A Technical Manual from the experts
in Business-Critical Continuity™
NetXtend™ FLEX Series -48VDC/+24VDC
Power/Battery Enclosure
Description and Installation Manual, 460-200-051 (Version C, November 22, 2013)
This page is intentionally blank.
Emerson Network Power
Outdoor Enclosures
460-200-051
Version C, November 22, 2013
TABLE OF CONTENTS
1. ABOUT THIS DOCUMENT
1
1.1
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.2
Reason for Reissue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1.3
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1.4
Usage for Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1.5
Printing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1.6
Information Not Provided in this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1.7
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1.8
Notice of Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2. PRODUCT OVERVIEW
4
2.1
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
2.2
Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2.3
Safety Listed AC Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2.4
Commercial AC Service Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2.5
Enclosure Dimensions, Weights, and Physical Specifications . . . . . . . . . . . . . . . . .
6
2.6
Equipment Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
2.7
Enclosure Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
3. SEQUENCE OF PROCEDURES
18
3.1
18
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. PREPARATION AND PRECAUTIONS
19
4.1
Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
4.2
Materials Required for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
4.3
Tools and Test Equipment Required for Installation . . . . . . . . . . . . . . . . . . . . . . . . .
21
4.4
Safety and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
5. FRONT DOOR, LOCKS, AND REMOVABLE PANELS
Outside Plant Equipment
Proprietary Information
27
Page i of x
460-200-051
Version C, November 22, 2013
Emerson Network Power
Outdoor Enclosures
5.1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
5.2
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
5.3
Opening and Closing the Enclosure Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
5.4
Intrusion Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
5.5
Door Activated Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
5.6
Removing/Installing Rear Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
6. ENCLOSURE PLACEMENT
33
6.1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
6.2
Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
6.3
Site Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
6.4
Concrete Foundation Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
6.5
Form Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
6.6
Transportation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
6.7
Unpacking the Enclosure at the Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
6.8
Preparing the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
6.9
Preparing the Concrete Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
6.10 Preparing the Plinth Option for Enclosure Placement . . . . . . . . . . . . . . . . . . . . . . . .
44
6.11 Preparing to Lift the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
6.12 Lifting the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
6.13 Placing the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
7. SEALING EQUIPMENT COMPARTMENT CABLE ENTRIES
55
8. AC POWER
56
8.1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
8.2
Enclosure AC Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
8.3
Grounding the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
8.4
AC Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
Page ii of x
Proprietary Information
Outside Plant Equipment
Emerson Network Power
Outdoor Enclosures
460-200-051
Version C, November 22, 2013
9. DC POWER
62
9.1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
9.2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
9.3
DC Power Cabling Color Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
9.4
Emerson NetSure™ 512ngbb DC Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
10. OSP CABLES
68
10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
10.2 Sealing Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
10.3 Installing OSP Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
11. ALARM WIRING
70
11.1 Connecting External Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
12. BATTERIES
74
12.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
12.2 Battery Compartment Cooling and Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
12.3 Battery Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
12.4 VRLA Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77
12.5 SAFT Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
13. INITIAL POWER UP
99
13.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
13.2 Prerequisite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
13.3 Initial Power Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
14. ECU (ENVIRONMENTAL CONTROL UNIT)
AND THERMAL COMPONENTS
107
14.1 ECU Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107
14.2 Overview Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108
14.3 ECU Power Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
Outside Plant Equipment
Proprietary Information
Page iii of x
460-200-051
Version C, November 22, 2013
Emerson Network Power
Outdoor Enclosures
14.4 Thermal Components and ECU Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110
14.5 ECU User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115
15. MAINTENANCE, TROUBLESHOOTING, AND REPLACEMENT PROCEDURES
119
15.1 Enclosure Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
119
15.2 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
119
15.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
121
15.4 Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
126
16. ACCESSORIES AND REPLACEMENT PARTS
146
17. REVISION RECORD
148
Page iv of x
Proprietary Information
Outside Plant Equipment
Emerson Network Power
Outdoor Enclosures
460-200-051
Version C, November 22, 2013
LIST OF FIGURES
Fig. 1
Front and Rear Perspective Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Fig. 2
Front Perspective View with Door Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Fig. 3
Enclosure Dimensions (cont’d on next page) . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Fig. 3
Fig. 3: Enclosure Dimensions (cont’d from previous page) . . . . . . . . . . . . . . .
8
Fig. 4
Equipment and Battery Compartment Dimensions . . . . . . . . . . . . . . . . . . . . . .
9
Fig. 5
Enclosure Base Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Fig. 6
Pad Mounting Rubber Barrier Pad (P/N 141340) . . . . . . . . . . . . . . . . . . . . . . . .
11
Fig. 7
Optional Re-Usable Pad Mounting Template (P/N F1010279) . . . . . . . . . . . . .
12
Fig. 8
Optional Pour-in-Place Pad Mounting Template (P/N F1010243) . . . . . . . . . . .
13
Fig. 9
Perspective Views of Enclosure with Features . . . . . . . . . . . . . . . . . . . . . . . . .
14
Fig. 10
Front Door Swing-Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
Fig. 11
Front Door Wind Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
Fig. 12
Intrusion Alarm and Light Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
Fig. 13
Removing/Installing Rear Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
Fig. 14
Site Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
Fig. 15
Pad Sizing (from outside perimeter of cabinet to pad edge) . . . . . . . . . . . . . .
35
Fig. 16
Ground Level View of Typical Pad Construction
(w/out pour-in-place pad template) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fig. 17
Ground Level View of Typical Pad Construction
(with pour-in-place pad template) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fig. 18
Removing Bottom Battery Tray to Access Enclosure’s Mounting Holes . . . .
41
Fig. 19
Removing Bottom Rear Conduit Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
Fig. 20
Removing Plinth Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
Fig. 21
Attaching Plinth Option to Pour-in-Place Pad Template and Cabinet . . . . . . .
46
Fig. 22
Replacing Front Plinth Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
Fig. 23
Removing Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
Fig. 24
Lifting the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
Fig. 25
Attaching Enclosure to Optional Pour-in-Place Pad Template . . . . . . . . . . . .
53
Outside Plant Equipment
Proprietary Information
Page v of x
460-200-051
Version C, November 22, 2013
Emerson Network Power
Outdoor Enclosures
Fig. 26
Replacing Bottom Battery Tray after Enclosure Placement . . . . . . . . . . . . . . .
54
Fig. 27
Cable Cones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
Fig. 28
Enclosure Ground Ring Termination Location . . . . . . . . . . . . . . . . . . . . . . . . . .
57
Fig. 29
AC Input Channel and Knockout Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
Fig. 30
AC Input Channel Covers and Terminal Block Location . . . . . . . . . . . . . . . . . .
60
Fig. 31
AC Input Terminations Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
Fig. 32
NetSure™ 512ngbb DC Power System (582137000ZZ001) . . . . . . . . . . . . . . . .
63
Fig. 33
Rectifier Local Indicators Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
Fig. 34
Converter Local Indicators Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
Fig. 35
ACU+ Local Indicators and Menu Navigation Keys Locations . . . . . . . . . . . . .
66
Fig. 36
Routing OSP Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
Fig. 37
Local Alarm Block Schedule (cont’d on next page) . . . . . . . . . . . . . . . . . . . . . .
71
Fig. 37
Fig. 37: Local Alarm Block Schedule (cont’d from previous page) . . . . . . . . . .
72
Fig. 38
Typical Bunching Block Jumper Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
Fig. 39
Typical Battery Alarm Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73
Fig. 40
Battery Heater Control Unit Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
Fig. 41
Power and Battery Cabinet Battery Tray Shim . . . . . . . . . . . . . . . . . . . . . . . . . .
78
Fig. 42
Removing the Battery Holding and Retaining Brackets . . . . . . . . . . . . . . . . . .
79
Fig. 43
Disengaging the Battery Tray from the Battery Frame . . . . . . . . . . . . . . . . . . .
80
Fig. 44
Locking the Battery Tray to Open Position . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80
Fig. 45
Placing the VRLA Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
Fig. 46
Securing the Batteries with Battery Holding Bracket and Shims . . . . . . . . . . .
82
Fig. 47
Placing VRLA Batteries on Topmost Battery Tray . . . . . . . . . . . . . . . . . . . . . . .
83
Fig. 48
Battery Shelf Configuration for NorthStar Red Batteries . . . . . . . . . . . . . . . . .
84
Fig. 49
Battery Disconnect Circuit Breaker Locations . . . . . . . . . . . . . . . . . . . . . . . . . .
86
Fig. 50
Battery Placement in Battery Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87
Fig. 51
VRLA Typical Battery Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88
Fig. 52
Typical Battery Connection
Page vi of x
Proprietary Information
Outside Plant Equipment
Emerson Network Power
Outdoor Enclosures
460-200-051
Version C, November 22, 2013
(rear of power system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Fig. 53
Pulling out Battery Tray by 9.75 inches and Securing Open Position . . . . . . .
89
Fig. 54
Removing the Battery Holding Bracket and Shims . . . . . . . . . . . . . . . . . . . . . .
90
Fig. 55
Removing the Rear Battery Holding Bracket and Battery Heater Pad assembly
90
Fig. 56
Placing the SAFT Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91
Fig. 57
SAFT Batteries String . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
Fig. 58
SAFT Block Mapping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
94
Fig. 59
Removing Block-end covers to Expose Terminals . . . . . . . . . . . . . . . . . . . . . .
95
Fig. 60
Placing Blocks B, D, F, G and I on Battery Shelf . . . . . . . . . . . . . . . . . . . . . . . .
96
Fig. 61
Measuring Voltage between (+) Terminal and Cable . . . . . . . . . . . . . . . . . . . . .
97
Fig. 62
Measuring Voltage between (+) Terminal and Cable . . . . . . . . . . . . . . . . . . . . .
97
Fig. 63
Installing Rectifier and Converter Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101
Fig. 64
Programming the Battery Capacity into the ACU+ Controller . . . . . . . . . . . . .
104
Fig. 65A
ECU and Thermal Components Overview Diagram (cont’d on next page) . . . .
108
Fig. 65B ECU and Thermal Components Overview Diagram (cont’d from previous page)
109
Fig. 66
Enclosure Intrusion Switch Wiring
(two intrusion switches wired in series, each switch provides a close loop circuit
when the door or panel is closed, opening a door or removing a panel opens the circuit)
.................................................................
125
Fig. 67
Latch Mechanism on the Rectifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
128
Fig. 68
Latch Mechanism on the Converter Module . . . . . . . . . . . . . . . . . . . . . . . . . . .
130
Fig. 69
ACU+ Controller Configuration Label Location . . . . . . . . . . . . . . . . . . . . . . . . .
