sitestar cabinet installation instructions · if the sitestar cabinet is configured without the...
TRANSCRIPT
SiteTel Sweden AB, Haukadalsgatan 8A, SE 164 40 Kista, Swedenwww.northbattery.com
SITESTAR CABINET
INSTALLATION INSTRUCTIONS
Doc. No: D000100-INS-02, Rev D Page 2 of 94
Copyright
© NorthStar SiteTel 2012. All rights reserved. No part of this document may be reproduced in any form without 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. NorthStar SiteTel shall have no liability for any error or damage of any kind resulting from the use of this document.
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Contents
1 INTRODUCTION ................................................................................................ 6
1.1 Target Group ................................................................................................................................. 6
1.2 Documents ..................................................................................................................................... 6
1.3 Illustrations ..................................................................................................................................... 6
1.4 Prerequisites .................................................................................................................................. 6
1.5 Abbreviations ................................................................................................................................. 6
2 HEALTH AND SAFETY INFORMATION ........................................................... 7
2.1 Batteries ......................................................................................................................................... 7
2.2 Electrical Equipment ...................................................................................................................... 9
2.3 Refrigerant ................................................................................................................................... 10
2.4 RoHS/WEEE ................................................................................................................................ 10
2.5 In Case of Fire ............................................................................................................................. 11
2.6 Damages ..................................................................................................................................... 11
3 TOOLS AND EQUIPMENT .............................................................................. 11
4 CONTENT OF THE PACKAGING ................................................................... 12
5 UNPACKING AND CHECKING THE EQUIPMENT ......................................... 12
6 GENERAL TORQUES DURING ASSEMBLING ............................................. 14
7 FOUNDATION .................................................................................................. 14
7.1 Preparing the Foundation ............................................................................................................ 14
7.2 Hole Pattern for Cabinet without EQ Zone 4 Reinforcement ....................................................... 16
7.3 Hole Pattern for EQ Zone 4 Cabinet ............................................................................................ 17
7.4 Alternative Foundation ................................................................................................................. 17
8 LIFTING THE CABINET INTO POSITION ....................................................... 19
8.1 Lifting Cabinet without EQ Zone 4 Reinforcement ...................................................................... 19
8.2 Lifting Cabinet with EQ Zone 4 Reinforcement ........................................................................... 20
9 OPEN AND CLOSE THE CABINET DOOR ..................................................... 22
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10 INSTALLING THE CABINET ........................................................................... 23
10.1 Installing Cabinets without EQ Zone 4 Reinforcement ................................................................ 23
10.1.1 Remove the Plinth from the Cabinet ............................................................................................ 23
10.1.2 Installing the Plinth at the Foundation ......................................................................................... 25
10.1.3 Installing the Cabinet at the Plinth ............................................................................................... 25
10.2 Installing EQ Zone 4 Cabinet ....................................................................................................... 26
10.2.1 Prerequisites ................................................................................................................................ 26
10.2.2 Installing the Cabinet ................................................................................................................... 27
10.2.3 Securing the EQ Zone 4 Reinforcement ...................................................................................... 27
11 DOOR ............................................................................................................... 28
11.1 Door Latch ................................................................................................................................... 28
11.2 Changing from Left Hanging Door to Right Hanging Door .......................................................... 30
11.2.1 Disconnecting the Door ............................................................................................................... 31
11.2.2 Removing Door Latch .................................................................................................................. 32
11.2.3 Removing Swing Handle ............................................................................................................. 36
11.2.4 Removing the Door ...................................................................................................................... 37
11.2.5 Removing the Vertical Safety Beam ............................................................................................ 38
11.2.6 Moving Latch Points .................................................................................................................... 39
11.2.7 Installing the Vertical Safety Beam .............................................................................................. 41
11.2.8 Installing the Door ........................................................................................................................ 42
11.2.9 Moving the Locking System ......................................................................................................... 42
11.2.10 Installing the Swing Handle ......................................................................................................... 47
11.2.11 Installing the Door Latch .............................................................................................................. 48
11.2.12 Reconnecting the Door ................................................................................................................ 51
12 EARTH GROUNDING ...................................................................................... 52
13 INSTALLING OPTIONAL EQUIPMENT AND SPARE PARTS ....................... 53
14 INSTALLING CUSTOMER EQUIPMENT ........................................................ 53
14.1 Maximum Equipment Heat Load ................................................................................................. 54
14.2 Customer Equipment Placement ................................................................................................. 54
14.3 Routing Customer Equipment Cables ......................................................................................... 55
15 ROUTING BATTERY CABLES ....................................................................... 55
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16 ROUTING GAS VENTILATION TUBES .......................................................... 59
17 ROUTING BATTERY TEMPERATURE SENSOR CABLE.............................. 61
18 INSTALLING BATTERIES ............................................................................... 62
18.1 Preparing Batteries For Installation ............................................................................................. 62
18.1.1 Pasting Battery Separators to the Batteries ................................................................................ 62
18.1.2 Pasting Temperature Sensor Holder to one Battery ................................................................... 64
18.2 Preparing EQ Zone 4 Cabinet ..................................................................................................... 64
18.3 Installing Batteries ....................................................................................................................... 68
18.3.1 Installing Batteries ....................................................................................................................... 69
18.3.2 Connecting Gas Ventilation Tubes .............................................................................................. 70
18.3.3 Connecting Battery Cables .......................................................................................................... 72
18.4 Reinstalling EQ Zone 4 Components .......................................................................................... 74
19 CABLES AND FUSES ..................................................................................... 76
20 EXTERNAL ALARM CONNECTION ............................................................... 77
20.1 Reconfiguring the External Alarm ................................................................................................ 77
21 CONNECTING POWER ................................................................................... 79
21.1.1 Connecting to Electricity Networks .............................................................................................. 79
21.1.2 Connecting AC Power to the CLU Power Connection Terminal ................................................. 80
21.1.3 Connecting DC Power to the CLU Power Connection Terminal ................................................. 88
22 STACKING OF 1.1 M HIGH CABINETS .......................................................... 89
23 ENVIRONMENTAL CONSIDERATIONS ......................................................... 90
24 COMMISSIONING ............................................................................................ 91
24.1 Starting up the System ................................................................................................................ 91
24.2 ECO Mode ................................................................................................................................... 93
25 RECYCLING .................................................................................................... 94
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1 INTRODUCTION
This document describes how to install the SiteStar Cabinet, an outdoor/Indoor battery backup system.
