet on floorCabinet on wallCabinet on pole

Cabinet grounding

Cabinet AC installation

Cabinet cable installation

Cabinet equipment installation

Cabinet battery installation (optional)

BBS cabling(optional)

Installation check

Installation power up

Performing concluding routines

Figure 6Cabinet Installation flowchart

P022442A

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Unpacking and Checking Materials

5Unpacking and Checking Materials

This section provides information for unpacking and checking the materials. The cabinet is transported in a transport package. In addition to the cabinet,several items like circuit breakers, rectifiers, controllers, cable lugs, batteries and installation frames are packed separately.

Unpack and check the equipment as follows:

1.Examine the packaging for damage. If it has been damaged, make an immediate complaint to the transport company.

2.Check that the items delivered correspond to the packing list. More information can be found in Site Installation Documentation.

3.Unpack the cabinet.

Note:Allow the cabinet to remain on the pallet until required for installation.

4.Dispose of the crate in accordance with local regulations.

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Moving the Cabinet into Position

6Moving the Cabinet into Position

This section provides the procedure for moving the cabinet into position for installation.

The weight of the cabinet is approximative 70 kg. This weight is excluding batteries and installation kit.

When the cabinet is in position a required minimum space around the cabinet is required as shown in Section 2.4 on page 5.

It is recommended that the space in front of the cabinet is increased for more comfortable working conditions.

Note:Cabinets must be moved and installed without batteries.

The following methods are recommended depending on available equipment and the distance to the installation location:

Using a pallet truck to move the cabinet on its pallet as described in Section6.1 on page 17.

Using a hand truck to remove the cabinet from its pallet as described in Section 6.2 on page 19.

Using a lifting device to remove the cabinet from its pallet as described in Section 6.3 on page 21.

Carrying the cabinet by hand as described in Section 6.4 on page 22.

Note:All the above alternatives require at least two people to move the cabinet and install it on either ground, wall or pole.

6.1Using a Pallet Truck to Move the Cabinet

Caution!

Tip risk. Unsecured equipment can tip over if not secured properly, causing injury to personnel. Secure products with a high center of gravity as soon as possible to avoid accidents.

If a pallet truck or similar is available, the following procedure is recommended:

1.Move the pallet, using a pallet truck, close to the installation location.

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Figure 7Moving the Cabinet on a Pallet Truck

2.Gently remove the cabinet from the pallet.

Ge1692A

Figure 8Removing the Cabinet from the Pallet

Ge1693A

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Caution!

Tip risk. Unsecured equipment can tip over if not secured properly, causing injury to personnel. Secure products with a high center of gravity as soon as possible to avoid accidents.

If a hand truck is available, this following procedure is recommended:

1.Gently remove the cabinet from the pallet

Moving the Cabinet into Position6.2Using a Hand Truck to Move the Cabinet

Figure 9Removing the Cabinet from the Pallet

Ge1693A

2.Push the cabinet onto the hand truck using a board between the hand truck and the cabinet to prevent damage

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Figure 10Using the Hand Truck

Ge1694A

3.Gently move the cabinet into position close to the installation location.

Figure 11Move the Cabinet into position

Ge1695A

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Caution!

Tip risk. Unsecured equipment can tip over if not secured properly, causing injury to personnel. Secure products with a high center of gravity as soon as possible to avoid accidents.

The roof panel of the cabinet is fastened with four bolts. The bolts with dimension M8, can temporarily be replaced by lifting eye bolts. The lifting eye bolts are part of the toolset in Table 1 and must be ordered separately.

If a lifting device is available, the following procedure is recommended:

1.If the roof panel has not been removed previously, remove the four corner bolts of the roof panel with a secure TORX T40.

2.Insert the four M8 lifting eyes on top of the cabinet and tighten them finger-tight. The cabinet is now ready for lifting.

3.Attach lifting straps to the lifting eyes, and lift the cabinet close to the installation location.

Note:The lifting device must be designed and approved for the current weight.

Warning!

Overloading, or other wrong use of lifting devices, can cause serious injury to anyone hit by falling equipment. Use long enough lifting straps to create an angle of minimum 60 between lifting straps and roof. A smaller angle increases the strain on the straps and can cause them to snap. Please refer to Figure 13.

4.Attach the cabinet to its ground location or on its wall or pole frame as described in Section 8.1 on page 29.

5.Remove the lifting straps and lifting eyes.

Note:It is not necessary to reinstall the screws for the cabinet roof, at this stage, as it will be removed during the installation process.

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Moving the Cabinet into Position6.3Using a Lifting Device to Move the Cabinet

Installing PBC

Figure 12Lifting Eye Bolts

P022464B

Min 60

Figure 13Lifting the Cabinet

6.4Carrying the Cabinet by Hand

P022426A

It is possible to carry the cabinet by hand. It is recommended to do this by at least two people. It is a difficult operation as the cabinet has no handles and there are no natural points for a good and secure grip.

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Moving the Cabinet into Position

Caution!

The equipment is heavy. Lifting the equipment without the aid of a lifting device can cause injury.

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Preparing the Cabinet

7Preparing the Cabinet

The cabinet comes with some factory installed items and panels. Some cover panels must be removed during the installation process.Please refer to Figure 3 showing the interior of the cabinet. It is recommended to do the following steps:

Remove the door stop at the bottom. This will make it possible to open the door to almost 180 degree.

Remove the cover plate for the fan unit to install all the DC cables. The cover plate is fastened with screws in each corner.

The cover plate for the multifunction unit is fastened with hinges at the bottom. Open the cover by unscrewing the two top corner screws, open the cover downwards and unscrew the bottom screws at the hinges halfway and remove the cover plate completely.

Remove the cover panel over the AC-main power terminal.

Remove the roof panel by removing all the screws on the topside of the cabinet. The roof is secured by two hooks at the front side and they are accessible when the door is opened, as shown in Figure 14.

For lifting purpose only, the 4 corner screws are removed and replaced with lifting eye bolts.

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T40 Torx

4

Figure 14Cabinet Roof

7.1Correct Roof Panel Sealing

P022473C

When the roof panel is installed it is important it is correctly sealed. At the back of the cabinet the outlet air filter is located. On top of the filter a bar is loosely placed. This bar has on its top side a sealing which is a part of the complete roof sealing. See Figure 15 for details of how this bar is placed. To installthe roof panel, do the following steps:

1.Check the sealing gasket at the top of the cabinet.

2.If the gasket is damaged, replaced it.

3.If the gasket is dry, replace it.

4.Check that the bar at the back of the cabinet is properly placed on top of the air outlet filter, with the seal upwards

5.Place the roof panel in correct position.

6.Use metal washer on top of rubber washer to form a proper environmental sealing.

Note:The rubber washer is about 6 mm think. Using the correct torque will compress it to about 3 mm and end at a mechanical stop.

7.Tighten all the M8 bolts with 6 Nm torque.

8.Secure the roof with the two hooks and tighten the screws holding the hooks in the correct locking position, as shown in Figure 14.

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Preparing the Cabinet

If the cabinet is installed on a wall or on a pole, two additional locking plates must be installed at the end of the of the equipment installation process, with the following procedure:

1.Before installing the M8 roof top bolts, swing the locking plate into correct position as shown in the enlarged picture in Figure 24.

2.Place the metal washer on top of the rubber washer on top of the locking plate. Tighten the M8 bolt with a torque of 6 Nm.

3.Tighten the M10 bolt for the locking plate in the frame with a torque of37 Nm.