131
Fig. 70
Latch Mechanism on the ACU+ Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
132
Fig. 71
LED Light Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
132
Fig. 72
LED Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
133
Fig. 73
Heat Exchanger Internal Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
135
Fig. 74A
Heat Exchanger External Fan Replacement (cont’d on next page) . . . . . . . . . .
137
Fig. 74B Heat Exchanger External Fan Replacement
(cont’d from previous page, cont’d on next page) . . . . . . . . . . . . . . . . . . . . . . . .
138
Fig. 74C
139
Heat Exchanger External Fan Replacement (cont’d from previous page) . . . .
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Outdoor Enclosures
Fig. 75
Battery Vent Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
141
Fig. 76
Pulling out Battery Tray by 9.75 inches and Securing Open Position . . . . . . .
142
Fig. 77
Removing Battery Retainer from Battery Tray . . . . . . . . . . . . . . . . . . . . . . . . . .
142
Fig. 78
Removing the Rear Battery Holding Bracket and Battery Heater Pad Assembly
143
Fig. 79
Placing the VRLA Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
143
Fig. 80
Securing the Batteries with Battery Holding Bracket and Shims . . . . . . . . . . .
144
Fig. 81
Surge Suppressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
145
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ADMONISHMENTS USED IN THIS DOCUMENT
DANGER
Warns of a hazard the reader will be exposed to that will likely result in death or
serious injury if not avoided. (ANSI, OSHA)
WARNING
Warns of a potential hazard the reader may be exposed to that could result in
death or serious injury if not avoided. This admonition is not used for situations
that pose a risk only to equipment, software, data, or service. (ANSI)
CAUTION
Warns of a potential hazard the reader may be exposed to that could result in
minor or moderate injury if not avoided. (ANSI, OSHA) This admonition is not
used for situations that pose a risk only to equipment, data, or service, even if
such use appears to be permitted in some of the applicable standards. (OSHA)
ALERT
Alerts the reader to an action that must be avoided in order to protect equipment, software, data, or service. (ISO)
ALERT
Alerts the reader to an action that must be performed in order to prevent
equipment damage, software corruption, data loss, or service interruption.
(ISO)
FIRE SAFETY
Informs the reader of fire safety information, reminders, precautions, or policies, or of the locations of fire-fighting and fire-safety equipment. (ISO)
SAFETY
Informs the reader of general safety information, reminders, precautions, or
policies not related to a particular source of hazard or to fire safety. (ISO, ANSI,
OSHA)
NOTICE
Informs the reader of general rules or policies not related to safety. (ANSI)
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Version C, November 22, 2013
NetXtend™ FLEX SERIES -48VDC/+24VDC
POWER/BATTERY ENCLOSURE
DESCRIPTION AND INSTALLATION
1. 5ABOUT THIS DOCUMENT
1.1 Purpose
This document provides description and installation instructions for Emerson Network
Power’s NetXtend™ FLEX Series -48VDC/+24VDC Power and Battery Enclosure wired for
three strings of -48V batteries and the capabilities of installing up to (8) +24VDC converters.
See Fig. 1 for enclosure front and rear perspective views.
Procedures related to the provisioning, start-up, and acceptance of associated telecom
equipment are not covered in this document.
Rear View
Front View
Fig. 1 : Front and Rear Perspective Views
TABLE A - Cabinet Part Number and Description
Finished Good No.
F2012504
Outside Plant Equipment
Description
-48VDC/+24VDC Power and Battery Enclosure
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Outdoor Enclosures
1.2 Reason for Reissue
Whenever this document is reissued, the reason for reissue will be stated on the REVISION
RECORD located at the back of this document.
1.3 Intended Audience
This document is intended for those installing the enclosure, planning the installation, or
supporting this enclosure.
1.4 Usage for Training
This document may be used to support training requirements and creation of MOPs for
installers, as well as support personnel.
1.5 Printing Instructions
The format of this document is such that it may be printed on standard letter size paper. Though
black and white printing is acceptable, for best clarity of the illustrations, the manual should
be printed in color.
1.6 Information Not Provided in this Document
Refer to other local practices, building codes, and manufacturers’ documents as applicable for
the correct methods, tools, and materials to be used in performing procedures not specifically
described in this document. This includes, but is not limited to:
•
•
Setup and maintenance of rectifiers, converters, controller, and batteries.
OSP cable fishing, sealing, grounding, splicing, and termination.
Documents that supplement the information in this document are referenced in Section 3.,
Sequence of Procedures.
Note: The information contained in this document is subject to change without notice
and may not be suitable for all applications.
1.7 Safety
Please refer to Section 2., Product Overview for information about Standard Compliance and
listing of safety regulated components.
Please refer to Section 4., Preparation and Precautions for safety notices, warnings, cautions,
and the like.
Page 2 of 148
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460-200-051
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1.8 Notice of Disclaimer
Emerson reserves the right, in its sole discretion, to revise the information contained in this
document at any time without notice.
Emerson expressly advises that any use of or reliance upon information or opinion in this
manual is at the risk of the User and that Emerson shall not be liable for any damage or injury
incurred by any person arising out of the use of said information or opinion.
Note also that local conditions may give rise to a need for additional professional
investigations, modifications, or safeguards to meet site, equipment, environmental safety, or
operating company specific requirements. In no event is the information or opinion contained
in this manual intended to replace federal, state/provincial, local, or other applicable codes,
laws, or regulations. Specific applications will contain variables unknown to or beyond the
control of Emerson. As a result, Emerson cannot warrant that the application of the information
or opinion in this manual will produce the technical result or safety intended.
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Version C, November 22, 2013
Emerson Network Power
Outdoor Enclosures
2. PRODUCT OVERVIEW
2.1 Application
The following “Product Overview” is for engineers, planners, and those who need/want an
understanding of the system, as a whole. See Fig. 2 for an enclosure front perspective view
with major features identified.
The NetXtend™ FLEX Series -48VDC/+24VDC Power/Battery Enclosure...
•
•
•
•
provides a stable, secure, and water-tight environment for a -48VDC/+24VDC Power
System, outside plant equipment, and batteries supporting wireless telecommunications
applications.
depends upon a proven structural system, integrated mechanical components, and a sealing
system that withstands rain, dust, snow, and hurricane winds.
provides climate control solutions to keep equipment operating within its optimum
temperature range.
can be pad or platform mounted.
The enclosure provides two (2) compartments.
•
•
The top compartment houses a -48VDC 525 AMP / +24VDC 400 AMP DC Power System
and contains a heat exchanger to cool the compartment. Additional space is available for
support equipment.
The bottom compartment provides three (3) battery shelves for three (3) battery strings (1
per shelf). This compartment contains a fan/vent system for forced air cooling and three
(3) battery heater pads.
Equipment Compartment
Battery Heater Control Unit
Heat Exchanger
Battery Compartment
Ventilation Fan
(Mounted in center
area of Rear Panel)
Battery Compartment
(Equipped with three
Battery Heater Pads)
Fig. 2 : Front Perspective View with Door Open
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2.2 Standards Compliance
The NetXtend™ FLEX Series -48VDC/+24VDC Power/Battery Enclosure is designed to meet
the following standards:
•
•
Telcordia, GR-487-CORE, Generic Requirements for Electronic Equipment Cabinets,
Issue 3, April 2009, (including Seismic Zone 4 requirements).
UL Listed under File E255047 Category NWIN (reference 60950).
2.3 Safety Listed AC Components
A typical NetXtend™ FLEX Series -48VDC/+24VDC Power/Battery Enclosure includes the
following listed or recognized components for United States:
•
•
•
•
•
AC Terminal Blocks - Phoenix Contact P/Ns UT 10:
— UL File E60425
Liquid Tight Flexible Non-Metallic Conduit - T/B LTC050 Conduit:
— UL File E95745
GFI AC Receptacle:
— Legrand Pass & Seymour 1594-I / 1595-I - UL File E42190
— Leviton 6599-I / 7599-I / 8599-I - UL File E48380
AC Battery Heater:
— Hi-Heat - UL File E95403
AC-DC Rectifiers:
— NetSure™ 512NGBB DC Power System
2.4 Commercial AC Service Center
AC power to be provided by customer via an upstream power source load center or Power
Pedestal.
Power Service Required: 120/240VAC or 120/208VAC, 1 phase, 60Hz with upstream fuse
protection and upstream surge protection.
Only load circuits to be brought into Emerson’s AC entry facility. Emerson does not provide
overcurrent devices in the enclosure.
Load circuits in the enclosure requiring power as per Emerson’s Enclosure AC Schematic.
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Outdoor Enclosures
2.5 Enclosure Dimensions, Weights, and Physical Specifications
•
•
•
•
•
•
Illustrations:
— Fig. 3 and Fig. 4 provide enclosure dimensional illustrations.
— Fig. 5 provides an enclosure base plate dimensional illustration.
— Fig. 6 illustrates the pad mounting rubber barrier.
— Fig. 7 illustrates the optional re-usable pad mounting template.
— Fig. 8 illustrates the optional pour-in-place pad mounting template.
Height: 72.06” (183.03 cm).
Width: 31.81” (80.80 cm).
Depth: 39.02" (99.11 cm).
Equipment and Battery Compartments Dimensions: Refer to Fig. 4.
Typical Weights:
— Shipping weight: 884 lb (401 kg).
— Lift weight: 752 lb (341 kg).
— On pad, with rectifiers and converters installed but without batteries: 778 lb (353 kg),
not including customer equipment and cabling.
— On pad, with rectifiers, converters, and batteries installed: 2206 lb (1001 kg).
Note: The enclosure is not to be lifted with batteries, rectifiers, or converters in
place. All batteries, rectifiers, and converters are to be installed once the
enclosure is secured to the pad. BATTERIES CANNOT BE LIFTED
WITH THE ENCLOSURE!
Note: Battery weight is based on Northstar NSB 180FT 180Ah Batteries weigh 129
lb (58.5 kg) each. A complete set of SAFT Batteries (10 units per shelf)
weighs 357 lbs (162 kg).
Note: Pad weight excludes incoming OSP cables.
•
•
•
Color: Off-white.
Finish: Finished in multistage dry powder polyester paint for maximum durability and
performance against corrosion.
Lifting: The enclosure has four lifting eyebolts on the top that allows it to be lifted and
lowered into position.
2.5.1 Typical Pad-Mount Overhead View
Fig. 3 provides an overhead view with the door open. This view shows the enclosure clearance
requirements to freely open the door.