1.1 TARGET GROUP
The target group for this document is the personnel involved in the site installation engineering process and those responsible for the installation and integration of the site.
1.2 DOCUMENTS
The following documents are available to provide detailed information on the SiteStar Cabinet and its handling:
D000100/1, SiteStar Cabinet Description
D000100/3, SiteStar Cabinet Maintenance
D000100/4, SiteStar Spare Parts
1.3 ILLUSTRATIONS
Illustrations in this document can show alternative designs.
1.4 PREREQUISITES
All performance statement in this document relies on the following:
Only approved hardware are used
Proper hardware handling
Installation instructions as well as documentation for externalequipment are followed
1.5 ABBREVIATIONS
Abbreviations used in this document.
AC Alternating Current
CB Circuit Breaker
CCU Climate Control Unit
CLU Climate Unit
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DC Direct Current
DCCU Direct Current Connection Unit
EN European Norm
ESD Electrostatic Discharge
EQ Earthquake
GWP Global Warming Potential
LED Light Emitting Diode
PE Protective Earth
PSU Power Supply Unit
RoHS Restriction of Hazardous Substances
SPD Surge Protection Device
WEEE Waste Electrical and Electronic Equipment
2 HEALTH AND SAFETY INFORMATION
2.1 BATTERIES
Warning!
High energy levels are present in this unit. Improper handling of the unit can lead to short circuiting that can result in serious injury. Exercise care when working with this unit.
Warning!
To avoid battery thermal runaway, the batteries must be connected to an external PSU with thermal compensated charging. Furthermore, the external PSU must shut off the battery system if the temperature reaches 50°C inside the cabinet.
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Warning!
It is important that every battery is connected with the ventilation tube, and that the first battery in the chain is plugged. The tube must be routed out of the cabinet.
If tubes are not connected properly, there is a risk that explosive gases will accumulate in the cabinet.
Caution!
Improper handling of batteries can result in the batteries short-circuiting, which can result in serious injury due to high energy levels. Exercise the necessary care when working with batteries.
Caution!
Batteries can leak electrolyte if improperly handled. Electrolyte in contact with skin or eyes can cause injury. In the event of electrolyte injuries, rinse the affected area with water and seek medical attention immediately. Use protective equipment when replacing batteries.
Caution!
Excessive heat can cause battery casing to soften and warp, potentially allowing acid to escape. In contact with the skin, acid can cause injury, and if breathed in, can affect the airways. Use protective equipment when replacing batteries.
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Caution!
Heavy batteries can cause injuries when lifting incorrectly.
Caution!
Heavy batteries can cause damages to the property when installed incorrectly.
Warning!
If the SiteStar cabinet is configured without the DCCU it is of vital importance that the Battery cables are provided with adequate protection at the site to ensure compliance to national wiring regulations.
Risk of personal injury and property damage.
2.2 ELECTRICAL EQUIPMENT
Installation personnel should exercise care when working on or around electrical equipment. In addition to this safety information, the specific safety instructions for all products involved in the installation procedure should be adhered to.
When work is being done in a power cabinet, the power supply system must be de-energized. The mains supply and, if applicable, all batteries must be disconnected.
Installation personnel must have competence for electrical installation according to local regulations.
Warning!
High energy levels are present in this unit. Improper handling of the unit can lead to short circuiting that can result in serious injury. Exercise care when working with this unit.
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2.3 REFRIGERANT
The refrigerant consists of R134a (1,1,1,2 – Tetrafluoroethane), which has a GWP of 1300. The required service intervals must be followed and proper care to avoid leakage at service and end of life must be taken.
Hazards
Inhalation of high concentrations may irritate the respiratory tractand cause drowsiness and dizziness. At very high levels there is arisk of breathing difficulties.
Skin contact or splashing in the eyes of the liquefied gas may causefrostbite.
All handling must take place so that inhalation and skin and eye contact is avoided. Avoid the steam coming into contact with the welding arcs. Avoid the steam coming into contact with hot surfaces (decomposition) If there is a suspicion of leakage from the cooling system, ventilate and leave the place. Call for a competent cooling technician.
In case of fire, the refrigerant, R134a, develops toxic and corrosive gases.
The cabinet must be standing upright for at least 1 hour before starting.
Caution!
The cabinet must be standing upright for at least 1 hour before starting.
Caution!
Inhalation of high concentrations may irritate the respiratory tract and cause drowsiness and dizziness. At very high levels there is a risk of breathing difficulties.
Skin contact or splashing in the eyes of the liquefied gas may cause frostbite.
2.4 ROHS/WEEE
For information, see document “DOC-081 – End of Life Treatment Plan”
This document is available on request.
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2.5 IN CASE OF FIRE
Take care of any injured persons – Call for help – Try to extinguish the fire.
Only use approved fire extinguisher for extinguishing electrical equipment.
After a fire the cabinet insulation might has been damaged. In this case the cabinet strength will be considerably reduced and can cause the cabinet to collapse when opening the door.
Warning!
In case of fire, toxic and corrosive gases will be formed.
Caution!
Excessive heat can cause battery casing to soften and warp, potentially allowing acid to escape. In contact with the skin, acid can cause injury, and if breathed in, can affect the airways. Use protective equipment when replacing batteries.
2.6 DAMAGES
If the cabinet gets a dented area in size of a hand, with a depth of 10 mm, the cabinet strength is reduced and has to be replaced.
If the door has been warped so much that it can’t close securely, it must be replaced.
3 TOOLS AND EQUIPMENT
The following tools are required for the cabinet installation:
8 mm wrench
13 mm wrench
18 mm wrench
Allen wrench 5 mm
Torque set 1 – 80 Nm
Spirit level
Screwdriver 0.4x2.5
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Screwdriver PZ #2
Torx T20 screwdriver (only when changing from left hanged door toright hanged door)
Torx T25 screwdriver
Torx T30 screwdriver
Torx T45 screwdriver
Insulated tools for battery and busbar connections
Insulation tape
4 CONTENT OF THE PACKAGING
Content of the packaging
Item No. Designation Art. No. Quantity
1 Cabinet 001/.. 1
2 SiteStar Cabinet Description SiteStar Cabinet Installation SiteStar Cabinet Maintenance SiteStar Cabinet Spare Parts
D000100/1 D000100/2 D000100/3 D000100/4
1 1 1 1
3 Cable Entry kit 1
5 UNPACKING AND CHECKING THE EQUIPMENT
This section describes how to unpack and check the cabinet.