Figure 15Sealing Bar for Cabinet Roof

P022493A

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Installation

8Installation

The cabinet can be installed on the ground, on a wall or on a pole. The SID explains where to install the cabinet. This section describes how the cabinet is installed.

Note:This document does NOT specify plugs and expanders to be used in the installation process. This information is site dependent and is found in the SID.

Some of installation instructions specify the head of bolt, the socket or bit to be used and the torque that must be applied in tightening the bolt or nut. The torque to be used for battery pole terminals is normally written on the battery. Please pay close attention to the values mentioned. If no values are given, use the table below as general guidelines.

Table 5General Torque Values

Dimension Torque in Nm Note

M6 9.8 For general use M8 24 For general use M10 41 For general useM12 80 For general use

Removing the roof panel of the cabinet is not required for installation. However the installation is much easier if the roof is removed.

Install the empty cabinet first and secure it to its foundation before installing any equipment into the cabinet.

Note:Empty means that no batteries, no wires, no controllers and no rectifiers are installed. Certain factory pre installed equipment is in place, for example, fans, circuit breakers and wire connector blocks.

Depending on where the cabinet is installed, certain steps can be made in a different order. Guidelines are given for each of the different installing options.

8.1Installing Cabinet

The cabinet can be installed on the floor, on the wall or on a pole. For the floor installation a foundation is installed under the cabinet and secured to the floor. For the other two options the cabinet is secured to a frame which first is installed on a wall or on a pole.

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8.1.1Installing Cabinet on a Floor

To install the cabinet on the floor, perform the following procedure:

1.Place the cabinet on its back on the floor, with a protection between cabinet and floor.

2.Install the ground foundation according to figure Figure 16. The four M10 bolts are placed in each corner. Insert bolts with washers from below into the foundation and up into the cabinet. The cabinet has nuts fastened at the inside corner points. Use 17 mm socket and tighten with recommended torque of 37Nm.

3.While cabinet is in this position, install the cable inlets as described in Section 8.1.4 on page 41. The unused inlets must have a plastic cover to seal the inlets. Which inlets to be used and which are unused is given later in the installation document in combination with information in the Site Installation Document.

4.Figure 17 shows the drill pattern for the foundation on the floor.

5.Drill the holes according to the SID.

6.Use a vacuum cleaner to clear the drilled holes.

7.Use the bolts and expanders specified in the SID.

8.Insert expanders into ground.

9.Raise the cabinet and place it in its correct location. Fasten to ground using bolts ant torque specified in the SID.

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4

4

Figure 16Cabinet installing on ground

P022427A

4 14

F

AB

Front

E

C

D

Figure 17Cabinet Drill Pattern, Foundation to floor.

P022457C

Note:The hole placement between frame and foundation is similar to the drill pattern, but there is a small and clear difference to the floor drill pattern.

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Table 6Drill Pattern Dimension

MeasurementDimension in mmA555

B490

C530D582

E24

F32.5

Figure 18Drilling

P009900C

8.1.2Installing the Cabinet on a Wall

This section describes the steps and equipment needed to install the frame on a wall and how to install the cabinet on the frame.

The frame is an optional equipment. It is delivered disassembled, and must be assembled during the installation process before the cabinet can be positioned on the frame. Before starting the work, check that all pieces are present according to Table 7. The frame parts are shown in Figure 19.

Table 7Wall Installation Frame - Part List

LegendDescriptionQuantity

AWall Bracket2BLocking plate2

CBrace2

DL-shaped bracket2EPole bracket0

Square washer plate8

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LegendDescriptionQuantity

Washer for M1018

Nut, M1014Bolt, M10 x 25 mm18

Bolts for wall installation , specified in the8Site Installation Document

Diameter can be up to 12 mm

Expander plugs for wall

A

B

C

D

E

Figure 19Frame Assembly Details

P022701C

To install the frame on the wall, the dimensions shown in Figure 20 and Table8 are important. Figure 21 shows all the parts of the frame. The frame is assembled with M10 bolts from the outside in all the joints. On the inside awasher is installed and followed by the nut.

Figure 24 shows how the cabinet is placed on the assembled frame, which is identical for both wall and pole installation. An enlarged detailed drawing shows how the locking plate is positioned.

Note:Pay close attention to vertical alignment of the two brackets, and that they are parallel and horizontal.

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C

AB

D

E

Figure 20Frame Dimensions, Front View

Table 8Frame Dimensions

DescriptionDimension in mmA945.5

B876.5

C200

DHole diameter, 13 mm

E500

P022702A

To install the frame on the wall, perform the following steps:

1.Prepare the installation work by marking all the holes on the wall for the upper and lower wall brackets. This can be done by marking the holes according to dimensions from Figure 20 or by creating a drill pattern.

Note:Pay close attention to vertical alignment of the two brackets, and that they are parallel and horizontal.

2.Drill the holes for the lower wall bracket. Use dimensions specified in theSID. Clean the holes and use expander plugs

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Installation

3.Use bolts specified in the SID with the square washer plates supplied in the installation kit. Tighten with the torque specified in the SID.

Note:The same brackets are used for pole and wall installation. Ahorizontal flip is the only difference between the two installations.

4.Drill the holes for the upper wall bracket. Use dimensions specified in theSID. Clean the holes and use expander plugs.

5.Use bolts specified in SID with the square washer plates supplied in the installation kit. Do not tighten yet.

6.Check vertical alignment, horizontal alignment and the distance according to Figure 20 before tightening with the specified torque.

7.Install L-shaped brackets on the lower wall bracket. For each side, use two M10 bolts installed from the outside as shown in Figure 21. Use washers and nuts. Tighten with 37 Nm Torque.

8.Install the brace on each side as shown in Figure 21. Use M10 bolts installed from the outside. Use washers and nuts. Check that L-shaped brackets are level before tightening with 37 Nm torque.

9.Install locking plates below the wall frame on the upper wall bracket, as shown in Figure 21. The rounded side must be towards the wall frame. Use M10 bolts installed from the outside. Use washers and nuts. Keep the nut loose enough, so the plate can swing easily. Do not tighten at this point.

10. Lift the cabinet onto the frame and push toward the rear. A lifting device can be used for this operation. Please see Section 6.3 on page 21 for details.

11. If the two rear screws for roof panel have not been removed previously, do so now and slide the cabinet backwards so that the cabinet bottom holes are aligned with the holes on the L-shaped bracket.

12. The cabinet is fastened with four M10 bolts from below. Place a washer on the bolt and insert it upwards through the upper part of the L-shaped bracket and into the bottom of the cabinet as shown in Figure 21. The cabinet has nuts already installed in its bottom plate. Compare to Figure16. Tighten with 37 Nm torque.13. Turn the locking plate forwards. Check alignment with roof top holes. If the installation of equipment is finished and the roof top is reinstalled, itis important to have a correct fastening and environmental sealing. Performthe following steps:

1.Install metal washer on top of rubber washer as shown in the enlarged picture in Figure 24. Tighten the M8 bolt with 6 Nm.

2.Tighten the M10 nut with 37 Nm torque to fasten the locking plate in the wall frame bracket.

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BC A

E D

Figure 21Wall Frame Assembly Details

P022703B

Table 9Frame Details for Wall Installation

DetailDescription

AM10 25 mm bolt. Inserted from outside

BWasher

CNut, tighten with 37 Nm torque

DSquare washer plate 50 50 mm

EFastening bolt. Specified in the Site Installation document

8.1.3Installing the Cabinet on a Pole

This section describes the steps and equipment needed to install the frame on a pole and to install the cabinet on the frame.