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Left Side View
Rear View
AC
Utility
OSP
Cables
39.02
3.0
72.06
Front View
460-200-051
Version C, November 22, 2013
31.81
Emerson Network Power
Outdoor Enclosures
Fig. 3 : Enclosure Dimensions (cont’d on next page)
Outside Plant Equipment
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Page 7 of 148
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Version C, November 22, 2013
Emerson Network Power
Outdoor Enclosures
Front
90.0 °
2.9
66.9
Front
120.0 °
15.3
62.9
Fig. 3: Enclosure Dimensions (cont’d from previous page)
Page 8 of 148
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Outside Plant Equipment
Outside Plant Equipment
INTERNAL VIEW OF RIGHT-HAND WALL
Heater
Pad Control
ECU
GFCI Outlet
41.1
(Battery Chamber
Opening)
26.1
(Equipment Chamber
Opening)
Intrusion Switch
LED Light Switch
A
A
FRONT VIEW
(DOORS REMOVED)
25.6
(Rack Mount)
A
A
Alarm Blocks
Proprietary Information
Heater Pad
Thermostat
Location
3-String
180 Amp/Hr
Batteries
Welded
3-Shelf
Battery Rack
25.1
(15 RU Rack)
Single Pole
Battery Breaker
LED Light
INTERNAL VIEW OF LEFT-HAND WALL
Optional
Customer
Equipment
Master Ground Bar
(10-position)
12RU NetSure 512
Power System
Surge Suppressor
Emerson Network Power
Outdoor Enclosures
460-200-051
Version C, November 22, 2013
Fig. 4 : Equipment and Battery Compartment Dimensions
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AC
Utility
OSP
Cables
3.50
2.82
4.86
9.45
Ø .750
21.728
10.86
Front
22.83
4.50
31.82
Cabinet Bottom View
Fig. 5 : Enclosure Base Dimensions
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460-200-051
Version C, November 22, 2013
Shaded area
to be scored (3-sides)
4.48
22.85
4X 1.00 X 45 °
3.91
35.20
21.730
Ø 1.00
thru
6X
10.860
3.86
4.49
22.830
31.80
Cabinet Bottom View
Fig. 6 : Pad Mounting Rubber Barrier Pad (P/N 141340)
Outside Plant Equipment
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Outdoor Enclosures
7.14
17.50
14.00
6X Ø 3.0
10.50
4X 1.00 X 45 °
Chamfer
7.00
3.50
6X Ø 1.0
AC Utility
OSP Cables
34.16
32.20
21.73
10.86
3.86
4.46
22.84
31.77
Cabinet Bottom View
Fig. 7 : Optional Re-Usable Pad Mounting Template (P/N F1010279)
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Outside Plant Equipment
Outside Plant Equipment
40.42
Proprietary Information
4X 1.00
5.44
10.86
21.73
36.88
6X Ø .75
“E” size
Holes
2.68
7.12
5.41
28.18
31.77
22.83
R.75 (4X)
17.50
14.00
10.50
7.00
3.50
“E” size Hole position for mounting cabinet
without Plinth (Hilti Item # 00371808
Desc: HSL - 3 - B M 12/25)
“A” size Hole positions for mounting cabinet
with Plinth (Hilti Item # 00371811
Desc: HSL - 3 - B M 16/25)
6X Ø 2.75 - (C-size Holes)
4X Ø 1.00 - (A-size Holes)
2X Ø .25 - (B-size Holes)
Front
Top View
OSP
Cables
AC
Utility
Emerson Network Power
Outdoor Enclosures
460-200-051
Version C, November 22, 2013
Fig. 8 : Optional Pour-in-Place Pad Mounting Template (P/N F1010243)
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Outdoor Enclosures
2.6 Equipment Overview
Fig. 9 illustrates perspective views of the enclosure with the door open and the features
identified. Refer to Fig. 32 for an illustration of the DC Power System.
Environmental
Control Unit
GFCI Protected
(ECU)
LED Light
Convenience Outlets
Switch
Intrusion
Switch
(4) Lifting Brackets
Battery Heater Control Unit
Document Pocket (side entry)
Heat Exchanger
LED Light Fixture
Alarm Blocks
DC Power
System
Battery Breakers
Equipment
Compartment
Front
Front
Battery
Compartment
Intrusion Switch
(located behind panel)
Battery Compartment
Ventilation Fan
(mounted in center of
area of rear panel)
(3) Removable Rear
Access Panels
(1/4-Turn Locks)
AC Junction
Box
Rear
Rear
Earth Ground
Connection Point
AC
Utility
OSP C
ables
Conduit
Knockouts
Re
Conduit
Knockouts
ar
AC
Utility
OSP
Cables
Fig. 9 : Perspective Views of Enclosure with Features
Page 14 of 148
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Version C, November 22, 2013
2.7 Enclosure Features
Mounting Options - The enclosure is designed to be pad or platform mounted. It shall be lifted
into place using the lifting eyebolts provided on the top of the enclosure.
Exterior Finish Specifications - The enclosure is finished in multistage dry powder polyester
paint (off-white) for maximum durability and performance against corrosion.
Front Door - The enclosure has a front environmentally sealed door that provides access to
the Equipment Compartment and Battery Compartment. The front door includes an active Heat
Exchanger (with fans).
•
•
•
•
•
The front door is equipped with a locking mechanism equipped with a padlock hasp that
supports a lock with an arm diameter less than 3/8”.
The front door securing mechanism is a swing handle with multi-point rod-latch
mechanism.
The front door has an intrusion alarm switch, as well as a self-locking wind latch that
secures the door open during installation or maintenance activities. Door wind latch
secures at 90° and 120°. The front door has a second intrusion switch which activates the
DC light upon door entry.
Front door and rear access panels have EPDM rubber environmental seals.
The inside of the front door contains a document holder.
Rear Access Panels - Three (3) access panels are located on the rear of the enclosure. Each
access panel contains 1/4 turn locks and lift off to be removed. Panels are interlocked and upper
panels must be removed before removing lower panels. Top rear access panel cannot be
removed until levers inside the Equipment Compartment are automatically disengaged by
opening the front door. Top rear access panel is equipped with an intrusion switch that can send
an alarm if connected to an alarming device.
Equipment Compartment - The Equipment Compartment houses:
•
•
•
•
•
•
•
•
•
•
•
•
•
Customer equipment.
The DC Power System and DC Distribution.
The Environmental Control Unit (ECU) managing cooling/heating and acoustics.
A principal ground bar.
A 120V 20A convenience outlet.
Five 2" OSP Cable Wrap-Around Sealing Cones.
Cable entry for ground cables.
AC junction box for connection of customer AC feeds utilizes pass-through connection
blocks for easy termination of customer wiring to specific enclosure electrical circuits.
Door-activated convenience light.
Intrusion or light switches.
Alarm blocks.
Battery heater control unit.
Three (3) battery string disconnect circuit breakers.
Equipment Rack - Constructed of 11ga. steel, welded and painted.
•
25.6" equipment mounting is based upon EIA Wide pattern (or sometimes called Modified
EIA spacing of 5/8, 5/8 x 1/2). Supplied with untapped holes. Holes are intended for use with
#12-24 thread-rolling screws.
Outside Plant Equipment
Proprietary Information
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Version C, November 22, 2013
•
•
Emerson Network Power
Outdoor Enclosures
Equipment mounting rails are connected to the equipment ground reference bar by a #6
AWG ground cable.
The equipment mounting rails are designed to accept standard 12 inch (30.48 cm) deep
with 6.7 in. (17 cm) front offset mounted equipment in a perpendicular mount.
Grounding - The 10-position enclosure Principal Ground Bar (alias Master Ground Bar
[MGB]) is located at the rear of the Equipment Compartment.
•
•
The MGB ground bar is mounted on isolators.
The default ground lug geometry is two hole with 1/4” post and 5/8” spacing.
AC Power - See Section 2.4, Commercial AC Service Center.
Convenience Outlet - A GFCI (Ground Fault Circuit Interrupter) protected convenience outlet
on a 20A branch circuit is provided within the Equipment Compartment.
DC Surge Suppressor - A DC Surge suppressor circuit is provided.
DC Power - The enclosure includes an integrated NetSure™ 512NGBB DC Power System
(582137000ZZ001). For additional information, please refer to Section 9., DC Power.
Battery Compartment - The Battery Compartment houses three (3) -48V strings of batteries.
This compartment contains a fan/vent system for forced air cooling and three (3) battery heater
pads.
•
•
•
•
The Battery Compartment includes an alarmed Battery Ventilation Fan to keep the Battery
Compartment within a few degrees of ambient conditions.
For service during an extended power outage, an AC Generator should be used until
commercial power is restored.
For more information, including supported batteries and compartment size, refer to
Section 12., Batteries.
A SAFT battery kit can be ordered to accommodate three (3) strings of 180 AMP-hrs
SAFT batteries (P/N 80-94793-01).
Cable Entry/Exit - Cable entry/exit is made into a dedicated compartment at the bottom rear
of the enclosure. Cable can pass either through conduits placed in the concrete pad or above
ground level into the bottom back panel of the enclosure. Either entry supports up to (6) 2"
trade-size (2.5" actual) conduits.
Alarms - The "alarm interconnect block" is used to terminate alarms from an adjacent battery
cabinet. These alarms are then routed to the power system. The "alarm block" contains 13
cabinet internal and environmental alarms and those alarms are processed through the power
system. Another separate thirty-two (32) pair block is available for site “bunching” by the
customer, from adjacent enclosures.
Heat Exchanger (HX) - The enclosure has a heat exchanger managed by an electronic
Environmental Control Unit (ECU). The Heat Exchanger is designed with three Inner Loop
and three Outer Loop fans, allowing for a single fan to fail, with minimal loss of performance.
Thus, a fan failure is not a catastrophic event leading to an immediate shutdown.
Environmental Control Unit (ECU) - The ECU is an intelligent device monitoring internal
conditions and adjusting the HX fans and Battery Vent Fan accordingly to the needs. As such,
the enclosure properly cools/heats the system, and provides a quiet enclosure for the
neighborhood. The ECU also provides alarms for:
•
•
ECU Malfunction.
Fan Malfunction.
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Outdoor Enclosures
•
•
•
•
460-200-051
Version C, November 22, 2013
Thermal Sensor (Thermistor) Malfunction
Over and Under Temperature Conditions.
Equipment Compartment and Rear Panel Intrusion.
Fan Control Logic - The ECU controls provide independent control of the internal and
external HX fans, adapting to the environment, equipment load and responding to faults,
intrusions, etc. This complex control enables the enclosure to achieve the low acoustic
profile and maintain the equipment under proper operating conditions in accordance with
the requirements of the carrier.