To avoid injuries to the personal unpacking and installing the cabinet, it is important to take special notice to the lifting instructions.
To avoid damages to the cabinet during unpacking and lifting, it is important to follow the lifting instructions and to protect surfaces to avoid scratches from sharp tools and so on.
Do not push the cabinet when it is lying down. The back will be damaged.
Note: Handle the cabinet with care. The edges and corners must not be knocked against hard surfaces.
Note: Do not use sharp tools when removing the packaging.
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Do as follows to unpack the cabinet:
1. Examine the packaging for damage. If it has been damaged,immediately register a complaint with the transport company.
2. Check that the items delivered correspond to the packing list.
3. Unpack the cabinet.
Leave the final unpacking of each unit until it is required during the installation. This will help to avoid losing or misplacing smaller items such as sets of parts supplied with the units.
At delivery the door is left hanging. If the door has to be right hanging, the change to right hanging door is done with the cabinet standing up. See chapter 11.2 for instructions.
Recycle all waste materials that can be recycled and sort waste so that it can be disposed of according to local regulations. See section 25 - Recycling, page 94, for further information.
Warning!
Do not leave the door open when the cabinet is lying down. The door can close and cause serious injury.
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6 GENERAL TORQUES DURING ASSEMBLING
Dimension Torque Note
M12 80 Nm
M8 15 Nm
M8 8 Nm For battery poles
M6 9 Nm Generally
ST 4.8 4 Nm Self drilling and self tapping screws.
End torque, start torque is higher.
ST 4.2 1 Nm
ST 3.5 1 Nm Self drilling and self tapping screws.
End torque, start torque is higher.
7 FOUNDATION
This section describes the foundation the cabinet is to be installed upon and how to prepare it.
7.1 PREPARING THE FOUNDATION
The foundation, the cabinet is to be installed upon, must withstand a load of 1500 kg.
The support points need to be horizontal within 1 mm. See Figure 1.
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Figure 1 Leveling Support Points
If the cabinet is to be installed at a place that can be flooded, the foundation must be prepared so that no water can reach the cabinet. See Figure 2.
Figure 2 Foundation in Flooded Areas
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7.2 HOLE PATTERN FOR CABINET WITHOUT EQ ZONE 4
REINFORCEMENT
Figure 3 shows the hole pattern for assembling the cabinet.
Note: The hole pattern 460 x 620 mm is the preferred configuration for assembling the plinth to the foundation.
The hole pattern 360 x 620 mm and 360 x 632, shown in italic, are alternative configurations for assembling the plinth to the foundation.
Hole dimensions in the plinth are Ø 10 mm.
Figure 3 Hole Pattern for Cabinet without EQ Zone 4 Reinforcement
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7.3 HOLE PATTERN FOR EQ ZONE 4 CABINET Figure 4 shows the hole pattern for assembling the EQ Zone 4 cabinet.
Hole dimensions are Ø 18 mm.
Figure 4 Hole pattern for EQ Zone 4 cabinet
7.4 ALTERNATIVE FOUNDATION
The surface pressure with a fully equipped cabinet will be approximately 4000 kg/m2.
In the case the ground conditions makes it necessary to spread the cabinet weight it is recommended to use beams to assemble the cabinet upon. Figure 5 shows an example of an installation with beams.
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Figure 5 Installation With Beams
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8 LIFTING THE CABINET INTO POSITION
See D000100/1, SiteStar Cabinet Description, for information about the cabinet weight.
Note: No batteries are allowed in the cabinet while lifting it.
Warning!
Be careful when lifting and lowering of the cabinet. Risk of personal injury.
Caution!
Be careful when lifting and lowering of the cabinet. Risk of property damage.
8.1 LIFTING CABINET WITHOUT EQ ZONE 4 REINFORCEMENT
The SiteStar Cabinet without EQ Zone 4 reinforcement can be lifted by two persons gripping it by their hands on the sides of the cabinet as in Figure 6.
The cabinet can also be lifted as in Section 8.2.
Be careful so that no dents occur.
Note: Do not use a hand truck. It will damage the cabinet bottom.
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Figure 6 Lifting Cabinet
8.2 LIFTING CABINET WITH EQ ZONE 4 REINFORCEMENT
Note: Only use lifting device that are approved to carry a minimum load of 200 kg.
Do as follows to lift the cabinet using lifting eye bolts:
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1 Remove the four M8 screws holding the cabinet roof.
Fit lifting eye bolts, Figure 7.
Figure 7 Lifting Eye Bolts
2 Attach lifting slings to a lifting device equipped with a lifting hook.
3 Secure that the angle between the lifting slings, A in Figure 8, are maximum 90°.
Figure 8 Lifting the Cabinet
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9 OPEN AND CLOSE THE CABINET DOOR
Warning!
When opening the door before the cabinet is secured to the foundation, the empty cabinet can tip. Arrange some support for the door.
Risk of personal injury.
Do as follows to unlock and open the cabinet door:
1. Raise the cabinet to a standing position
2. Unlock the swing handle
3. Lift and turn the swing handle
4. Open the door
Figure 9 Unlocking and Opening Swing Handle
Do as follows to close and lock the cabinet door:
1. Release the door latch
2. Close the door
3. Turn and push the swing handle to locked position. The swinghandle will lock automatically
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10 INSTALLING THE CABINET
This section contains instructions for how to install the following cabinets:
Cabinets without EQ Zone 4 Reinforcement
EQ Zone 4 Cabinets
10.1 INSTALLING CABINETS WITHOUT EQ ZONE 4
REINFORCEMENT
This section describes how to install a cabinet without EQ Zone 4 reinforcement.
The section describes how to:
Remove the plinth from the cabinet
Install the plinth at the foundation
Install the cabinet at the plinth
10.1.1 REMOVE THE PLINTH FROM THE CABINET
Warning!
When opening the door before the cabinet is secured to the foundation, the empty cabinet can tip. Arrange some support for the door.
Risk of personal injury.
The standard cabinet is equipped with a plinth at the bottom of the cabinet.
At delivery the plinth is assembled to the cabinet. Before the plinth can be installed to the foundation, it has to be removed from the cabinet.