The pole installation kit is an optional equipment. It is delivered disassembled, and must be assembled during the installation process before the cabinet can be positioned on the frame. Before starting the work, check that all pieces are present according to Table 10. The frame parts are shown in Figure 19.

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Table 10Pole Installation Frame - Part List

LegendDescriptionQuantityAWall Bracket2

BLocking plate2

CBrace2DL- shaped bracket2

EPole bracket2

Bolt M12 x 400 mm4Washers for M124

Nut, M128

Self locking nut, M128

Square washer plate8

Washer for M1018

Nut, M1014

Bolt, M10 x 25 mm18

To install the frame on a pole, the dimensions shown in Figure 20 and Table8 are important. Figure 22 shows all the parts of the frame. The frame isassembled with M10 bolts from the outside in all the joints. On the inside a washer is installed and followed by the nut.

Figure 24 shows how the cabinet is placed on the assembled frame, which is identical for both wall and pole installation. An enlarged detailed drawing shows how the locking plate is positioned.

Note:Pay close attention to vertical alignment of the two brackets, and that they are parallel and horizontal.

To install the frame on a pole, perform the following procedure:

1.Prepare the wall brackets with the M12 bolts, washers and nuts as shown on the right hand side of Figure 23.

Note:The same brackets are used for pole and wall installation. Ahorizontal flip is the only difference between the two installations.

2.Install the lower wall bracket to the pole as shown in Figure 22 with details shown in Figure 23 left side. Check that the bracket is horizontal. Do not tighten to full torque at this point.

3.Install the upper wall bracket to the pole as shown inFigure 22 with details shown in figure Figure 23 left side. Check that the bracket is horizontal and that the distance between brackets is as shown in Figure 20. Do not tighten to full torque at this point.

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4.Install L-shaped brackets on the lower wall bracket. For each side, use two M10 bolts installed from the outside as shown in Figure 22. Use washers and nuts. Tighten with 37 Nm torque.

5.Install the brace on each side as shown in Figure 22. Use M10 bolts installed from the outside. Use washers and nuts. Check that theL-brackets are level before tightening with 37 Nm torque.

6.Install locking plates below the wall frame on the upper bar, as shown in Figure 22. The rounded side must be towards the wall frame. Use M10 bolts installed from the outside. Use washer and nut. Keep the nut loose enough, so the plate can swing easily. Do not tighten at this point.

7.Lift the cabinet onto the frame and push toward the rear. A lifting device can be used for this operation. Please see Section 6.3 on page 21 for details.

8.If the two rear screws for roof panel have not been removed previously, do so now and slide the cabinet backwards so that the cabinet bottom holes are aligned with the holes on the L-shaped bracket.

9.The cabinet is fastened with four M10 bolts from below. Place a washer on the bolt and insert it upwards through the upper part of the L-shaped bracket and into the bottom of the cabinet as shown in Figure 22. The cabinet has nuts already installed in its bottom plate. Compare to Figure16. Tighten with 37 Nm torque.

10. Tighten all the M12 nuts with 65 Nm torque.

11. Turn the locking plate forwards. The enlarged picture in Figure 24 shows the details. Check alignment with roof top holes.

If the installation of equipment is finished and the roof top is reinstalled, it is important to have a proper fastening and proper environmental sealing. Perform the following steps:

1.Install metal washer on top of rubber washer as shown in the enlarged picture in Figure 24. Tighten the M8 bolt with 6 Nm.

2.Tighten the M10 nut with 37 Nm torque to fasten the locking plate in the wall frame bracket.

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Installation

A

D BC

Figure 22Pole Frame Assembly Details

Table 11Frame Details for Pole Installation

DetailDescription

AM10 25 mm bolt. Inserted from outside

BWasher

CNut, tighten with 37 Nm torque

DSquare washer plate 50 50 mm

EM12 400 bolt, with square plate

P022704C

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HGF

EDCBA

Figure 23Pole Frame Bracket Details

Table 12Pole Frame Bracket Description

LegendDescription

AM12 bolt with square head

BWall bracket

CRound metal washer

DNut

EPole bracket

FSquare washer plate

GSelf locking nut

HNut

P022705B

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Figure 24Assembled Pole Installation Frame

8.1.4Installing Cable Inlets

P022706C

There are several holes with different diameters punched in the metal frame at the bottom of the cabinet. These holes are intended for cable inlets. One cable is allowed per hole. For a proper environmental sealing, cable inlets are installed in the holes. When tightened with a correctly dimensioned cable the inlet will serve both as environmental sealant and as strain relief to the cable. Please refer to Figure 26.

The cable inlet is shown in Figure 25. The inlet is tightened to the cabinet with two nuts. One from above and one from below, as shown in the picture. Make sure the cable gland is installed from the outside of the cabinet.

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Figure 25Cable Inlet

P022430A

Note:Even unused inlets must have a cable inlet installed and covered with a cover seal.

789

18 192223

11011121620215

234

6131415

172425

Figure 26Cable Inlet Positions in Cabinet Bottom

P022444A

The cable inlets are dimensioned for various different cable types and dimensions. Some cables are necessary and some are optional. This is described in detail in the Site Installation document. This document also lists the lengths of the different cables. All the possible options are shown in Table 13

Table 13Cable Inlets and Hole Pattern in Cabinet.

Positionin PBC 05

PG SizeCableDiameter

Cable TypeCable PurposeConnection Type

1PG 1610-14 mmGreen/Yellow 35 mm2

Ground CableCable lug 8mm - Open ended

2PG 2918-25 mmAC mains. 5x 16 mm2

AC main power. Number of conductors can vary

Open end - Open end

3PG 1610-14 mm3 x 1.5-2,5 mm2

Or

2 x 1.5 -2,5 mm2

220 VAC cable to heater in BBSOpen end - Open end

4

5PG 115-10 mm4 x 2 x 0.5 mm2In PBC: Incoming alarm cable

In BBS: incoming alarm cable.

Open end - Open end

Open end - Open end

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Table 13Cable Inlets and Hole Pattern in Cabinet.

Positionin PBC 05

PG SizeCableDiameter

Cable TypeCable PurposeConnection Type

6PG 115-10 mm4 x 2 x 0.5 mm2In PBC: outgoing alarm cable to RBS In BBS: outgoing alarm cable to PBCor BBS

Open end - Open end

Open end - Open end

7-15PG 1610-14 mm2 x 6-16 mm2

Shielded cable

16PG 2113-18 mm2 x 16 mm2

1 x 25- 70 mm2

Shielded cable

17PG 2113-18 mm2 x 16 mm2

1 x 25- 70 mm2

Shielded cable

PBC to RRUOpen end - Open end

PBC to RBSOpen end - Open end

PBC to RBSOpen end - Open end

18PG 115 - 10 mm2 x 2.5 - 6 mm2From PBC to BBS for DC to fanOpen end - Open end

19PG 115 - 10 mm2 x 2.5 - 6 mm2From PBC to BBS for DC to fanOpen end - Open end

20PG 94 -8 mmtemp sensorIn PBC: Incoming temperature sensor

21PG 94-8 mmtemp sensorIn PBC: Incoming temperature sensor

In BBS: Outgoing temperature sensor

Special Cable

Special Cable

22-25PG 2918-25 mm1x 50 mm2

1x 70 mm2

1 x 95 mm2

PBC to BBS. Always in Pairs. Un- shielded

Open ended- Open ended

8.2Grounding the Cabinet

This section describes how to install the cabinet grounding cable.