Acoustic Performance - The enclosure employs passive and active features, such as
adaptive fan control and acoustic dampening, to manage and minimize acoustic noise.
Mounting Accessories
•
•
•
A rubber barrier pad is included to prevent corrosion between the concrete pad and the
enclosure mounting surfaces, P/N 141340. See Fig. 6.
A optional re-usable pad mounting template kit is available for marking hole locations. See
Fig. 7.
An optional pour-in-place pad template kit is available. See Fig. 8.
See Table R for template ordering information.
Outside Plant Equipment
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Version C, November 22, 2013
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Outdoor Enclosures
3. SEQUENCE OF PROCEDURES
3.1 General
The following procedures are required to be performed in the order listed to fully install the
enclosure.
Other practices and manufacturer’s documents will be required to complete the installation of
the system. This includes, but is not limited to:
•
•
Set-up and maintenance of:
— rectifiers, converters, and controllers,
— batteries.
OSP cable fishing, sealing, grounding, splicing, and termination.
TABLE B - Sequence of Procedures
Document
Section 2
Section 5
Section 6
Section 6.3
Section 7
Section 8
Section 9
Section 9.4
Section 10
Section 11
Section 12
Section 13
Section 14
Section 15
SD-2012504-01
J-2012504-01
Page 18 of 148
Title
Description
Provides information that will help the project
engineer determine an appropriate use and location
for the enclosure.
Describes how to access the internal compartments
Doors and Locks
of the enclosure (equipment, battery, and cable entry
compartments).
Describes the transportation and storage
Enclosure Placement requirements, the safe handling of the enclosure,
and the procedures to install the enclosure on a pad.
Enclosure Grounding Describes the grounding requirements for the
enclosure.
Sealing Cable Entries Provides methods for sealing the Equipment
Compartment cable entries.
AC Power
Provides wiring information for the electrician.
Provides information regarding the DC power
DC Power
system and distribution.
Emerson Netsure
Provides operating and maintenance instructions for
Power System
Emerson DC power system and distribution.
Provides procedures for preparing the cable sheaths
OSP Cables
and routing the cables within the enclosure.
Alarm Wiring
Describes the wiring for the enclosure alarms.
Provides information and installation instructions for
Batteries
the various models of batteries used in the
enclosure.
Describes the power up sequence for the AC power,
Initial Power Up
the DC power, and the batteries.
Describes the operation of the enclosure
ECU and Thermal
Environmental Control Unit (ECU) and Thermal
Components
Components.
Maintenance,
Troubleshooting,
Provides maintenance, troubleshooting, and
and Replacement
replacement information.
Procedures
SD Drawing
Enclosure schematic drawing.
J Drawing
Enclosure job drawings.
Product Overview
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Outdoor Enclosures
460-200-051
Version C, November 22, 2013
4. PREPARATION AND PRECAUTIONS
4.1 Installation Overview
The following is the recommended sequence for the installation and start-up procedures. The
sequence may change according to job and site conditions.
•
•
•
•
•
•
•
•
•
•
•
•
Ensure all site drawings and approvals are in place.
Obtain the recommended tools and test equipment.
Read Section 4.4, Safety and Precautions carefully.
Check that all the equipment and materials have been delivered.
Proceed with the physical installation of the enclosure.
Install and verify ground cables.
Install and verify the AC power.
Install and verify the DC power.
Route, splice, and verify the OSP cables.
Install and verify the alarm cables.
Install and verify the batteries.
Turn-up, verify, and adjust the system.
TABLE C - NetXtendTM Series Cabinet Recommended Anchors
Without
Mounted on
External Plinth
External Plinth
Battery Cabinet
(Seismic Zone 4)
(6) 1/2" Hilti HSL
(6) 1/2" Hilti HSL
Battery Cabinet
(Seismic Zones 2-3)
(4) 1/2" Hilti HSL
(6) 1/2" Hilti HSL
--
Power Cabinet w/ 3
Battery Shelves & ATS
(Seismic Zone 4)
(6) 1/2" Hilti HSL
(6) 1/2" Hilti HSL
--
Power Cabinet w/ 3
Battery Shelves & ATS
(Seismic Zones 2-3)
(4) 1/2" Hilti HSL
(4) 1/2" Hilti HSL
--
NetXtend™ Cell Site
Series Cabinet
All Other Cabinets
(Seismic Zones 2-4)
(4) 1/2" Hilti HSL
(4) 1/2" Hilti HSL
Any Cabinet
(less than
Seismic Zone 2)
(4) 1/2" Hilti HDI
(4) 1/2" Hilti HSL
Notes
Cabinets with 4 and 5 battery
shelves.
Includes cabinets with 3 battery
shelves and light weight loads at
the top. Consult Emerson
engineering for details.
--
Note: It is up to the customer to select anchors, to investigate the proper use of the
anchors, and to determine the requirements for the concrete pad to work with the
anchors.
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4.2 Materials Required for Installation
The following materials are required to install the enclosure.
TABLE D - Materials Required for Installation
Description
Part Number
Quantity
Comments
1/2" - 13 x 3.0 Lg
SST* Hex Head Screw
140174
6
For Platform Mounting (Included)
1/2" - 13 SST* Hex Nut
P25849
6
For Platform Mounting (Included)
1/2" SST* Lock Washer
P29739
6
For Platform Mounting (Included)
1/2" SST* Flat Washer
P74233
12
For Platform Mounting (Included)
Heavy Duty Load Washer
Andrew
P/N MT-25002,
or equivalent
6
For Platform Mounting
(Available through Distribution)
Leveling Shim Kit
547061
1
(Included)
Rubber Pad
141340
1
(Included)
Recommended Anchors
(6) 1/2” Hilti HSL Heavy Duty Expansion Anchor. (Not Included)
Note: It is up to the customer to select anchors, to investigate the proper
use of the anchors, and to determine the requirements for the concrete pad
to work with the anchors.
Refer to Fig. 8 when using the pour-in-place pad template.
Recommended Ground
Bar Lug (2 AWG)
Panduit
LCDX2-14A-E
Recommended Branch
Circuit Protection and
Wire Size for AC Input to
NetSure™ 512NGBB DC
Power System
External 30A / 2-Pole
Circuit Breaker
(Typical Square D,
Type “QO”,
P/N P53081)
Wire Size: 10 AWG.
Recommended Branch
Circuit Protection and
Wire Size for AC Input
to GFCI
External 20A / 1-Pole
Circuit Breaker
(Typical Square D,
Type “QO”,
P52870)
Wire Size: 12 AWG.
Recommended Branch
Circuit Protection and
Wire Size for AC Input to
Battery Heaters
External 15A / 1-Pole
Circuit Breaker
(Typical Square D,
Type “QO”,
P50717)
Wire Size: 14 AWG.
1
(Not Included)
8
(Not Included)
-1
(Not Included)
-1
(Not Included)
--
*SST = Stainless Steel
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4.3 Tools and Test Equipment Required for Installation
The following tools, test equipment and materials are required for the physical installation of
the enclosure:
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•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Can wrench; 3/8”and 7/16” (which is traditionally provided with such enclosures)
Non-contact voltage detector
Digital multimeter (DMM), 0 to 200 V dc, 0 to 300 V ac
— Digital clamp-on meter, 0 to 30 A dc, 0 to 60 V ac, recommended
Torque wrench, 1/2" drive, recommended
Ratchet, 1/2" drive, 3/8" drive and 1/4" drive
Socket, 3/4" deep, 1/2" drive
Socket set, range from 1/4” to 1"
3" and 6" extensions, 1/2" drive
5/ " and 7/ " ratchet wrench
16
16
36" carpenter’s level
Lineman’s scissors
Lineman’s strippers
Lineman’s cutters
Crimping tool with dies from #6 AWG to #2 AWG
Electrician’s insulated screwdrivers, Phillips, No. 1 and 2
Electrician’s insulated screwdrivers, flat-blade, small and large
Insulated 3/8”, M6, M8, M10 nut drivers for battery installation.
Silicone sealant
NO-OX-ID-A or approved equivalent
Outside the scope of this document, are the tools to fish, splice and terminate OSP Cables and
laptop to setup the power system controller.
Equipment associated with lifting the enclosure by the eyebolts is listed separately, in a
subsequent section.
Torque values may be listed and, unless directed otherwise, values are for reference only.
Torque tools are not required for normal installation practices.
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4.4 Safety and Precautions
The following precautions shall be observed at all time when handling and installing the
enclosure:
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•
•
•
•
•
•
•
•
•
•
•
Observe the general safety precautions against personal injury and equipment damage.
The procedures outlined in this manual are only recommended guidelines. Ensure that all
NEC (National Electric Code) and local codes for safety and wiring are followed.
— Use listed two-hole compression connectors (lugs) to terminate all ground
connections. Selected lug shall match wire and type, and crimped applied as specified
by the lug manufacturer.
— Apply NO-OX-ID-A to all ground connections.
— Insulation of field-wire conductors should be rated no less than 105°C, and gauge in a
manner that is consistent with the NEC and local codes.
Always use a non-contact voltage detector, when approaching an enclosure, to verify no
leaks or shorts are presents on the external body.
Read Section 6., Enclosure Placement, in its entirety prior to attempting to handle or
secure the enclosure.
A minimum of two persons are required to safely install the enclosure.
Hard hats and steel-toed boots should be worn while maneuvering the enclosure.
Safety glasses should always be on while on-site.
Safety gloves should be on when working in temperature extremes, with batteries, or with
sharp objects.
All electricians, operators, and technicians have been trained for the task at hand.
Keep bystanders away.
Ensure that all personnel on site are familiar with the first-aid kit location and emergency
procedures in the event of an injury.
Never leave the enclosure unattended. If leaving the site, close and secure the enclosure.
4.4.1 Safety Precautions Definition
Definitions of the safety admonishments used in this document are listed at the front of this
manual, under "Admonishments Used in this Document".
4.4.2 Safety Precautions
DANGER
Risk of Electrical Shock, General
•
•
•
•
All ground connections must be installed and verified prior to connecting
any power cables (AC or DC) and turning-up of enclosure.
When connecting any discrete power connection, make the connection first
with the ground/return and break last with ground/return.
Remove rings, metallic wrist bands, or bracelets, etc.
Do not install equipment showing any physical damage.
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DANGER
Risk of Electrical Shock, AC
•
•
Proper actions, include, but not limited to:
— Verify before contacting the enclosure that no current leakage or ground
fault condition is present.
— Verify a proper ground is in place.
— Verify for AC hook-up, all enclosure circuit breakers are OFF and the
utility incoming feed is OFF.