When opening the door, the empty cabinet can tip. Arrange some support for the door before removing the screws holding the plinth to the cabinet.
Open the door and remove the four screws and washers, A and B in Figure 10, connecting the plinth to the cabinet. Save the screws and washers for the re-installation of the cabinet.
If necessary, remove the external alarm terminal, C in Figure 10, and the AC connection terminal, D in Figure 10, before removing the screws.
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Figure 10 Remove Plinth
Close the door and remove the cabinet from the plinth by lifting it as in section 8.
When the cabinet has to be placed anywhere without standing on its plinth, the door has to be closed and not to be opened due to risk of damages.
If the cabinet gets a dented area in size of a hand with a depth of 10 mm, it is destroyed and has to be replaced.
Warning!
Do not stay close to hanging load. Risk of personal injury.
Warning!
Be careful when lifting and lowering of the cabinet. Risk of personal injury.
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Caution!
Be careful when lifting and lowering of the cabinet. Risk of property damage.
10.1.2 INSTALLING THE PLINTH AT THE FOUNDATION
Install the plinth at the foundation as in Figure 11. Tighten the fasteners to a torque of 15 Nm.
Figure 11 Installing Plinth at Foundation
10.1.3 INSTALLING THE CABINET AT THE PLINTH
Warning!
When opening the door before the cabinet is secured to the foundation, the empty cabinet can tip. Arrange some support for the door.
Risk of personal injury.
Lift the cabinet in place and fit it to the plinth.
Open the door and re-use the screws and washers from the removal of the plinth to fasten the cabinet to the plinth, Figure 12. Tighten the four M8 screws to a torque of 15 Nm.
For easier installation, remove the external alarm terminal, C in Figure 12, and the AC connection terminal, D in Figure 12, before fitting the cabinet to the plinth.
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Figure 12 Assembling the Cabinet to the Plinth
Key to Figure 12
A Washer
B Screw
C External Alarm Terminal
D AC Connection Terminal
10.2 INSTALLING EQ ZONE 4 CABINET
This section describes the following steps for how to install an EQ Zone 4 Cabinet:
Prerequisites
Installing the cabinet
Securing the EQ Zone 4 reinforcement
10.2.1 PREREQUISITES
To make it easier to fit the fasteners it is recommended to remove the external alarm terminal and the CLU Power Connection Terminal before any work starts. Figure 13 shows the location of the external alarm terminal and the CLU Power Connection Terminal.
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Figure 13 External Alarm Terminal and CLU Power Connection Terminal
10.2.2 INSTALLING THE CABINET
Lift the cabinet as in section 8.
Fit two fasteners to each EQ Zone 4 feet as in Figure 14. Tighten the fasteners to a torque of 80 Nm.
Figure 14 Installing EQ Zone 4 Cabinet
10.2.3 SECURING THE EQ ZONE 4 REINFORCEMENT
When the cabinet is installed and tightened to the foundation, the EQ Zone 4 reinforcement has to be secured to the cabinet walls.
Secure the EQ Zone 4 reinforcement to the cabinet walls by tightening the eight enclosed screws, four screws at the left wall and the four screws at the right wall, at the top shelf, to a torque of 4 Nm. Figure 15.
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Figure 15 Securing EQ Zone 4 Reinforcement to the Cabinet Wall
11 DOOR
This section describes:
Door latch
Changing from left hanging door to right hanging door
Note: Do not open the door if the cabinet is standing without being assembled to the foundation. The cabinet will tip and the door will get damaged.
11.1 DOOR LATCH
Cabinet without EQ Zone 4 Reinforcement
The opened door is locked in position with a wind stopper latch. When the door is opened the latch locks at its utmost position. Lift the latch some millimeters, close to the cabinet shelf, to unlock it when closing the door. See Figure 16.
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Figure 16 Door Latch at Cabinets without EQ Zone 4 Reinforcement
EQ Zone 4 Cabinet
Lift the latch from the door some millimeters to unlock it when closing the door. See Figure 17.
Figure 17 Door Latch at EQ Zone 4 Cabinet
Alternative Door Latch
The cabinets can be equipped with a later version of the door latch that fits all cabinets versions.
The opened door is locked in position. When the door is opened the latch locks at its utmost position. Lift the latch some millimeters, close to the cabinet shelf, to unlock it when closing the door. See Figure 18.
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Figure 18 Alternative Door Latch
11.2 CHANGING FROM LEFT HANGING DOOR TO RIGHT
HANGING DOOR
At delivery the door is left hanging. If the door has to be right hanging, the change to right hanging door must be done with the cabinet standing up.
The following section contains instructions for:
Disconnecting the door
Removing door latch
Removing swing handle
Removing the door
Removing the vertical safety beam
Moving latch points
Installing the vertical safety beam
Installing the door
Moving the locking system
Installing the swing handle
Installing the door latch
Reconnecting the door
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11.2.1 DISCONNECTING THE DOOR
It is recommended to disconnect the door when changing from left to right hanging door.
Do the following to disconnect the cabinet door:
1 Cut the cable ties and disconnect the alarm cable.
Figure 19 Disconnecting Alarm Cable
2 Disconnect the CLU power cable at the CLU fuse and at the DC SPD if equipped.
Figure 20 Disconnecting CLU Power Cable
Figure 21 Disconnecting CLU Power Cable
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11.2.2 REMOVING DOOR LATCH
The cabinet can be equipped with different door latches depending on cabinet design, Figure 22.
Figure 22 Door Latch
A. Door latch for a cabinet without EQ Zone 4 reinforcement
B. Door latch for a cabinet with EQ Zone 4 reinforcement
C. Alternative door latch that fits all cabinet versions.
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Door Latch in Cabinet without EQ Zone 4 Reinforcement
Do as follows to remove the door latch:
1. Loosen the bottom battery shelf and lift it up.
2. Remove the screw holding the door latch in the cabinet and the twoscrews holding the door latch in the door.
3. Remove the door latch.
Figure 23 Removing Door Latch
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Door Latch in Cabinet with EQ Zone 4 Reinforcement
Do as follows to Move the door latch:
1. Remove the nut holding the door latch.
2. Lift the door latch.
3. Move the door latch to the opposite side.
4. Fasten the nut at the new position. Do not tighten the nut too much.
Figure 24 Moving Door Latch
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Alternative Door Latch that fits all Cabinet Versions
Do as follows to remove the door latch:
1. Remove the top screw holding the door latch to the door latchbracket.
2. Swing the door latch to the opposite side.
3. Remove the two screws holding the door latch bracket.
4. Remove the door latch bracket.
Figure 25 Removing Door Latch
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11.2.3 REMOVING SWING HANDLE
The swing handle is fastened to the locking system with a screw from the inside of the door. The screw can be reached with a screwdriver through a hole at the back of the door.