The cabinet ground cable must be a 35 mm2 green/yellow cable. It is installed through the inlet position 1 at the bottom. Refer to figures Figure 26 and Table 13.

The cabinet is equipped with a Main Earth Terminal (MET) on the left hand side in front of the battery compartment, see Figure 27.

To install the grounding cable, perform the following steps:

1.Connect the cable lug on the grounding point, the lower M8 stud on theMET.

2.Connect the other end of the ground cable to site grounding terminal.

3.Use plastic strip wire to secure the ground cable to the left inside frame of the cabinet to the hole near the MET.

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4.Tighten the nut around the bottom of the cable inlet to form a tight seal in the cable gland.

13 mm

24 Nm

Figure 27Ground Cable Installation on Main Earth Terminal (MET)

8.3Installing Incoming AC Power

This section describes how the AC main power is installed.

P022460A

The incoming AC main power cable is installed through the inlet position 2 at the bottom. Refer to figures Figure 26 and Table 13.

The AC distribution unit is "box-like" and the front and rear view is shown in the Figure 28. The AC main power terminal is shown in Figure 29, when the cover plate on the left front side is removed.

The type of AC cable depends on the market, and is specified in the site installation document. Electricity delivered to the site may vary. The cabinet can be adapted to several different configurations. At the back of the AC distribution unit, are both the strapping terminal and the Surge Protecting Device (SPD).

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Figure 28AC Distribution Unit

P022432A

PE N L3 L2 L1

Figure 29AC Main Power Terminal

P022668A

Before beginning installation, it is necessary to determine which type of supply is available and then which strapping is needed. This is done using the data in Table 14, Figure 31 and Figure 30.

Position number 1 is the factory default setting. This corresponds to three phases and separate neutral and protective earth lines, with a total of five conductors.

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Table 14AC Configuration and Strapping

Posit ion

Numb er

ConfigurationVoltage range

V AC

NominalVoltage

Phase-Neutral

V AC

Installation figure

13W + N + PE346/200 -433/250

23W + PEN346/200 -433/250

230A

230A

31W + N+ PE200 - 250230B

41W + PEN200 - 250230B

53W + N + PE208/120 -220/127

63W + PEN208/120 -220/12773W + N + PE200/100 -240/120

83W + PEN200/100 -240/120

120C

120C

110C

110C

93W + PE200-240D

102W + PE + N200/100 -240/120

112W + PEN200/100 -240/120

115E

115E

PENL3

L2L1

Figure 30AC Main Power Input Terminal and optional Strapping

Ge1626A

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Do the following steps for the correct AC main power installation:

1.Identify which AC main power configuration is delivered from the local electricity company in accordance with Table 14 and Figure 31.

2.If the default setting is used, go to Step 9.

3.Remove the AC distribution unit by removing the screws on the side of this module.

4.Install the correct strapping in the main power terminal as shown inFigure31 and inFigure 30

5.Install the correct strapping blocks in the strapping terminal, see Figure 31.

6.Install the wires marked X1-X3 correctly in the strapping terminal, as shown in Figure 31.

7.Install the correct strapping in SPD. This is required if the PEN combination is used. See Figure 31.

8.Return the AC distribution unit in its location with a torque of 10 Nm.

9.Remove the left plate on the AC main power distribution unit. The AC main power terminal is located beneath the plate.

10. Feed the AC cable through the cable inlet position 2 at the bottom of the cabinet. Refer to figures Figure 26 and Table 13.

11. Feed the cable along the left interior of the cabinet and through the hole on the left side into the AC distribution box.

12. Strip the AC cable to 10 mm length.

13. Install the AC main power cable in the terminal in accordance with the main power configuration as shown in Figure 31.

14. Use plastic strip wire to secure the AC main power cable and the ground cable to the left inside frame of the cabinet.

15. Install the cover of the left plate on the AC distribution unit using four screws to hold in place.

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Mains Input Terminal Strapping TerminalSPD

PE N L3 L2 L1

AX3 X2 X1

PE N L3 L2 L1

PE N L3 L2 L1

17 16 15 14 13 12 11

7 6 5 4 3 2 1

B

PE NL

ZHONG GUANG

DEHN

PE N L3 L2 L1

C

X3 X2X1

L1 L2 L3 N N

N N N N PE

L1 L2 L3 N

PE

PE N L3 L2 L1

17 16 15 14 13 12 11

PE N L3 L2 L1

7 6 5 4 3 2 1

If PEN connection If PEN connection

D

PEL3 L2 L1

X3 X2 X1

PE N L3 L2 L1

E

17 16 15 14 13 12 11

7 6 5 4 3 2 1

PE NL2 L1

Figure 31Configuration for Different AC Main Power

8.4Installing the AC Service Outlet (Optional)

P022476A

There is space on the AC distribution unit to install an optional AC service outlet. This section describes how it is installed.

The steps in this section can be done if all the incoming AC main power cable installations and configurations have been made. The AC main distributions unit must also be firmly replaced in its position, if it has been removed.

The AC service outlet comes ready assembled and is ready for installation. It consists of two parts: the outlet contact and the circuit breaker and they are interconnected by a piece of cabling. Figure 32 shows the European outlet. Other outlet types can be ordered.

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Note:All outlets are equipped with a residual circuit breaker. To install the AC service outlet, perform the following steps:1.The narrow middle panel of the AC distribution unit is removed by loosening the screw on the top of the panel and then lifting the panel.

2.Connect the three pin connector at the back of the circuit breaker with the connector on the cable just behind the previously removed panel.

3.Insert the panel with the circuit breaker into the bottom slot and fasten it on the top side with the screw from the removed panel.

4.The AC outlet is installed piggy-back on the large panel by sliding the two small flanges into the holes of the panel, and then securing the outlet with the screw on the top end.

Figure 32AC Service Outlet

8.5Connecting Power Distribution to Site Equipment

P022433A

This section describes the installations of cables, Circuit Breakers (CB) and other optional cabling in the system.

Cables to external equipment, and internal equipment, are terminated at various terminals and boards inside the cabinet. The MET and AC connections have been described. External AC and DC connections are described in the coming sections.

On the right hand side on the inside of the cabinet are several connector blocks and boards, see Figure 33. Details will be given in subsequent chapters. Alarm signals and sensors are among the cables which are terminated in this area.

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At the top is the connector block for incoming external digital alarms from other cabinets as shown in detail inFigure 44.

One step below is the interface board for the cabinet controller unit. External temperature sensors are connected to this board. Details are shown inFigure 46

Towards the bottom is an earth connector block for cable shield connection. Refer to Figure 43.

Figure 33Cabinet Right Inside Terminals

8.5.1Installing Circuit Breakers and Connecting Cables

P022465A

This section describes how to install circuit breakers in the cabinet and how DC distribution cables are connected to both the CB with 48 V and the 0 V the connector blocks.

CB's for AC distribution are factory installed.

Figure 34, Figure 35 and Figure 36 shows the DC power shelf from different views and with panels and CB's removed.

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ABC

D

ENTESCE

Figure 34DC Power Shelf

P022459A

Table 15Power Shelf positions

PositionDescription

APriority load for DC distributions. A Factory installed CB in the left most position at 6A is reserved for fan supply. Eightpositions towards the left are available for user configuration.

BBattery circuit breakers. 12 CB positions in total. One block of 4 positions is factory installed.