Use a trained licensed electrician.
DANGER
Risk of Electric Shock
•
•
•
•
•
The DC bus is powered by DUAL power sources – Rectifiers and DC
Batteries.
To properly work on the system, de-energize by disconnecting BOTH power
sources. Even with the batteries turned off by using a local battery (circuit
breaker) disconnect, batteries are still “LIVE” and hazardous, including a
voltage >50VDC, and a source of high short circuit current.
Use extreme caution around the batteries and terminals.
Do not smoke.
Remove all jewelry, use proper PPE, and use only insulated tools.
DANGER
Risk of Electrical Shock, OSP Cables
If joint buried cables are used, check the cable sheath for voltage in accordance
with local standards. If voltage is detected, do not proceed with the installation.
Contact the supervisor and do not proceed until the voltage hazard is
eliminated.
WARNING
Risk of Chemical Exposure
•
•
A battery can present harmful chemicals. Refer to the Battery Installation
Manuals and MSDS supplied with the batteries. Work in a ventilated area
and follow all safety procedures.
At a minimum, wear safety glasses and gloves when working with batteries.
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WARNING
Prevent Injuries, from Lifting the Enclosure
•
•
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•
•
•
•
•
•
Follow all local safety practices while lifting the enclosure. Wear all locally
approved safety gear. All persons working with lifting equipment must wear
standard safety headgear, eye protection, and (when required) gloves.
Keep bystanders away from work operations at all times.
Do not lift the enclosure over people. Do not let anyone work, stand, or pass
under a lifted enclosure.
Use all four points (eyebolts) to lift the enclosure.
Do not move or lift the enclosure with the front door open.
Never lift or move the enclosure with batteries, rectifiers, or converters
installed.
Do not allow the lifting equipment or enclosure to touch any electrical wiring
or equipment.
Operate all lifting equipment within safety constraints, as defined by the
manufacturer and local practices; for example, do not exceed the capacity
of reach.
Do not use slings, clevises or shackles of insufficient capacity.
Crane Operation
Only properly trained operators shall operate the crane.
Do not operate the crane until all stabilizers are extended. The
stabilizers must be in firm contact with the ground or other adequate
support structure. Do not retract or extend the stabilizers when the
enclosure is suspended from the crane.
Do not lift the enclosure over people. Do not let anyone work, stand,
or pass under a lifted enclosure.
Only the crane rigging crew should set up the crane and rigging.
Do not exceed the lifting capacity of the crane.
•
Forklift Operation
The forklift must be rated for a lifting capacity of 4,000 lbs (1814 kg), or
greater.
Required Equipment:
•
•
•
•
One hoist, crane, or forklift capable of lifting 4,000 lbs (1814 kg).
Four wire-rope slings, 8-ft. (2.44 m) long (minimum). Each sling should have 1,500 lb.
(700 kg) capacity.
Four connecting links (clevises) (rated for a minimum of 1500 lb), to attach the wire-rope
slings to the enclosure lifting eyes.
A 75-ft (20 m) rope, 5/8” (1.5 cm) in diameter, to use as a tagline. A tagline is used to guide
the enclosure into position while it is lifted and lowered.
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CAUTION
Prevent Equipment Damage, Proper Handling
•
•
•
Do not stack nor lay the enclosure on its side.
Similarly, do not stack batteries or lay them on their side.
To avoid possible personnel injury or damage to the enclosure, do not
remove it from the pallet until at the installation site, at the point of transfer
onto the pad.
CAUTION
Prevent Equipment Damage, Maintain Ventilation
To optimize the service life of this equipment, make sure there are no
obstructions in front of the ventilation openings.
WARNING
Risk of Injury, from Unsecured Enclosure
•
•
•
Do not push or lean against an unsecured (unbolted) enclosure as it may tip
over causing bodily injury.
Do not pull cables, terminate cables, install or place any batteries, rectifiers,
or converters until enclosure has been secured onto a pad.
Use caution when opening and closing doors to an enclosure not secured
onto a pad.
WARNING
Risk of Injury to Eyes and Skin, from Optic Devices
Do not look into a fiber cable or device, nor hold such cable or device against
body, fabric or other material.
WARNING
Risk of Hazardous Substances
After handling of the enclosure or any such component, such as batteries,
cables, busbars, etc., always wash hands immediately after.
WARNING
Risk of Explosion
For safety reasons, never restrict or block the airflow through the door or entry
panel ventilation openings.
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CAUTION
Prevent Equipment Damage, from Condensation
•
•
Until the enclosure is turned up for service, the bags of desiccant shipped
with the enclosure must remain in the enclosure to prevent condensation.
Once service is in-place, remove the desiccant.
CAUTION
Prevent Equipment Damage, Build a Good Pad
•
•
•
The pad should be level to within 1/4-inch (6.4 mm) over the entire length and
width, with a crown in the middle to prevent any pooling of water and twist
to the enclosure frame.
When mounting the enclosure on a pad, the compression strength of the
concrete pad used must be a minimum of 4000 psi as determined by ASTM
C39 test of compression strength of concrete cylinders.
Always use a barrier pad between the concrete and the pad to prevent
corrosion.
CAUTION
Prevent Equipment Damage, Operating Temperature
•
•
The enclosure is approved for operation in an environment with an expected
temperature range of –40°F to +115°F (–40°C to +46°C) and 5% to 95%
relative humidity range, condensing. Do not use at temperatures or humidity
exceeding these ranges.
The enclosure is not for indoor use.
CAUTION
Prevent Damages Caused by Electrostatic Discharges (ESD)
When handling the ECU unit, wear an appropriate antistatic device (a wrist strap
for example) that is properly connected to a designated antistatic grounding
point (on a framework, on an anti-static floor mat, etc.). ESD-protective
packaging material shall also be used when carrying/shipping the ECU unit.
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5. FRONT DOOR, LOCKS, AND REMOVABLE PANELS
5.1 Safety Precautions
DANGER
Risk of Electrical Shock, AC
•
Proper actions, include, but not limited to:
— Verify before contacting the enclosure that no current leakage or ground
fault condition is present.
— Verify a proper ground is in place.
WARNING
Risk of Explosion
For safety reasons, never restrict or block the airflow through the door or entry
panel ventilation openings.
5.2 Front Door
The enclosure front door is equipped with a swing handle, multi-point rod-latch system. The
swing handle latch includes provisions for a customer supplied padlock.
A wind latch on the front door of the enclosure keeps the door secure when open.
Refer to Section 5.3, Opening and Closing the Enclosure Front Door for instructions to open
and secure the door with the wind latch.
5.3 Opening and Closing the Enclosure Front Door
Open and close the enclosure front door as described in the following procedures.
5.3.1 Opening the Front Door
Procedure
Step 1:
Step 2:
Step 3:
Step 4:
Is the environment safe? Use a non-contact voltage detector to assist in determining
if access to the enclosure is safe.
If required, unlock and remove the padlock from the front door latch.
Lift the swing-latch and rotate approximately 90° clockwise to disengage door
closing mechanism. Open the door. See Fig. 10.
To secure the door in the open position, swing the enclosure door open wide enough
so that the shoulder of the wind latch slides along the bar slot and into the first hole
at the other end of the bar. Note that latch will first fall into position at 90-degrees
and must be lifted again to open to 120-degrees. See Fig. 11.
Note: To disable the intrusion alarm, refer to Section 5.4, Intrusion Alarm.
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Fig. 10 : Front Door Swing-Latch
Wind Latch
90°
Wind Latch
120°
Fig. 11 : Front Door Wind Latch
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5.3.2 Closing the Front Door
Procedure
Step 1:
Step 2:
Step 3:
Step 4:
Lift the wind latch arm to release the shoulder from the hole in the bar so it can slide
along the bar slot as the door is closed. If the door was open to the 120-degree
position, the latch must be lifted again at the 90o position to fully close the door. See
Fig. 11.
Close the door.
While holding the door closed, rotate and lower the swing-latch into the lock bed.
See Fig. 10.
If required, replace padlock.
5.4 Intrusion Alarm
The Power/Battery Cabinet is equipped with an intrusion alarm system. There are a total of two
(2) intrusion alarm switches in the cabinet: one (1) for the front door, and one (1) on the top
rear panel that alarms.
Refer to Section 5.6, Removing/Installing Rear Access Panels. Top rear panel must be removed
before removing the panel below it and likewise for the cable entrance panel. The intrusion
alarm switches are connected to the alarm block. If connected to an alarm sending device, an
alarm can be sent whenever the front door is opened or the top access panel is opened or
removed. The intrusion alarm can be disabled while performing routine maintenance as
described in the following procedure. Refer to Fig. 12 for an illustration of one of the intrusion
alarm switches.
Procedure
Step 1:
Open the front door, the thermal system components turn off and the intrusion alarm
activates.
DANGER
The intrusion switches are wired into the ECU. DO NOT disable an intrusion
alarm by pulling the plunger on an intrusion alarm switch. This will silence the
intrusion alarm, but the ECU thermal components also return to normal ECU
control and may start.
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Step 2:
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Outdoor Enclosures
To disable the intrusion alarm, momentarily depress the Audible Alarm Cutoff /
Maintenance / Reset pushbutton located on the ECU. See Fig. 65A for location.
Refer to Section 14.5, ECU User Interface for further information. The intrusion
alarm is reset by replacing the rear access panel(s) if removed, and closing the front
door.
Door Activated
Intrusion Alarm
Switch (also located
at top rear access panel)
Door Activated
Light Switch
To
ECU
Switch View
Fig. 12 : Intrusion Alarm and Light Switches
5.5 Door Activated Light Switch
The enclosure is equipped with a door activated light switch. The light can be turned off by
pulling the plunger on the door activated light switch. Refer to Fig. 12 for location of the door
activated light switch.
5.6 Removing/Installing Rear Access Panels
CAUTION
Spring loaded locking rods prevent opening the rear panels without performing
Section 5.3.1, Opening the Front Door, first.
There are three rear access panels.
•
•
•
Each access panel contains 1/4 turn locks and lift off to be removed.
Panels are interlocked and upper panels must be removed before removing lower panels.
The top rear access panel cannot be removed until two rods inside the Equipment
Compartment are disengaged. These rods should automatically disengaged when the front
door is opened.
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•
460-200-051
Version C, November 22, 2013
The top rear access panel is equipped with an intrusion switch as described in Section 5.4,
Intrusion Alarm.
Refer to the following procedure to remove/install rear access panels.
Procedure
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Step 7:
Step 8:
Step 9:
Open the front door.