Do the following to remove the swing handle:
Use a screwdriver (T30) to loosen the internal screw holding the swing handle. Pull the swing handle out as in Figure 26.
Figure 26 Removing Swing Handle
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11.2.4 REMOVING THE DOOR
Do the following to remove the cabinet door:
Note: To lift the door it is necessary to use two persons.
1 Arrange sufficient support for the door.
Figure 27 Supporting the Door
2 Unscrew the door from the hinge. Remove the screws in the numbered order.
Remove the door.
Unscrew and remove the hinge from the cabinet.
Figure 28 Removing the Door
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11.2.5 REMOVING THE VERTICAL SAFETY BEAM
Do the following to remove the vertical safety beam:
Unscrew the six screws holding the vertical safety beam. Save the screws for the reinstalling at the opposite side.
Remove the vertical safety beam, Figure 29.
Figure 29 Removing Vertical Safety Beam
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11.2.6 MOVING LATCH POINTS
Do as follows to move the latch points to the opposite side:
1. Remove the latch points as in Figure 30 on page 39. Save thescrews for the reinstallation.
Figure 30 Removing Latch Points
2. Install the latch points with the saved screws at the opposite side asin Figure 31. Fold the seal so it does not get caught. Tighten thescrews to a torque of 2 Nm.
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Figure 31 Installing Latch Points
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11.2.7 INSTALLING THE VERTICAL SAFETY BEAM
Do the following to install the vertical safety beam at the opposite side:
Re-use the six M4 screws to install the vertical safety beam, Figure 32. Tighten to a torque of 2 Nm.
Figure 32 Installing Vertical Safety Beam
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11.2.8 INSTALLING THE DOOR
Do the following to install the door at the opposite side:
Note: To lift the door it is necessary to use two persons.
1 Install the hinge to the cabinet using the enclosed new M4 screws.
Tighten the screws to a torque of 2 Nm.
2 Arrange sufficient support for the door.
Figure 33 Supporting the Door
3 Fit the door to the hinge. Re-use the six M4 screws in the numbered order and tighten to a torque of 2.5 Nm.
Figure 34 Attaching Hinge
11.2.9 MOVING THE LOCKING SYSTEM
Do as follows to move the locking system to the opposite side:
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1. Dismantle the door cover as in the figure below. Start with thescrews (A) at the sides.
Figure 35 Dismantle the Door Cover
2. Remove the plastic cover at the opposite lock position. Figure 36.
Figure 36 Plastic Cover
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3. Remove the lock housing from the door cover, Figure 37. Save thescrews for the installation at the opposite side.
Figure 37 Removing Lock Housing
4. Knock out the plastic covering the door holes for the latch points.Use a screwdriver and a hammer. Figure 38.
Figure 38 Knocking Out Plastic Cover
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5. Remove the nuts holding the espagnolette lock. A and B inFigure 39.
Figure 39 Remove Espagnolette Lock
6. Turn the espagnolette lock upside down and reinstall it at theopposite side of the door.
Figure 40 Turning Espagnolette Lock
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Figure 41 Reinstalling Espagnolette Lock
7. Secure that the espagnolette lock is in open position.
8. Install the lock housing at the opposite side in the door cover,Figure 42.
Figure 42 Installing Lock Housing
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9. Install the plastic cover at the new side in the door cover.
10. Reinstall the door cover.
11.2.10 INSTALLING THE SWING HANDLE
Do the following to install the swing handle:
Hold the swing handle in open position and gently push the swing handle into the door locking system and fit the handle to the square pin socket inside as in Figure 43. Fit the screw from the back of the door and tighten to a torque of 2 Nm. Use a T30 screwdriver with minimum 75 mm blade length.
Figure 43 Installing the Swing Handle
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11.2.11 INSTALLING THE DOOR LATCH
Door Latch in Cabinets without EQ Zone 4 Reinforcement
Do as follows to assemble the door latch:
1. Put the washer into the door latch as in Figure 44, step 1.
2. Slide the washer into the housing as in Figure 44, step 2.
3. Fit the screw (M4x16) through the housing and the washer as inFigure 44, step 3.
Figure 44 Assembling Door Latch
Do as follows to install the door latch:
1. Place the bushing, A in Figure 45, over the blind rivet.
2. Fit the door latch screw to the blind rivet through the bushing.Tighten the screw to a torque of 2.5 Nm.
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Figure 45 Installing the Door Latch in the Cabinet
3. Fit the two screws holding the door latch in the door. Tighten thescrews to a torque of 1 Nm.
4. Reinstall the bottom battery shelf. Tighten the six screws to a torqueof 1 Nm.
Figure 46 Installing the Door Latch to the Door
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Door Latch in Cabinets with EQ Zone 4 Reinforcement
Do as follows to install the door latch
Move the screw holding the door latch in the door to its new position, Figure 47.
Figure 47 Moving Screw holding Door Latch in the Door
Alternative Door Latch that fits all Cabinet Versions
Do as follows to install the door latch:
1. Fit the door latch bracket.
2. Fit the two screws holding the door latch bracket.
3. Fit the door latch to the door latch bracket.
4. Fit the top screw holding the door latch to the door latch bracket.
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Figure 48 Installing Door Latch
11.2.12 RECONNECTING THE DOOR
Do the following to reconnect the door:
1 Connect the CCU/CLU power cable at the CLU fuse and at the DC SPD if equipped.
Figure 49 Connecting CLU Power Cable
Figure 50 Connecting CLU Power Cable
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2 Connect the alarm cable.
Figure 51 Connecting Alarm Cable
12 EARTH GROUNDING
Connect the site earth grounding to the cabinet according to the following:
Cabinet without EQ Zone 4 Reinforcement
Connect the earth grounding cable to the double M8 earth point at either side of the cabinet plinth, Figure 52.
Figure 52 Earth Grounding
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EQ Zone 4 Cabinet
Connect the earth grounding cable to the grounding studs in the bottom of the cabinet, Figure 53.