CMain load CB's. Eight positions available for user configuration.DSystem controller for on-site and remote system access. ERectifiers.

The location, type and number of CB's is depending on the configuration, and is described in the SID.

Circuit breakers are installed at the front of the power system. Figure 35 shows the DC Multifunction Unit. There is a rail for circuit breakers in the front. Behind the CB's there is a 0 V connector block for the corresponding wire pair.

Note:Figure 35 shows the open front cover in a forward position. Remove the cover during installation by halfway unscrewing the screws on the hinges at the bottom.

The lower connector, the pegs shown in Figure 35, are feeding the CB's.

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B

ACDKE

F

JG

H

Figure 35DC Multifunction Unit for PBC Table 16DC Multifunction Unit Details

P022737A

Positi on

Function

ARelays, for power switching to main load and priority load

BDC Surge Protection Device

CConnector block on top of Controller for battery temperature sensor connection

D0 V connector blocks

EDIN rail for CB supportFSystem Controller for on-site and remote system access (1)

GCurrent feeding pegs from relays to circuit breakers

HCircuit breaker

JSpace between 0 V connector blocks and CB's, in which alarm cables are located

KCB terminal for load connection

(1) The system controller for a PBC 05 can be either standard (SCU+) or advanced (ACU+). The system controller for a PBC 05 Solar Hybrid can only be ACU+.

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Circuit breakers occupy between one to four positions depending on the load current. The number and type of CB's is specified in the SID. Figure 37 shows how a CB is installed.

Figure 36DC Multifunction Unit, Left view

A circuit breaker is installed in the following steps:

1.Verify in the SID which type and which position should be used.

2.Make sure all screws in the bottom are completely loosened.

3.Slide the CB from above over the peg .

P022448A

4.Move the top portion inwards as shown on the left hand side of the figure below.

5.Slightly lift the CB so its top end slides over the rail, and then let it drop downwards.

6.Tighten all the bottom end screws as shown on the right hand side of the figure.

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12

Figure 37Circuit Breaker Installation

Circuit Breaker Alarms

P022736A

The PBC 05 system controller is capable of detecting open CB and generate alarms. For that purpose the proper alarm cables need to be installed. The alarm cables are partly factory installed. The installation already done, is the connection for the digital input to the controller. The other end of the cable needs to be installed in the circuit breaker together with the 48 V cable.

Two bundles with CB alarm cables can be found in the groove between theCB suspension DIN rail and the 0 V connector blocks. Please refer to Figure35 and Figure 38. One bundle consists of several black cables. They are shrink wrapped together in the factory delivery, and they are all unmarked. Inaddition there are three colored cables. These are each marked with a battery fuse number, Batt1, Batt2 and Batt3. Number one is intended for the optionalinternal battery string. This CB with fork and alarm cable is factory installed.Number 2 and 3 are intended for the optional external battery cabinets.

For each load in the multifunctional unit an alarm cable must be installed. The battery cables have their dedicated colors and corresponding alarms. Allthe black cables are identical, and any can be used an any CB location. Forinstallation of an alarm cable, please see the details in Figure 39. It shows an alarm cable installed together with the fork in one CB. The same applies ifno fork is used.

Unused alarm cables are bundled together and wrapped in insulated tape and tucked back and secured into the groove.

The fans are located at the back of the shelf above the DC power system. Towards the front is space to feed all the cables to the CB and 0 V rails, which are all installed from above. A cable can have a single terminal or a fork based terminal, depending on the current rate. Figure 39 shows a cable installed with a fork and Figure 40 without a fork. A fork can have two to four teeth connecting to the CB's or 0 V rails, and the Figure 39 shows a fork with two teeth.

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20

Figure 38Alarm Cables

P022492A

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Figure 39Cable Connected to Forks

To Install a cable with fork, perform the following steps:

P022475B

1.Insert the fork in the terminals on the 0 V connector block at the back and tighten all the screws as shown in the figure above.

2.Insert the fork in the terminals on the circuit breaker and tighten all the screws as shown in Figure 39.

3.Strip about 15 mm of the cables.

4.Connect the plus (+) cable to the fork on the 0V connector block. Insert CBalarm cable and tighten the screw.

5.Connect the minus ( ) cable to the fork on the circuit breakers and tighten the screw.

Note:The fork used in the 0V connector block always has two teeth, even ifCB fork has three or four teeth.

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P022738A

Figure 40Cable Connected Directly to 0 V Terminal and Circuit Breaker

To install a cable without fork, perform the following steps:

1.Strip about 15 mm of the cables

2.Connect the plus (+) cable to the ground connector block at the back. Insert the alarm cable and tighten the screw.

3.Connect the minus ( ) cable to the circuit breakers. Tighten the screw.

8.5.2Connecting DC Input on Solar Subrack

The solar subrack is a power device providing electricity for load by using solar energy. The subrack contains the solar connection point and wind connection point. The wind connection point is optional.

Table 17DC Solar Input

ConnectionPoint

Input Voltage RangeOutput Power

Solar2 x (68-106 V DC, Maximum50 A)

Wind44-58,5 V DC, Maximum115 A

Maximum 6 kW

Maximum 5 kW

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Installing PBC

1+2 -3+4 -+

Solar connectionWind connection

Figure 41Cable Connection on Solar Subrack

P023390A

To install a DC input cable from one solar system, perform the following steps:

1.Strip about 10 mm of the cables

2.Connect the (+) cable from the number one solar system to the 1+ on the solar connection point see Figure 41.

3.Connect the minus ( ) cable to the 2-.

4.Tighten the screws firmly.

To install a DC input cable from a second solar system, perform the following steps:

1.Strip about 10 mm of the cables

2.Connect the (+) cable from the number two solar system to the 3+ on the solar connection point see Figure 41.

3.Connect the minus ( ) cable to the 4-.

4.Tighten the screws firmly.

To install a DC input cable from a wind generator, perform the following steps:

1.Strip about 10 mm of the cables

2.Connect the (+) cable from the wind generator to the + on the wind connection point see Figure 41.

3.Connect the minus ( ) cable to the -.

4.Tighten the screws firmly.

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8.5.3Connecting the Incoming Alarm Cable (Optional)

The local controller unit in the cabinet can support both internal end external alarms. This section describes how external digital alarm signals are connected.

External digital alarms are connected to the alarm connector block, shown in Figure 44 . The system is prepared for three external alarms. The alarm inputs are designed in a Normally Closed (NC) configuration.

The Figure 44 shows the alarm connector block which is located on the right hand side of the cabinet. The figure shows, on the left hand side, the factory default delivery. Three wire straps are inserted to close the loop and to prevent the external binary alarms. The position of the alarm connector block is shown in Figure 33. The system controller software is setup assuming three typesof external alarms, namely:

Fan alarm in external cabinet.

Door open in external cabinet.

Fuse open in external battery string

The incoming alarm cable is of type 4x2x0,5 mm 2. It is installed through the inlet position 5 or 6 at the bottom. Refer to figures Figure 26 and Table 13.

The alarm cables has one extra pair of wires that is unused. Strip the cable as shown in Figure 42.

To install alarm cables, perform the following steps:

1.Install cable through the inlet at the bottom and fed it to the alarm connector block.

2.Remove strapping on positions 1-2.

3.Install open door alarm on terminals 1-2.

4.Remove strapping on positions 4-5.

5.Install External Battery fuse open alarm on position 4-5.

6.Remove strapping on position 7-8.

7.Install External Fan alarm on position 7-8.