From the front of the enclosure, verify that the left-hand and right-hand locking rods
are in the forward position which disengages the rods from the top rear access panel
1
/4-turn locks. Refer to Fig. 13.
Use a can wrench and turn the 1/4-turn locks (after verifying locking rods in the
above step) located at the top corners of the top rear access panel according to the
open-close labels. Refer to Fig. 13.
Slowly tilt the top of the top rear access panel down, until the safety chain attached
to it can be accessed. Unhook the safety chain from the top corner of the top rear
access panel. Refer to Fig. 13.
Lift the top panel to disengage it from the tabs on the panel below it and pull it away
from the enclosure.
Note: The panel is electrically bonded to the enclosure with a 6AWG cable.
The cable is long enough to allow the panel to be placed on the ground
next to the enclosure. The cable should not be disconnected from the
panel.
To remove the lower panels, use a can wrench and turn the 1/4-turn locks located at
the top corners of the rear access panel according to the open-close labels (lowest
rear panel only has one lock at the top center of the panel). Refer to Fig. 13.
Lift the panel to disengage it from the tabs on the panel below it and pull it away
from the enclosure.
Note: The panel is electrically bonded to the enclosure with a 6AWG cable.
The cable is long enough to allow the panel to be placed on the ground
next to the enclosure. The cable should not be disconnected from the
panel.
Reverse the above steps to reinstall the panels. Ensure that you re-attach the safety
chain to the top corner of the top rear access panel. Also, ensure the front door is in
the open position before replacing the top rear access panel (when the front door is
closed, the two locking rods are automatically pushed in to engage the locking
mechanism). Turn the 1/4-turn locks according to the open-close labels to secure the
access panel.
Close and secure the front door.
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These rods must be disengaged from the top
rear access panel 1/4-turn lock (both sides)
before removing the top rear access panel.
Un-hook safety chain
from this bracket.
Inte
rior
hydrophobic
air vent
patches
w
Vie
Rear View
Fig. 13 : Removing/Installing Rear Access Panels
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6. ENCLOSURE PLACEMENT
6.1 Overview
This section contains the procedures required for physical installation of the enclosure.
6.2 Site Selection
The cabinet may be installed on a new or existing concrete pad, roof top, or metal platform.
Obtain rights-of-way and other permits (building permit, electrical permit, etc.), depending on
local codes and authorities, prior to installing the cabinet.
The mounting pad or platform must be installed (according to local practices) before the
cabinet can be installed.
Roof Top Site Considerations
Consider the following when deciding on the location for the roof top site.
•
•
•
Obtain all necessary building permits and other local approvals as necessary per local
building codes.
Select locations that will provide enough space to place the mounting platform and cabinet,
and provide safe working conditions.
Select locations where there are no electrical lines that could touch the cabinet and energize
it.
Concrete Pad or Platform Considerations
Consider the following when deciding on the location for the concrete pad or platform.
•
•
•
•
•
•
Place the cabinet on servitudes, on dedicated (recorded) easements, or on property owned
by the company. Avoid any unrecorded easements.
Use public safety road and street rights of way only where there is enough space to place
the cabinet and provide safe working conditions. The cabinet should be easily accessible
with adequate parking to ensure safety for people and vehicles. Place the cabinet where it
will not create a visual or physical obstruction to either vehicles or pedestrians.
Select locations that will minimize accidental or intentional vandalism. Consider the use
of protective posts when the cabinet is located near parking areas where vehicles could
back into it. Do not place the cabinet in ditches or areas subject to flooding. Do not place
the cabinet in an area where the pad is subject to vehicle loads.
Place the cabinet at least 42 inches (106.68 cm) away from any obstruction, fence, hedge,
etc. Include adequate area for craft personnel to perform maintenance procedures.
Where ordinances or other require that the enclosure be hidden behind natural landscaping
plants, preference should be given to evergreens that will produce leaves, sticky pollen or
waste that could fall and clog the heat exchanger intakes.
If an area is subject to frost, choose a site free of heaving. Minimize snow buildup or being
plowed into. Placement should support access for snow removal in the event of a snow/ ice
storm.
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Outdoor Enclosures
6.3 Site Ground
DANGER
Risk of Electrical Shock, General
All enclosure grounding and ground ring must be installed prior to connecting
any power cables (AC or DC) and turning-up of enclosure.
Ensure that all NEC (National Electric Code) and local codes for safety and wiring are
followed. Consideration for corporate standards also apply.
All external ground wires, whether from the Ground Ring or OSP Cables, shall only be dressed
to the Principle Ground Bar located on the floor of the Equipment Compartment or Ground
Ring Termination located at lower rear of enclosure.
Before an enclosure is placed, a ground ring supporting the path and conditions shown in
Fig. 14 must be in-place.
TO
AC JUNCTION
BOX
TO
EQUIPMENT RACK
TO
DC RETURN
MASTER
GROUND BAR
GRN
GRN
Note: Main cabinet ground wires:
GRN - DC
GRN/YEL - AC
GRN/ YEL
GRN
TO EARTH
GROUND
CUSTOMER
CONNECTION
GROUND RING
TERMINATION
(TOP VIEW)
TO DC SURGE
PROTECTOR
GRN
Ground Ring
8’ Ground Rods
Fig. 14 : Site Ground
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6.4 Concrete Foundation Pad
CAUTION
The compression strength of the concrete pad used must be a minimum of
4000psi as determined by ASTM C39 test of compression strength of concrete
cylinders.
The power/battery cabinet is installed on a concrete foundation pad, which is either
cast-in-place or precast. Fig. 15 shows the general position of the enclosure on the concrete
pad.
= D + 48” (122 cm)
(MINIMUM Pad Design)
= W + 48” (122 cm)
(MINIMUM Pad Design)
Front
Fig. 15 : Pad Sizing (from outside perimeter of cabinet to pad edge)
•
Use concrete only for the foundation pad. Do not use substitute materials, such as
reinforced plastics, since they lack the rigidity required for enclosure placement. The ideal
pad dimension extends two feet beyond the open radius of all doors. The minimum
recommended pad size is two feet (24 inches or 60.96 cm) beyond the perimeter of the
enclosure.
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•
•
•
•
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Outdoor Enclosures
If not using a metal mounting template, use the mylar-type Reusable Film Template
(F1010279) or the dimensions in Fig. 7 to orient the mounting bolt holes and conduit
openings in the pad. The metal mounting template (F1010243) consists of galvanized
metal mounting plates with support rails. A rubber barrier pad is installed between the pad
and the enclosure to prevent corrosion.
For excavated pad applications, excavate a hole for the pad and cable conduits in
accordance with the engineering work prints, generally to a depth of 30" (76.20 cm) for
standard applications and 60" (115.24 cm) for areas where there is heavy frost.
Use a minimum of 6" (15.24 cm) of sand or gravel as a base for the foundation pad. This
will level the location to accept the pad.
Use a high-early strength concrete mix so the enclosure may be placed three days
following concrete pouring. Coarse aggregate used in the concrete shall be graded from
3
/4-in (1.90 cm) to No. 4 only.
Note: Referring to Fig. 15, determine the proper pad size for your application and space
available. The MINIMUM recommend pad size extends 24" (60.96cm) past all
sides of the enclosure. If space permits and it is desired, a larger pad can be
constructed thus providing area to walk around the installed enclosure. Refer to
Fig. 3 for enclosure dimensions.
Note: Referring to Fig. 5, note conduit and mounting locations. Note that conduits may
also be run to the rear lower access panel.
Optional Pour-in-Place Pad Template: Referring to Fig. 8, note conduit and
mounting locations for the pour-in-place template assembly.
Note: Referring to Fig. 16 or Fig. 17, prepare a form per Section 6.5, Form Preparation.
Follow local practices or building codes if different than the information
included in this section.
CABLE CONDUITS
2" (5.08 cm) ABOVE
CONCRETE PAD
2" (5.08 cm)
6" (15.24 cm)
CONCRETE PAD
WOODEN FORM
(2 x 6) TYPICAL
2" (5.08 cm)
WELDED MESH
6 X 6 X 4/4 (4 GAUGE WIRE)
GROUND WIRE TO
GROUNDING SYSTEM
COMPACTED
SOIL
SAND
OR GRAVEL
16" STAKES
Fig. 16 : Ground Level View of Typical Pad Construction
(w/out pour-in-place pad template)
Page 36 of 148
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CABINET TEMPLATE
FLUSH WITH, TO 1/4" (6.4 mm)
ABOVE TOP OF CONCRETE
CABLE CONDUITS
2" (5.08 cm) ABOVE
CONCRETE PAD
2" (5.08 cm)
6" (15.24 cm)
CONCRETE PAD
WOODEN FORM
(2 x 6) TYPICAL
2" (5.08 cm)
WELDED MESH
6 X 6 X 4/4 (4 GAUGE WIRE)
GROUND WIRE TO
GROUNDING SYSTEM
COMPACTED
SOIL
SAND
OR GRAVEL
16" STAKES
Fig. 17 : Ground Level View of Typical Pad Construction
(with pour-in-place pad template)
6.5 Form Preparation
•
•
•
•
•
•
•
•
•
•
•
For excavated pad applications, clear an area for the pad and cable conduits in accordance
with the engineering work prints. For a typical installation, excavate the foundation hole
to a depth of 12" to 16" (30.48cm to 40.64cm). If the soil is not firm, compact it.
Install a ring ground system around the proposed foundation pad according to local
practices and building safety codes. Place the ground rod(s) and ground wire(s) as
indicated on the engineering work prints.
Construct a level base for the pad, using a minimum of 6" (15.2 cm) of sand or gravel. The
pad should be level to within 1/4-in (0.63 cm) over the entire length and width. Tamp as
needed.
Dig a trench to the area(s) where the cable and electrical conduit will rise into the
enclosure. Excavate the trenches to a depth of 30" (76.2 cm) for a standard installation, and
60" (152.4 cm) for areas where there is heavy frost. Do not damage any installed cables.
Place all conduits into their approximate position in the form area allowing them to sweep
up in their appropriate locations as indicated on the engineering work prints.
If using a metal template, place the metal mounting template(s) into their approximate final
position in the form area allowing the conduits to come up through the template(s) in their
appropriate cable entry ports or open areas as indicated on the engineering work prints.
Backfill and tamp the trench(es) so the conduits remain in their position.
Remove the template(s) and fasten wooden stakes onto them to reposition them in the form
area later.
Construct a level wooden form frame from using 2x6 materials for the desired pad area and
size. Be careful not to damage any installed cables driving stakes into the ground.