Figure 53 Earth Grounding Studs in EQ Zone 4 Cabinet
13 INSTALLING OPTIONAL EQUIPMENT AND SPARE
PARTS
Follow the installation manuals enclosed to the optional equipment and spare parts when installing the equipment into the cabinet.
14 INSTALLING CUSTOMER EQUIPMENT
This section contains information about:
Maximum equipment heat load
Customer equipment placement
Routing customer equipment cables
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14.1 MAXIMUM EQUIPMENT HEAT LOAD
See D000100/1, SiteStar Cabinet Description, for information about maximum allowed heat load of the customer equipment to be installed.
14.2 CUSTOMER EQUIPMENT PLACEMENT
When adding customer equipment the air flow needs to be carefully considered to avoid hot spots.
Figure 54 shows the air flow inside the cabinet and the recommended positioning of customer equipment with air flow back to front.
Figure 54 Equipment Position in Cabinet
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14.3 ROUTING CUSTOMER EQUIPMENT CABLES
Route customer equipment cables through the cable ducts in the shelves to the connection field in the cabinet bottom.
Secure the cables with cable ties to the tie mounts at the cabinet walls.
Route the cables out of the cabinet through the cable entries at the cabinet sides.
15 ROUTING BATTERY CABLES
It is recommended that the battery cables are routed before the batteries are installed.
Routing Battery Cables from the Connection Field to the Battery Compartment
Route cables between the connection field and the battery compartment through the cable ducts at each side in the front of the bottom shelf.
The cable ducts exists in two versions. An early cylindrical version and the later box formed version. See Figure 55.
Figure 55 Cable Ducts
Prepare Cable Duct
Alternative: Cylindrical Cable Duct
Use a small screwdriver to prepare the cylindrical cable ducts before routing the cables through.
Alternative: Box Formed Cable Duct
Remove the plastic foam sealing and use a screwdriver or a knife and hammer to knock out the bottom in the box formed cable duct. Replace the sealing and route the cables through.
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Routing Battery Cables between the Battery Shelves
The battery cables are preferably routed at the front of the battery shelves.
Position the cables towards the corners to secure ventilation in the front of the cabinet.
Secure the cables with cable ties, Figure 56.
Figure 56 Securing Single Cable
If the cabinet is fully equipped with all batteries, the cables need to be secured together. After the first cable is secured to the shelf, as in Figure 56, the other cables are secured to the first. Figure 57.
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Figure 57 Securing Multiple Cables
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If necessary, cables can be routed in the back of the cabinet. Cable routing in the back of the cabinet is done in the same way as in the front. Figure 58 shows routing of multiple cables.
Figure 58 Securing Cables in the Back of the Cabinet
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16 ROUTING GAS VENTILATION TUBES
This section describes how to route the gas ventilation tube before installing the battery strings.
Warning!
It is important that every battery is connected with the ventilation tube, and that the first battery in the chain is plugged. The tube must be routed out of the cabinet.
If tubes are not connected properly, there is a risk that explosive gases will accumulate in the cabinet
Note: When installing ventilation tubes, always use tubes with flammability class UL94V-2, or better.
Note: One battery venting kit is needed for each 48 V battery string.
Do the following to route the gas ventilation tubes:
1. Cut the venting tube in four pieces for each battery string, three pieceswith length = 110 mm, the fourth tube is the remaining length. Use theshort pieces for connecting the batteries in the battery string. Seesection 18.3.2, page 70, for further information.
2. Route the long venting tube through the inlet and up through theclosest cable duct at the bottom shelf.
3. Route next long venting tube up to next shelf at the opposite side,either in front of the shelf, or through the cable ducts in the shelf if it isan EQ Zone 4 Cabinet.
4. Continue routing the long venting tubes up to the top shelf accordingto Figure 59.
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Figure 59 Routing Gas Ventilation Tube
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17 ROUTING BATTERY TEMPERATURE SENSOR
CABLE
If the cabinet is to be equipped with battery temperature sensors, the battery temperature sensor cable must be routed before the batteries are installed.
Route the battery temperature sensor cable through the cable duct at left or right side from the connection field up to the battery compartment and fasten them temporarily until the batteries are installed.
Cabinets without EQ Zone 4 Reinforcement
Route the battery temperature sensor cable at the left or right side in front of the battery shelves.
EQ Zone 4 Cabinet
Route the battery temperature sensor cable at the left or right side through the cable ducts in the battery shelves.
Figure 60 Routing Battery Temperature Sensor Cables
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18 INSTALLING BATTERIES
This section contains:
Preparing batteries for installation
Preparing EQ zone 4 cabinet
Installing batteries
Reinstalling EQ zone 4 components
18.1 PREPARING BATTERIES FOR INSTALLATION
This section describes how to prepare one battery string.
Figure 61 Battery String
18.1.1 PASTING BATTERY SEPARATORS TO THE BATTERIES
Cabinets without EQ Zone 4 Reinforcement
Paste two battery separators on each battery block according to Figure 62.
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Figure 62 Battery Separator Positions
EQ Zone 4 Cabinets
When installing batteries into EQ Zone 4 Cabinets, it is not necessary to use the battery separators between the batteries.
When installing 170/180 Ah batteries it is necessary to use front separators to achieve proper distance between the batteries and the front bar.
Paste one front separator to the front of each battery according to Figure 63.
Figure 63 Pasting Front Separators to the 170/180 Ah Batteries
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18.1.2 PASTING TEMPERATURE SENSOR HOLDER TO ONE BATTERY
If the battery string is to be equipped with a battery temperature sensor it is recommended to install the temperature sensor holder as follows:
Paste the temperature sensor holder on battery block no. 2 according to Figure 64.
Figure 64 Temperature Sensor Holder Position
18.2 PREPARING EQ ZONE 4 CABINET
This section is only valid for EQ Zone 4 Cabinets.
If the cross braces and the front bars are installed, they must be removed before any batteries can be installed. When installing 170/180 Ah batteries it also is necessary to remove the corner pieces.
Do as shown in Figure 65 to remove the cross braces.
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Figure 65 Removing Cross Braces
Do as shown in Figure 66 to remove the front bars.
Figure 66 Removing Front Bars
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Do as shown in Figure 67 to remove the corner pieces.