8.Secure cable to right hand side of cabinet with plastic wire straps.

9.Twist the shield and cut to appropriate length so it can be properly fastened at the cable shield connector block. Refer to figureFigure 43.

10. Tighten the cable inlet nut.

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B

A

C

Figure 42Alarm Cable

P022452A

Table 18Cable stripping

PositionLength

ADismantle the cable to appropriate length. B5 mmCCut the shield to appropriate length to fit to cable shield terminal

Figure 43Cable Shield connector block

P022467A

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1

48 V DC120 V DC

Figure 44Alarm connector block

A BP022729A

Table 19Alarm Terminal Positions

PositionFunction

A 48 V DC to external fan

BDigital alarms from external cabinet in NC loop function.

8.5.4Connecting Outgoing Alarm Cables

The local controller in the cabinet can process both internal and external sources. All alarms that are processed can be generated to an external management or signal entity. The controller has the following two different output formats:

Digital relay output.

RJ 45 connector for Local Area Network (LAN) connectivity. The RJ45 connector is inserted in the socket of the controller Digital output signals are generated in the IB2 board.

8.5.5Connecting DC Supply to Fans in Other BBS 05 Cabinets (Optional)

The cabinet can supply 48 V DC to fans in external battery cabinets. This section describes how to install the outgoing 48 V DC.

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Installing PBC

DC power is provided to external fans from the alarm connector block, shown in Figure 44

The outgoing 48 V DC cable to external fan is of type 2x2,5 mm2. It is installed through the inlet position 18 or 19 at the bottom. Refer to figures Figure 26 and Table 13.

1.Install cable through the inlet at the bottom and route the cable to the alarm connector block.

2.Install the cable on position 11 for the 48 V connection.

3.Install the cable on position 12 for the 0 V connection.

4.Secure the cable to the right hand side of the cabinet with plastic wire straps.

5.Tighten the cable inlet.

8.5.6Connecting 48 V DC to other Site Equipment

The cabinet can supply 48 V DC to various other RBS site equipment. For example the Radio Remote Unit (RRU) and transmission systems can be supplied with DC power. This section describes how to install these power feeds. The type and number is site dependant and is described in detail in the SID.

This installations process requires cable routing through the bottom inlets, along the right hand side of the cabinet up to the top to ground connector block and Circuit Breakers at the top of the cabinet.

Cables are installed through the inlets position 7-15,16 and 17at the bottom. Refer to figures Figure 26 and Table 13.

Cable type, dimension and length are described in detail in the SID.

Cable inlet, based on dimension is defined as listed in Table 13 if not specified in the SID.

The number of CB's and the position to be used is described in the SID.

Seal unused cable inlets at the bottom of the cabinet.

Some cables will have shielding. The shield is connected to the cable shield connector block on the right hand side of the cabinet. Refer to Figure 43.

All DC load cables come in pairs. One for the 48 V DC and one for 0V. In some cases the cable has one conductor, and in some cases the cable might have two conductors. Cables may be shielded or not. Cablespecification like type and length are given in the SID.

For each installed equipment, that is supported by a separate circuit breaker, an alarm cable must be installed. This alarm is triggered when the

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CB triggers and disconnects power to this particular equipment. Please seeSection 8.5.1 on page 50 for more information on alarm cables.

Cable routing and installation in the DC multifunction unit is much easier if the roof panel is removed as described in Section 7 on page 25 and Figure 14.

For each of the cable pairs, follow the procedure below:

1.Insert the cable from below through the correct inlet.

2.Route the cable to the right hand side of the cabinet.

3.Route the cable to the top of the cabinet by feeding it upwards between the cabinet and the rack frame on the right hand side.

4.If the cable is shielded, perform the following steps:

Before feeding the cable to the top, split the shield from the cable.About 60 to 70 cm should be sufficient.

Cut the shield to proper length, twist it, and terminate the shield in the cable shield connector block on the right-hand side as shown in Figure 43.

5.Connect the 0 V cable to the 0 V rail at the back from above. Section 8.5.1 on page 50 describes the options with and without a fork.

6.The 48 V cable is connected to the CB at the front. This is done from above. Please refer to Section 8.5.1 on page 50 showing the options with and without a fork.

Repeat the above steps for all other cable pairs.

To conclude this installation perform the following steps:

1.Tighten all the cables together with a plastic strap wire and also tie the bundle to the right side frame of the cabinet.

2.Tighten the cable inlet nut to form both a tight environmental seal as well as a strain relief.

8.5.7Connecting the Battery Temperature Sensor

This section describes the installation of the battery temperature sensor. It controls the load voltage, depending on temperature.

The control unit in the DC multifunctional unit terminates the signals from all the battery temperature sensors. The cabinet can monitor the input from up to 3 temperature sensors. The controller software controls the load current to the batteries depending on the temperature. Only one of the input signals from the sensor is able to control the load current. Hence it has to be decided which of the temperature sensors has the controlling function. The other two sensors are recognized but only from alarm purpose of high or low temperature.

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The sensor that is selected to control the load current has to be terminated at the connector on top of the control unit. The factory installed temperature sensor, which is intended for internal optional battery string, is terminated at the controller. Please refer to Figure 35 and Figure 45 for details. The other end, the sensor element, is routed to the battery shelf. The other two optional sensors are connected to J11 and J12 on the IB2 as shown in Figure 46.

The temperature sensor itself, is inserted on the side of the selected battery in a temperature sensor holder

If the temperature sensor is to be installed on the side of one battery block, this is done during the process of battery installation as described in Section8.5.10 on page 68.

If the temperature sensor is to be installed on the front of a battery block it can be placed in correct position at any time.

Note:A PBC 05 cabinet can support up to two external battery cabinets.The system may be designed so that the battery load voltage is controlled from an external cabinet. In that case it becomesimportant which of the temperature sensors is connected to the different terminals.

Figure 45Battery Temperature Sensor Termination

Note:Red cable to the left and blue cable to the right.

P022494B

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8.5.8Connecting the External Battery Temperature Sensor (Optional)

The controller interface board IB2, located on the right hand in-side of the cabinet has several connectors. At the bottom side are two connectors, labeled J11 and J12, giving room for two external battery temperature sensors as shown in Figure 46.

J9

SW1J8

J7

J1J6

J10J5

J4

J3

J2J11

J12

Figure 46Interface Board 2

P022466A

The battery sensor cable has on one side a temperature sensor and on the other side a three pin connector. Neither end can pass through the bottom end cable inlet.

Cables are installed through the inlets position 20 and 21 at the bottom. Refer to figures Figure 26 and Table 13.

To install the external temperature sensor, perform the following steps:

1.Remove the plastic housing on the connector for each of the pins. This is done by pressing the spring of the pin contact using a small flat screwdriver and pulling the wire. The metal connector comes out of the housing, still attached to the wire. Repeat this for all the three wires as shown in Figure47 on the left side.

Note:Make sure to list to which position each wire belongs. In Figure 47 the cables are in the following order, top to bottom: black, blue, red.

2.Feed the wire, with the three metal connectors from the inside of the external cabinet to the outside.

3.Feed the wire, with the three metal connectors upwards through the cable inlets in the PBC 05 from below.

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4.Install the plastic housing on the metal connectors by pushing the cable connectors back into the housing. The spring will lock the connector into the housing as shown on the right side of Figure 47.

5.Connect the connector to the IB2 temperature sensor input as instructed below.