If required, use local practices to treat the area below the pad and for two feet (61cm)
around the perimeter against insect infestation.
Place a mesh wire (6 x 6, 4 gauge) into the form area. Be sure the mesh wire is centered
vertically. In place of using wire mesh No. 3 (3/8-inch or 9mm) or larger, reinforcing rods
placed on 15" (381 mm) centers may also be used. Cut or reposition the metal mesh or rods
where ever necessary to avoid any conduits or template stakes.
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Version C, November 22, 2013
•
Emerson Network Power
Outdoor Enclosures
Place the templates back into their position(s) with the conduits protruding though them.
Square and level the templates on the stakes so the tops of the mounting plates are flushed
with, or no more than 1/4-inch (6mm) above the top of the pad. Square the template(s) so
the diagonal measurement between the anchor bolts is equal.
Note: The enclosure must clear the finished concrete surface so that any base panel
below the enclosure or end chamber(s) can be removed.
•
The conduit should extend approximately 2" (50.8mm) above the template (Fig. 16 or
Fig. 17). Cover the conduits at the top to keep concrete from entering them during the pour.
Note: Make sure the conduit ends extend vertically through the template (perpendicular
to the template surface).
•
•
•
•
•
•
Be sure that all the wire mesh or reinforcing bars are set approximately 2" (50.8 mm) off
the bottom of the form.
Use a high-early strength concrete mix so the enclosure may be placed three days
following concrete pouring. Coarse aggregate used in the concrete shall be graded from
3
/4-in. (18 mm) to No. 4 only. The compression strength of the concrete must be a
minimum of 4000 psi as determined by ASTM C39 test of compression strength of
concrete cylinders.
Pour the concrete. Finish the concrete so that the entire surface is flush with or 1/4-in (6
mm) below the top of the template mounting plates.
Cure the pad for a minimum of three days before enclosure installation, or according to the
type of concrete used and/or local practices.
DO NOT install the enclosure or support any significant load before the pad is completely
cured. After the second day, the forms may be removed.
After the pad has cured, drill appropriately sized pilot holes in the pad for the anchor being
used to mount the enclosure to the pad. Note that a re-usable pad mounting hole location
template, an optional pour-in-place pad template are available for making hole locations.
Refer also to Fig. 5 and Fig. 7 for enclosure base mounting hole location dimensions.
Note: Use appropriate anchors to secure enclosure to concrete pad. Refer to Table C and
Table D for recommended anchors. Refer to Fig. 8 when using the pour-in-place
pad template.
Page 38 of 148
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6.6 Transportation and Storage
DANGER
Risk of Electrical Shock, General
•
•
Do not install equipment showing any physical damage.
If packaging is damaged, do not accept receipt from the shipper.
CAUTION
Prevent Equipment Damage, Proper Handling
•
•
Do not stack nor lay the enclosure on its side.
To avoid possible personnel injury or enclosure damage, do not remove it
from the pallet until at the installation site, at the point of transfer onto the
pad.
WARNING
Risk of Injury, from Unsecured Enclosure
•
•
•
Do not push or lean against an unsecured (unbolted) enclosure as it may tip
over causing bodily injury.
Do not pull cables, terminate cables, install or place any batteries, rectifiers,
or converters until enclosure has been secured onto a pad.
Use caution when opening and closing the front door to an enclosure not
secured onto a pad.
CAUTION
Prevent Equipment Damage, from Condensation
•
•
Until the enclosure is turned up for service, the bags of desiccant shipped
with the enclosure must remain in the enclosure to prevent condensation.
Once service is in-place, remove the desiccant.
Use lifting equipment, such as a crane or forklift, appropriately rated for the weight of the load
to move the enclosure.
When moving an enclosure with a forklift, make sure that the fork is of sufficient length for the
pallet size (48” minimum) and capable of lifting 4,000 lbs (1814 kg).
For long-term storage, enclosure and packaging should be kept dry and not be exposed to
temperatures outside the range of –10°C to +40°C. Once packaging has been discarded and
enclosure has been securely placed on a pad, the enclosure may be exposed to conditions from
–40°C to +46°C.
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Outdoor Enclosures
Desiccant has been included for the enclosure to prevent condensation in the interior. If the
enclosure is to be stored for a period of 3 months or greater, the desiccant should be inspected
monthly, and if necessary replaced. Alternatively, a small heat source, such as a 100W
incandescent light bulb, may be securely and safely placed into the enclosure as a continuous
source of heat. The desiccant bags are to be discarded once the enclosure is in service.
For short-term storage, the enclosure should not be exposed to temperatures that exceed the
temperature range of –40°C to +70°C.
Note: The enclosure is shipped in protective packaging on a wooden pallet. Batteries (if
ordered), rectifiers, and converters will be shipped on a separate pallet.
6.7 Unpacking the Enclosure at the Installation Site
CAUTION
Do not open the door with door mounted climate control systems unless the
enclosure is secured to the pallet or the mounting surface. An unsecured enclosure is unstable and could tip over causing injury or equipment damage.
Procedure
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Inspect the exterior packaging for damage. If being received and exterior has been
damaged, do not accept shipment.
Check the packing slip to make sure all components ordered were received. If there
are missing components, notify your supervisor for further instructions.
Carefully remove all packaging material from around the enclosure. Dispose of the
packaging according to local practices.
Inspect the outside of the enclosure to be sure there is no shipping damage. If there
is damage, note how much damage there is and where it is located. Notify your
supervisor for further instructions.
If the enclosure appears undamaged, proceed with the installation. DO NOT
REMOVE THE PALLET UNTIL THE ENCLOSURE IS READY TO BE
MOUNTED.
Note: Do not install the enclosure or support any significant load before the
pad is completely cured.
6.8 Preparing the Enclosure
CAUTION
The door with the climate control systems is very heavy. Do not lean or pull on it.
Note: Refer to Section 5.3, Opening and Closing the Enclosure Front Door and
Section 5.6, Removing/Installing Rear Access Panels for opening the front door
and removing rear access panel procedures.
Procedure
Step 1:
Page 40 of 148
With the enclosure secured to the pallet, open the front door. Secure with the wind
latch.
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Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
460-200-051
Version C, November 22, 2013
If the enclosure is to be slid into place over existing conduit studs, remove the three
(3) rear access panels and put to the immediate side. See Section 5.6,
Removing/Installing Rear Access Panels. See also Section 6.8.1, Cabinet Conduit
Entry Options.
Remove the enclosure accessory kit, traditionally packed in the Battery
Compartment. Key items in the accessory kit include:
• Protective (barrier) rubber pad.
• Leveling shims.
• Can wrench.
Inspect enclosure interior, panels, door, and accessory kit for damage. In case of
damage, follow local procedures for reporting and resolving damage.
To access the enclosure’s mounting holes, the bottom battery tray needs to be
removed. Refer to Fig. 18 to remove the tray and other required components.
Close and latch the front door.
1. Remove the hex bolt and nylon slides that secure
the bottom battery drawer to the battery tray
(2 places on right and left sides).
2. Loosen the captive fasteners securing
the battery drawer.
front
battery holding
bracket
3. Loosen the screws to remove the
battery retaining bracket (8 places)
and the front battery holding bracket (4 places).
battery drawer
retaining bracket
4. Loosen the screws securing the rear
battery holding bracket and battery heater pad
assembly (4 places). Remove the said assembly
and carefully disengage heater pad cables
before removing the bottom battery drawer.
rear battery holding bracket
and battery heater pad
assembly
Fig. 18 : Removing Bottom Battery Tray to Access Enclosure’s Mounting Holes
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Version C, November 22, 2013
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Outdoor Enclosures
6.8.1 Cabinet Conduit Entry Options
The enclosure can be pad, plinth or platform mounted. Cables are brought into the enclosure
via conduits that either enter the conduit openings on the rear lower access panel (pad, plinth
or platform mounted), conduit openings on a bottom rear conduit plate (platform mounted), or
the bottom rear conduit plate can be removed to allow the conduits to simply enter the
enclosure as it is placed or slid into position (pad or plinth mounted). See Fig. 9 and Fig. 19.
Conduits Enter the Rear Lower Access Panel Option (pad, plinth or platform mounted):
The conduits enter the enclosure’s rear lower access panel. No enclosure pre-preparation
required, except planning for the conduit runs to the enclosure. It is advised to use LB pull
boxes at the enclosure connection to facilitate easier cable pulling. If adjacent LB pull boxes
interfere with each other because of conduit routing, it is advised to add a conduit extension
off the back panel to push one of the LB boxes away from the back panel.
Conduits Enter the Bottom Rear Conduit Plate Option (platform mounted): The
knockouts in the bottom rear conduit plate are to be removed as needed so that conduits can be
run to the plate and secured with conduit fittings.
Conduits Enter Directly into the Bottom of the Enclosure - No Bottom Rear Conduit
Plate Option (pad mounted): In this option, the enclosure can be slid into place over the
existing conduits. This requires removing the bottom rear access panel, rear lower plate, and
the bottom rear conduit plate. See Fig. 19.
•
•
•
•
•
See Section 5.6, Removing/Installing Rear Access Panels to remove the rear access panels.
Disconnect the bonding cable from the bottom rear access panel (2-hole lug) and set the
panel aside.
The top and middle rear access panels can be re-installed for enclosure installation.
The rear lower plate can be stored in the cable entry compartment with cables attached
during enclosure installation.
The rear lower plate MUST be re-installed after the enclosure is placed.
Page 42 of 148
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Remo
v
from e nuts, loc
inside
k
of cab washers,
an
le entr
y com d flat wash
partm
e
ent, 5 rs
place
s.
Note that the rear lower plate has cables attached to it.
Store the rear lower plate within the cable entry
compartment during enclosure installation.
Removing Rear Plate
(MUST BE RE-INSTALLED AFTER
THE ENCLOSURE IS PLACED)
Removing Bottom
Conduit Plate
Fig. 19 : Removing Bottom Rear Conduit Plate
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Version C, November 22, 2013
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Outdoor Enclosures
6.9 Preparing the Concrete Pad
Procedure
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Clean all debris from the concrete pad or the platform where the enclosure will be
placed.
If still present, remove any jig alignment tool, bolts, etc.
Make sure the six (6) enclosure anchor holes are present and usable before the
enclosure is placed.
From the accessory kit, place the rubber pad (barrier) onto the concrete base,
passing any cable present through the appropriate hole in the pad.
Note: If not already done, remove the perforated cutout for the cables from
the rubber pad.
Note: If necessary use tape, such as duct tape, to temporarily hold the edges
of the rubber pad down.