Figure 67 Removing Corner Pieces
The front bar spacers as well as the rear spacers in the back of the cabinet is adjustable for 100 Ah and 170/180 Ah batteries.
Fit the front bar spacers according to Figure 68 for the 100 Ah batteries or according to Figure 69 for the 170/180 Ah batteries. Tighten the M6 screws to a torque of 9 Nm.
Figure 68 Fitting Front Bar Spacers for the 100 Ah Batteries
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Figure 69 Fitting Front Bar Spacers for the 170/180 Ah Batteries
Fit the rear spacers in the back of the cabinet according to Figure 70 for the 100 Ah batteries or according to Figure 71 for the 170/180 Ah batteries. Tighten the M6 nuts to a torque of 9 Nm.
Figure 70 Fitting the rear Spacers for the 100 Ah Batteries
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Figure 71 Fitting the rear Spacers for the 170/180 Ah Batteries
18.3 INSTALLING BATTERIES
This section contains descriptions about:
Installing batteries
Connecting gas ventilation tube
Connecting battery cables
Caution!
Heavy batteries can cause injuries when lifting incorrectly.
Caution!
Heavy batteries can cause damages to the property when installed incorrectly.
Secure that the cabinet is attached to the base before any batteries are installed.
Make sure battery cables, battery temperature sensor cables and gas ventilation tubes are routed before installing the battery strings.
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18.3.1 INSTALLING BATTERIES
Install the battery blocks on the shelves. Start with battery block no. 1 at the position most to the left on the shelf.
Fit the temperature sensor into the temperature sensor holder and install battery block no. 2.
Install battery block no. 4 most to the right on the shelf.
Install battery block no. 3.
The distances between the battery blocks are normally given by the inter connections and the spacers.
To ensure necessary air circulation around the battery blocks it is important to keep a minimum distance of 7 mm between the battery blocks.
The distance between the wall and the outer battery block will be approx. 35 mm in Cabinets without EQ Zone 4 reinforcement and approx. 30 mm in EQ Zone 4 Cabinets.
Figure 72 Placement of Batteries
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18.3.2 CONNECTING GAS VENTILATION TUBES
Warning!
It is important that every battery is connected with the ventilation tube, and that the first battery in the chain is plugged. The tube must be routed out of the cabinet.
If tubes are not connected properly, there is a risk that explosive gases will accumulate in the cabinet
Note: When installing ventilation tubes, always use tubes with flammability class UL94V-2, or better.
Do the following to connect the gas ventilation tubes:
1. Use the short gas ventilation tube pieces from the venting tube routing,Section 16 - Routing Gas Ventilation Tubes, page 59, to connect thebattery blocks to each other as in Figure 73.
2. Connect the gas ventilation tube between the shelves as in Figure 74and Figure 75.
3. At the top shelf, fit the end stop to the battery at the end of the batterystring as in Figure 73.
Figure 73 Connecting Gas Ventilation Tubes
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Figure 74 Connecting Gas Ventilation Tube
Figure 75 Routing Gas Ventilation Tube
For more information, see the installation instruction for the battery kit.
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18.3.3 CONNECTING BATTERY CABLES
Warning!
To avoid battery thermal runaway, the batteries must be connected to an external PSU with thermal compensated charging. Furthermore, the external PSU must shut off the battery system if the temperature reaches 50°C inside the cabinet.
Note: Improper handling when connecting batteries can result in short-circuiting, which can result in serious injury due to high energy levels. Exercise the necessary care when working with batteries.
Secure that not connected cable lugs are insulated.
Connect the battery blocks into a battery string according to the following:
1 Attach the three interblock connectors between battery block no 1 and no 2, between battery block no 2 and no 3 and between battery block no 3 no 4, using M8 bolts and washers. Tighten to a torque of 8Nm.
Figure 76 Attach Interblock Connectors
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2 Connect the negative (-) cable to battery block no 1, using M8 bolt and washer. Tighten to a torque of 8Nm.
Figure 77 Connecting Negative Cable
3 Connect the positive (+) cable to battery block no 4 using M8 bolt and washer. Tighten to a torque of 8 Nm.
The battery string positive cable is not to be connected until all connections to the CF have been made.
Figure 78 Connecting Positive Cable
4 Fit the pole protections.
Figure 79 Fitting Pole Protections
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18.4 REINSTALLING EQ ZONE 4 COMPONENTS
This section is only valid for EQ Zone 4 Cabinets.
Do the following to reinstall the corner pieces, the front bars and the cross braces:
If removed, reinstall the corner pieces to the EQ Zone 4 structure as in Figure 80.
Tighten the four M6 screws at each corner to a torque of 9 Nm.
Figure 80 Reinstalling Corner Pieces
Fit the front bars to the EQ Zone 4 structure as in Figure 81.
Note: Use the inner front bar position for the 100 Ah batteries.
Use the outer front bar position for the 170/180 Ah batteries.
Tighten the six M6 screws at each front bar to a torque of 9 Nm.
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Figure 81 Reinstalling Front Bars
Fit the cross braces to the corner pieces as in Figure 82.
Tighten the turnbuckles (stretchers) by hand.
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Figure 82 Reinstalling Cross Braces
19 CABLES AND FUSES
The table below shows typical recommended values, using a cable with 90C insulation temperature rating. Individual calculations of a site specific installation, taking into consideration cable lengths, bundling, max temperature, insulation class, etc, can allow other configurations.
Maximum Cable Length [m] at specified Fuse Cable Area [mm] Fuse 150 A Fuse 200 A Fuse 250 A
35 2.8 2.1 1.7
50 5.7 4.3 3.4
70 8.5 6.4 5.1
95 11.5 8.7 6.9
If the cabinet is equipped with the optional DCCU, TPL type fuses up to 250 A can be used.
The DCCU is approved for a maximum of 405 A.
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20 EXTERNAL ALARM CONNECTION
The alarm cables are connected to the external alarm terminal located at the roof of the CF.
Connect the alarm cables to the terminal according to following table:
Alarm Output Markings
Terminal Number Marking
1 K1-NO (1)
2 COM
3 K1-NC (2)
4 Door-NC (2)
5 K3-NC (2)
6 GND
7 +12 V DC
8 Shield
(1) NO = Normally open
(2) NC = Normally closed
20.1 RECONFIGURING THE EXTERNAL ALARM
The controller is by factory default configured for individual alarms on alarm outputs K1, K2, and K3. The controller also supports sending summary alarm, NO or NC on alarm output K1.