6.Place the battery temperature sensor itself in the Battery Backup Systemfollowing the installations guidelines for that specific product.

Temp sensor

IB2 board

Figure 47Temperature Sensor Cable

P022470C

The control unit in the DC multifunctional unit terminates the signals from all the battery temperature sensors. The controller software controls the load current to the batteries depending on the temperature. Only one of the input signals from the sensor is able to control the load current. Therefore it must be decided which of the temperature sensors has the controlling function. The other two sensors are recognized but only from alarm purpose of high or low temperature.

The sensor that is selected to control the load current has to be terminated at the connector on top of the control unit. The other two sensors are connected to J11 and J12 on the IB2 as described above.

8.5.9Handling the Battery Temperature Sensor when no InternalBatteries in the PBC 05 Cabinet

This section describes how to handle the factory installed battery temperature sensor when the PBC 05 has no batteries. The following two scenarios exist:

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No batteries at all in the system. That is, no batteries in the PBC 05 cabinet and no connected BBS cabinet.

Go to Section 8.5.9.1 on page 67 for instructions on how to handle the battery temperature sensor.

Only batteries in a connected BBS. That is, no batteries in the PBC 05 cabinet but a connected BBS cabinet.

Go to Section 8.5.9.2 on page 67 for instructions on how to handle the battery temperature sensor.

8.5.9.1No batteries in the System

Follow the instruction to remove the factory installed battery temperature sensor:

1.Remove the temperature sensor cables from the SCU, as shown in Figure45.

2.Disable the temperature sensor function in the SCU as instructed in theSCU User Guide.

8.5.9.2Only Batteries in a Connected BBS

Follow the instruction to connect the battery temperature sensor from the BBScabinet to the SCU:

1.Follow step 1 to step 3 in Section 8.5.8 on page 65.

2.Remove the factory installed temperature sensor cables from the SCU, shown in Figure 45.

3.Connect the temperature sensor cable from the BBS to the SCU, as shown in Figure 48.

Note:Connect the red cable to the left and the blue cable to the right.The black cable is not used.

4.Place the battery temperature sensor itself in the Battery Backup Systemfollowing the installations guidelines for that specific product.

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Temp sensor

SCU

Figure 48Temperature Sensor Cable between BBS and SCU

8.5.10Installing the Battery String (Optional)

P022976A

The PBC 05 has the space to hold one internal battery string consisting of four batteries. This section describes how the batteries are installed. The product description document explains which battery types are approved. See the reference list for proper document titles.

Note:Battery blocks are heavy. A battery lift may be of assistance

The battery installation is much easier to do if the optional heater has not been installed yet. However it is not a requirement to do this in this particular order.

Figure 3 and Figure 50 show the battery compartment and the battery positioning in the cabinet.

The cable connection to the battery string is factory installed. The terminals with cable lugs come with protective covers, and the loose terminals are found in the battery compartment.

Compare Figure 50 and Figure 51, showing two different ways of installing the cables to the battery string. One battery string has the connections from above and the second battery string has the connections at the front, using adaptors. The front adaptor is used together with Enersys batteries. They are used only at the battery terminals to which the cables are connected.

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Note:Batteries can be secured in position by a battery strap as shown in Figure 49. This strap is an optional equipment that is only mandatory in earth quake zone 4.

Figure 49Battery Strapping

P022436A

Note:Before each battery block is installed in the process below, make sure the top part of the battery strap does not fall on the back of the battery, but stays on top.

To install batteries, perform the following procedure:

1.Install the battery strap as shown in Figure 49. Leave the front end lock open and the strap loose enough to place the batteries.

2.Install the battery block spacer on the right side of the first battery as shown in Figure 52.

3.Place the first battery block in the middle of the shelf and push in half-way, so the battery block does not fall out. Make room enough so the battery terminals stick out in the front.

4.Connect the battery cable to the battery from above and place the cable lug over the negative (-) terminal. Insert the bolt and tighten according to battery type.

5.Push the battery inside and to the left side position No 1, as shown in Figure 50. Make sure the top portion of the battery strap is on top and does not fall behind the battery blocks.

6.Place the second battery block in the middle of the shelf and push inhalf-way, so the block does not fall out. Make room enough so the battery terminals stick out in the front.

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7.Connect the battery cable to the battery from above and place the cable lug over the positive (+) terminal. Insert the bolt and tighten accordingto battery type.

8.Push the battery inside and to the right side position No 4, as shown in Figure 50. Make sure the top portion of the battery strap is on top and does not fall behind the battery blocks.

9.Install the battery block spacer and the temperature sensor holder on the right side of the third battery as shown in Figure 53.

10. Place the third battery block into the shelf and push in and to the left to position No 2 shown in Figure 50. Make sure the top portion of the battery strap is on top and does not fall behind the battery blocks.

11. Install the battery temperature sensor by inserting the sensor in the holder on the right hand side of the battery in position No 2 as shown in Figure 54.

12. Install the inter battery block spacer on the right side of the last battery as shown in Figure 52.

13. Place the last battery block into the shelf and push in half way.

14. Push in and to the right to position No 3 as shown in Figure 50. Make sure the top portion of the battery strap is on top and does not fall behind the battery blocks.

15. Install the battery inter block connection between batteries 1 and 2. Tighten according to battery type.

16. Install the battery inter block connection between batteries 3 and 4. Tighten according to battery type.

17. Install the battery pole protection cover on batteries 1 and 4 as shown inFigure 55. Leave the two last covers to the initialization stage.

Note:Leave the inter battery connection between batteries 2 and 3 uninstalled. This connector is installed during the start up process.

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1234

Figure 50Battery Positions

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Figure 51Battery Front End Adaptor

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HFront

0,5xH3030

Units of measurement: mm

Figure 52Battery Block Spacer Pads

P028071C

HFront

0,5xH0,5xH3030

Units of measurement: mmFigure 53Temperature Sensor Holder

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Figure 54Temperature Sensor Attachment

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Figure 55Battery Pole Protection Cover

P022727A

When all the batteries are in position, pull the two loose ends of the battery holding strap. This will tighten the top side of the strap.Figure 49 shows how the strap must be positioned with the lock at the front.Figure 56 shows in detail how the strap is fed through the lock and how it is secured by closing the lock towards the left.

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Figure 56Battery Strap Locking Mechanism

8.5.11Connecting the external Battery Backup Systems (Optional)

P022437A

In addition to the single battery string in the inside the cabinet, one or two additional cabinets with batteries can be installed. This section describes how the cables are connected.

Cables are installed through the inlets position 22 to 25 at the bottom as shown in Figure 26 and Table 13.

The cables are routed along the right-hand side of the cabinet up to the top to the ground connector block and Circuit Breakers.

For each installed external battery cabinet, a separate circuit breaker and alarm cable must be installed in the DC multifunctional unit. This alarm is triggered when the CB triggers and disconnects power to the external battery cabinet. Please see Section 8.5.1 on page 50 for more information on alarm cables.

For each of the cable pairs, follow the procedure below:

Cable type, dimension and length will be described in detail in the SID.

Cable inlet, by dimension is defined as listed in Table 13 if not specified in SID.

The number of CB's and the position to be used is described in the SID.

Unused cable inlets at the bottom of the cabinet need to be properly sealed.

All Battery Backup System cables come in pairs. One for the -48 V DC and one for 0 V path. Cable specification like type and length are given in the SID.

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Cable routing and installation in the DC multifunction unit is much easier if the roof panel is removed as described in Section 7 on page 25 and Figure 14.

For each of the cable pairs, follow the procedure below.

1.Insert the cable from below through the correct inlet.

2.Route the cable to the right hand side of the cabinet.

3.Route the cable to the top of the cabinet by feeding it between the cabinet and the rack frame on the right-hand side.

4.Insert the 0 V cable in the 0 V rail at the back from above. Section 8.5.1 on page 50 describes the options with and without a fork.

5.Insert a fork with four teeth on top of a CB combination as described in the SID. Install the battery fuse alarm cable in one of the CB terminals at the same time.

6.Insert the 48 V cable in the fork at the front from above.Section 8.5.1 on page 50 describes the options with and without a fork.

Repeat the above mentioned steps for all other cable pairs. Conclude this installation by the following steps:1.Tighten all the cables together with a plastic strap wire and also tie the bundle to the right side frame of the cabinet.

2.Tighten the cable inlet nut to form both a tight environmental seal as well as a strain relief.

8.5.12Installing the Heater (Optional)

In cold areas it may be necessary to install a heater. This section describes the process of installing the heater which is supplied by AC main power. The heater kit also includes a filter cover in the package.

Note:Never install the filter cover in the PBC 05 Cabinet

The heater is shown in Figure 57. It is a complete module. The heater is supplied by AC main power. A cable is factory installed from AC circuit breaker6. The cable end for the heater should be found behind the MET. Follow the steps below for heater installation.

1.Make sure CB 6 is in off position.

2.Pull out the cable pair behind the MET that supplies the heater.

3.Remove the plastic cover over the heater terminal block.

4.Loosen the two screws on the frame, on which the heater will hang.

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5.Install the heater module by sliding the heaters key holes over the loosened screws.

6.Tighten the screws to secure the heater in its position.

7.Connect the ground cable from the heater to the MET and secure by washer and nut. The ground cable is equipped with a cable lug and fits the M6 stud on the MET.

8.Connect the AC main power to the upper side of the terminal block.

9.Instal the plastic cover over the terminal block.

10. Secure the AC main power cable to the inside frame of the cabinet with a plastic wire strap.

11. Check that heater thermostat is set to 9 degrees Celsius.

Figure 57Heater

8.5.13Connecting the AC Heater Cable External (Optional)

P022439B

If the cabinet is used together with external BBS 05 cabinets, it is possible to support them with a heater power cable. This section will describe how the cable to external heaters are installed.

The cable is installed through the inlets position 3 or 4 at the bottom. Refer to figures Figure 26 and Table 13.

Follow the procedure below:

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1.Install the cable through the bottom inlet.

2.Make sure the heater CB 6 is in off position.

3.Remove the plastic cover of the Terminal Block AC.

4.Install the ground cable, which is pre installed in the heater Terminal BlockAC, by connecting its cable lug to one of the 6 mm bolts in the MET.

5.Strip AC heater cable.

6.Loosen the Terminal Block AC screws on the topside.

7.Connect the AC cable on the topside in the same connector blocks as the incoming AC.

8.Tighten screws.

9.Install plastic cover on Terminal Block AC.

10. Secure AC cable to the frame inside cabinet by using plastic strap wire.

11. Tighten cable inlet at bottom of cabinet.

8.5.14Installing the Rectifier Units

The rectifier units, shown in Figure 58, are not factory installed. Up to five rectifiers can be installed.

The rectifiers are installed by sliding them into the designated slots. They are secured by closing the latch at the bottom and by tightening the screw in the bottom right corner. Only slight hand power is sufficient to secure them in their slots.

Two different types of rectifiers are allowed in the system. The difference between them is the efficiency value. It is allowed to have both types installed in the system at the same time.

Note:If not all five rectifiers are used, the empty slots must have a cover plate installed at the front.

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Figure 58Rectifier

8.5.15Installing the Controller Unit

P022472A

The controller unit, shown in Figure 59, is not factory installed. The Standard Controller Unit (SCU) is installed by sliding it into its designated slot. It is secured by a latching arm at the bottom. When the controller unit is in place, the arm is closed to the bottom right corner and secured by a screw. Only slight hand power is sufficient to fasten the screw.

ENTESCFigure 59Controller unit

8.5.16Installing the Door Lock

P022441B

The cabinet has a factory installed door locking mechanism. The door has two locks. The key is a simple form of a triangular shape. Security can be improved by switching one or both locks to a proper lock with a key.

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Replacing the lock is done by unscrewing the nut and bolt in the door lock from the inside. The new lock is installed in the reverse operation with the nut and bolt. The process is shown in Figure 60.

Figure 60Installation of Door Locking Mechanism

8.6Checking and concluding the installation

P022497A

When the installation is completed it must be verified. Table 20 provides a checklist for the installation before power is switched on, and the start-up process is initialized.

Table 20Checklist

ItemDescriptionyesno

Cabinet.1Cabinet location as described in SID.2Cabinet clean and undamaged.3Cabinet fastened as described in SID.

4Check that filters for incoming air in the door and for the outgoing air at the back, are properly in place and are clean.

Main power.5Cabinet ground between MET and site ground.6Ground cable properly fastened and correctly tightened.

7AC main power cable correctly stripped, terminated and fastened in cabinet AC main power terminal.

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ItemDescriptionyesno

8AC main power cable correctly stripped, terminated and fastened in external circuit breaker.

9Check all bolts and nuts at the cabinet MET and cable shield terminals.

Cabling

10Check all cables to make sure no cable is damaged.

11Check all cables terminated in the cabinet for correct stripping.

12Check all terminal and fork screws to be properly tightened.

13Check that all cable ends outside the cabinet are properly terminated. Unconnected cable ends need to have a proper cover or wrapped in isolation tape.

14Check that all cables inside the cabinet are properly fastened to the inside frame, using plastic wire strapping.

15Check that all cable glands in the bottom, with a cable, are properly tightened.

16Check that all unused cable glands in the bottom are properly sealed.

Batteries.

17Check that all batteries in the string are of the same type, and all that are installed in the same direction, facing outwards.

18Check that the battery string has proper connection with0 V and 48V.19Check that the middle inter-cell connector is not installed.

20Check that all other inter-cell connectors are properly installed and tightened.21Make sure all Circuit Breakers are on the "off" position.

22Check that all tools and installation material has been removed from inside the cabinet.23Check that all cables are marked according to SIDinstructions.

After the checklist is completed for the installation of equipment, perform the following concluding steps before power-up:

1.Replace the cover plate in front of the cables and fans at the top inside of the cabinet. This plate is installed with four screws at each corner.

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2.Replace the cover plate for the multifunction unit by first installing the screws at the bottom hinges. The plate is then lifted up and secured at the top.

3.Replace the cabinet roof and secure it using washers and screws and optional locking plates as described in Section 7.1 on page 26.

4.Replace the doorstop.

5.Check that the door closes properly.

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Power Up and Verification

9Power Up and Verification

This section will provide guidelines and checklist for power up and verification of the PBC 05 system

Table 21Start-up preparation and Installation Test

ItemActionResultComment

1Check that ALL circuit breakers are in OFF position.

2Connect remaining battery interconnect strip between batteries 2 and 3.

Install the remaining pole protection covers on batteries2 and 3.

3Measure battery voltages and potential short circuits

4Check incoming main power voltage

Start up

The voltages must correspond to values given by battery manufacturer. Nominal value for a battery string is in the range of48 -51V.

Resistance between battery pole- and cabinet chassis should high(> 50 Ohm)

Resistance between battery pole+ and