Do as follows to reconfigure from individual to summary alarm:
1. Disconnect power.
2. Remove the CCU Front Plate.
a) Loosen the five screws holding the CCU Front Plate, No 1 in thefigure below.
b) Lean the CCU Front Plate forward, No 2 in the figure below.
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Figure 83 Removing CCU Front Plate
3. Locate configuration connector P16.
4. Remove the configuration jumper as shown in Figure 84.
Figure 84 Reconfiguring for Summary Alarm
5. Reinstall the CCU Front Panel.
6. Reconnect power.
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21 CONNECTING POWER
This section contains information about how to connect power to the cabinet.
The cabinet is equipped with a CLU Power Connection Terminal to connect the cabinet to electricity networks, Figure 85.
Figure 85 CLU Power Connection Terminal
Note: The cabinet is available in different voltage versions. Make sure the right version is used when connecting to the electricity network.
21.1.1 CONNECTING TO ELECTRICITY NETWORKS
Warning!
Ensure that the electricity is disconnected before work is started. Risk of personal injury.
The cabinet must be installed in accordance with national wiring regulations.
The cabinet has to be connected to the electricity network through a switch that allows contact separation in all poles that provide full disconnection under the over voltage category III.
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Use an external 10 A AC fuse when connecting the SiteStar cabinet alone to the electricity network. When using the SiteStar CLU Power Connection Terminals to connect the cabinet and external equipment, the fuse rating must be checked accordingly.
Note: If the local electricity network demands over voltage protection to protect SiteStar mains AC feed, this protector shall be installed at the site mains switch board as per local electrical regulations.
21.1.2 CONNECTING AC POWER TO THE CLU POWER CONNECTION
TERMINAL
Figure 86 to Figure 91 shows how to connect AC power to the CLU Power Connection Terminal according to the table below.
Power Type Voltage Range Nominal Voltage
Phase to Neutral
Figure
1W+N+PE 200 V AC to 240 V AC 230 V AC Figure 86
1W+PEN 200 V AC to 240 V AC 230 V AC Figure 87
2W+N +PE 200 V AC to 240 V AC 230 V AC Figure 88
2W+PEN 200 V AC to 240 V AC 230 V AC Figure 89
2W+N+PE 200/100 V AC to 240/120 V AC
115 V AC Figure 88
2W+PEN 200/100 V AC to 240/120 V AC
115 V AC Figure 89
3W+N+PE 346/200 V AC to 415/240 V AC
230 V AC Figure 90
3W+PEN 346/200 V AC to 415/240 V AC
230 V AC Figure 91
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Figure 86 1W+N+PE
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Figure 87 1W+PEN
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Figure 88 2W+N+PE
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Figure 89 2W+PEN
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Figure 90 3W+N+PE
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Figure 91 3W+PEN
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Secure the cables with cable ties so that they go free from the floor. See Figure 92.
Figure 92 Cables In/Out
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21.1.3 CONNECTING DC POWER TO THE CLU POWER CONNECTION
TERMINAL
Figure 93 to Figure 95 shows how to connect DC power to the CLU Power Connection Terminal.
Figure 93 CLU Connected to DCCU
Figure 94 CLU Connected to External PSU
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Figure 95 CLU Connected to Batteries
Secure the cables with cable ties so that they go free from the floor.
22 STACKING OF 1.1 M HIGH CABINETS
The 1.1 m high cabinet can be installed on top of another 1.1 m high cabinet.
Figure 96 Stacked Cabinets
Do as follows to install:
1. Install the lower cabinet as in previous chapters.
2. Install the upper cabinet plinth on top of the lower cabinet. Figure 97.
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Figure 97 Installing the Upper Cabinet Plinth upon the Lower Cabinet
3. Lift the upper cabinet up on the plinth.
4. Secure the cabinet before opening the door. The cabinet will tip over ifnot secured.
5. Attach the upper cabinet to the upper plinth as in chapter 10.1.3.
Changing door position is done in the same way as in previous chapters.
23 ENVIRONMENTAL CONSIDERATIONS
If the cabinet is exposed for extreme sun, it might be necessary to arrange for an extra sun protection. The sun protection is mainly needed to insure a long term reliable function of the cooling system. Extra sun protection is recommended if the temperature on a regular base exceeds +45°C.
Example, see Figure 98.
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Figure 98 Sun Protection
24 COMMISSIONING
This section describes:
Starting up the system
Adjustments
24.1 STARTING UP THE SYSTEM
Note: The cabinet needs to be in an upright position for absolutely minimum 1 hour before starting the compressor. Recommended time is 2 hours.
Do as follows to start up the system:
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1 Connect all cables (batteries, AC or DC and alarm if applicable).
2 Check the installation of the batteries.
Check that the ventilation tube is connected to all batteries. Secure that the free connection at the first battery block in the chain is plugged and that the ventilation tube is routed from the last battery block out of the cabinet.
3 Start-up sequence
Make sure the door, and thus the door switch, is open when switching on power to the cabinet. (If the door and thus the door switch is closed, the system will perform a factory test sequence during approx 30 minutes)
Check that the main circuit breaker in the cabinet is switched on and switch on the AC or DC power.
The system performs a self test at start-up. The start-up sequence is up to 2 minutes long. During the self test, all components in the system are tested, i.e. compressor, fan, heater (if equipped), temperature sensors, etc. The indicator ‘Test’ is lit during the self test sequence.
After the self-test is completed the system will go into operation mode, or indicate a fail. As the system goes into operation, the yellow ‘Test’ indicator will go out, and the green ‘Operational’ will be lit.
After approximately 1 minute in operation mode, Door Alarm is activated. The alarm is revoked 1 minute after closing the door.
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4 When everything is OK – close the door.
24.2 ECO MODE
To turn the eco operation mode on, first remove the plug. Then press the eco switch, placed behind the plug. Use a stick or a small screwdriver to press the switch. A green lamp will indicate when the system is in ECO mode. Figure 99.
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Figure 99 ECO Mode Switch
25 RECYCLING
It is strongly advised, that when cleaning after installing the cabinet, the personnel performing the installation pay particular attention to the environment. Primarily, recycle all waste materials that can be recycled and sort waste so that it can be disposed according to local regulations.
Recycle or dispose of all packing in accordance with local recycling regulations.