Dress any cables/conduits so they will easily enter the enclosure as it is being
lowered onto the foundation pad.
If present, remove the anchor bolts and washers from the foundation pad. Set the
hardware aside to attach the enclosure to the pad.
6.10 Preparing the Plinth Option for Enclosure Placement
Procedure
Step 1:
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Step 7:
Page 44 of 148
Remove the front and rear plinth cover: first, detach the rear access cover by
unscrewing two (2) 1/4-20 hex screws, as shown in Fig. 20; then unscrew (4) sets
each of 3/8" screws and 3/8" flat washers from the front plinth cover.
Prepare the plinth for installation by lifting the plinth and placing it over the
pour-in-place pad mount template. Make sure that all four mounting holes are
aligned (see Fig. 21).
To install the plinth to the pour-in-place pad mount template, use (4) locally
provided anchors to secure all four corners of the plinth. Refer to Table C.
To prepare the cabinet for installation to the plinth, lift the cabinet (refer to
Section 6.12, Lifting the Enclosure on page 50 ) on top of the plinth. Make sure that
all mounting holes are aligned (see Fig. 21).
To install the cabinet to the plinth, use (6) sets each of 1/2-13 screws, nuts and
washers (included with the cabinet and installation kit) and secure tightly.
To access the cabinet’s routing wires and cables located at the bottom front of the
cabinet, the front plinth cover should be removed by unscrewing (4) sets each of 3/8"
screws and 3/8" flat washers from the rear plinth cover. Refer to Fig. 22.
Note: Access of the cabinet’s routing wires and cables are done for scheduled
maintenance.
To access the cabinet’s routing wires and cables located at the bottom rear of the
cabinet, remove all three (3) access panels (refer to Fig. 23).
Replace the plinth covers. Refer to Fig. 23.
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Rear
Plinth
Cover
Re
ar
Fro
nt
of
Ca
of
Ca
bin
et
bin
et
Front
Plinth
Cover
Fig. 20 : Removing Plinth Covers
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460-200-051
Version C, November 22, 2013
Emerson Network Power
Outdoor Enclosures
Cabinet
Concrete Pad
Plinth
Option
Pour-in-Place
Pad-Mount
Template
Fig. 21 : Attaching Plinth Option to Pour-in-Place Pad Template and Cabinet
Page 46 of 148
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Front Plinth Cover
3/8 flat washer
(4 places)
3/8 hex screw
(4 places)
Fig. 22 : Replacing Front Plinth Cover
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Outdoor Enclosures
Access
Panels
Rear Plinth Cover
1/4-20 hex screw
(2 places)
Fig. 23 : Removing Access Panels
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6.11 Preparing to Lift the Enclosure
WARNING
Prevent Injuries, from Lifting the Enclosure
•
•
•
•
•
•
•
•
•
•
Follow all local safety practices while lifting the enclosure. Wear all locally
approved safety gear. All persons working with lifting equipment must wear
standard safety headgear, eye protection, and (when required) gloves.
Keep bystanders away from work operations at all times.
Do not lift the enclosure over people. Do not let anyone work, stand, or pass
under a lifted enclosure.
Use all four points (eyebolts) to lift the enclosure.
Do not move or lift the enclosure with the front door open.
Never lift or move the enclosure with batteries, rectifiers, or converters
installed.
Do not allow the lifting equipment or enclosure to touch any electrical wiring
or equipment.
Operate all lifting equipment within safety constraints, as defined by the
manufacturer and local practices; for example, do not exceed the capacity
of reach.
Do not use slings, clevises or shackles of insufficient capacity.
Crane Operation
Only properly trained operators shall operate the crane.
Do not operate the crane until all stabilizers are extended. The
stabilizers must be in firm contact with the ground or other adequate
support structure. Do not retract or extend the stabilizers when the
enclosure is suspended from the crane.
Do not lift the enclosure over people. Do not let anyone work, stand,
or pass under a lifted enclosure.
Only the crane rigging crew should set up the crane and rigging.
Do not exceed the lifting capacity of the crane.
•
Forklift Operation
The forklift must be rated for a lifting capacity of 4,000 lbs (1814 kg), or
greater.
Required Equipment:
•
•
•
•
One hoist, crane, or forklift capable of lifting 4,000 lbs (1814 kg).
Four wire-rope slings, 8-ft. (2.44 m) long (minimum). Each sling should have 1,500 lb.
(700 kg) capacity.
Four connecting links (clevises) (rated for a minimum of 1500 lb), to attach the wire-rope
slings to the enclosure lifting eyebolts.
A 75-ft (20 m) rope, 5/8” (1.5 cm) in diameter, to use as a tagline. A tagline is used to guide
the enclosure into position while it is lifted and lowered.
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Version C, November 22, 2013
Emerson Network Power
Outdoor Enclosures
6.12 Lifting the Enclosure
ALERT
Do not lift the enclosure with batteries, rectifiers, or converters installed.
Procedure
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Step 7:
Step 8:
Step 9:
Page 50 of 148
Ensure the front door is closed and latched.
Inspect the lifting eyebolts and ensure eyebolts and roof are free of damage.
Ensure that the four eyebolts on top of the enclosure have their sides oriented
towards the center of the enclosure with no exposed threads as shown in Fig. 24.
Install a clevis and shackle or a threaded shackle in each eyebolt at the top of the
enclosure as shown in Fig. 24.
Insert all four (4) 8’ minimum lifting slings securely through all four clevises or
shackles as shown in Fig. 24.
To prevent the enclosure from tipping when the pallet retaining bolts are removed,
slowly take up the slack with the crane.
Note: DO NOT tighten the slings so that the pallet lifts. The weight of the
pallet will make it difficult to remove the bolts from the pallet
brackets.
Note: It is important that the length of each sling allow for an angle 45° or
more.
Note: Failure to maintain a 45° angle or greater and using all four eyebolts
will void any warranty or service claim.
5
Use a /8" (1.5 cm) diameter rope, approximately 75-ft (20 m) long, as a tagline to
steady the enclosure during lifting and lowering operations. Attach the tagline to an
eyebolt on the right side of the enclosure (looking at the front).
Remove the pallet mounting hardware. (Requires 3/4” deep well socket.)
Lift the enclosure. The pallet should drop off from its own weight.
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Typical sling
arrangement
Never use the sling without
clevises or shackles as this
may break the eyebolts
Direction
of pull
Shackle
The angle
between the sling
cables and the top
of the cabinet shall
not be less than 45°
eyebolts
Shackle
Top of Cabinet
Fig. 24 : Lifting the Enclosure
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Outdoor Enclosures
6.13 Placing the Enclosure
ALERT
During lifting and placement, the enclosure must be lowered so that the enclosure is level and parallel to the pad surface. Place the enclosure so that it lines
up with the anchors. Make sure the enclosure is clear of the conduits in the
foundation pad.
Perform the following procedure to pad or platform mount the enclosure.
Procedure
Note: Refer to Fig. 25 when using the optional pour-in-place pad template. Refer also to
Section 6.8.1, Cabinet Conduit Entry Options before placing the enclosure.
Step 1:
Lower the enclosure to approximately 6” above the pad, level and parallel. The
enclosure should be lowered towards the front of the enclosure’s final placement,
out of the way of all OSP cables that may be present.
Step 2: Shift the enclosure, to the rear, over the final mounting location.
Step 3: As the enclosure is moved into place, verify the enclosure clears cables and conduit.
Step 4: Verify the barrier pad is in place and the enclosure is directly over the mounting
holes.
Step 5: Slowly lower (or slide) the enclosure in place, until it firmly rests on the pad. Keep
the slings on, with a little slack.
Step 6: Tap enclosure anchors loosely into position, leaving about 3/4" above the
enclosure’s mounting surface.
Step 7: Use a level and the shims supplied with the enclosure accessory kit to level the
enclosure as required. Slots in shims must be aligned with enclosure mounting holes
to work properly for seismic Zone 4 applications.
Step 8: Open and close the front door and verify it will open, close, and lock properly. If
not, adjust the shims, until the door functions properly.
Step 9: Complete installation of enclosure anchors.
Step 10: When the enclosure is secured, remove the slings, the tagline, and the lifting
eyebolts.
Step 11: Re-install the bottom battery tray and other required components. Refer to Fig. 26
for a procedure.
Step 12: Remove the rear access panels and put to the immediate side. See Section 5.6,
Removing/Installing Rear Access Panels.
Step 13: If leaving the site or enclosure unattended:
• Put the accessory kit back into the Battery Compartment.
• Install all rear access panels.
• Close and secure the front door.
• If storing for more than one month, review requirements of long-term storage.
Page 52 of 148
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ALERT
If the enclosure will not be powered up for an extended period, place a heat
source, such as a 100W light bulb inside the enclosure to prevent condensation.
See Detail A
Pad Template
REAR
FRON
T
Barrier Pad
Detail A
Concrete Pad
Fig. 25 : Attaching Enclosure to Optional Pour-in-Place Pad Template
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Emerson Network Power
Outdoor Enclosures
1. Connect the heater pad cables then secure
the rear battery holding bracket and
battery heater pad assembly using the
the screws (4 places).
rear battery holding bracket
and battery heater pad
assembly
front
battery holding
bracket
2. Install and secure the battery retaining bracket
using screws (8 places) and the front battery
holding bracket (4 places).
battery drawer
retaining bracket
3. Secure the bottom battery drawer
to the battery tray using the hex bolt
and nylon slides (2 places on right and left side).
4. Secure the battery drawer using the
captive fasteners.
Fig. 26 : Replacing Bottom Battery Tray after Enclosure Placement
Page 54 of 148
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7. SEALING EQUIPMENT COMPARTMENT CABLE ENTRIES
In keeping with local practices, seal all cable gromments and cones.
It is extremely important to maintain a well-sealed enclosure Equipment Compartment. Failure
to do so can jeopardize the enclosure sensitive electronics, as well as the proper functioning of
enclosure systems. All cable interfaces into the Equipment Compartment must be properly
sealed after installation of cables.
The rubber OSP cable boots can be removed and reinstalled after cables have been run into the
enclosure. It is suggested to use duct sealing foam and cable-ties (up to 0.18" width and 0.06"
thick) to seal cables entering the Equipment Compartment via the cable cones, as described in
the following procedure. Refer to Fig. 27.
The other cable entry fittings have internal rubber collars to aid in sealing against the cables,
but additional sealant and/or tape may be required to provide an acceptable seal.
Procedure
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
After cables have been run, determine the cable bundle diameter and cut the cable
boot to provide same-size opening.
Slit cable boot open along its length between the cable tie spine.
Wrap boot around cable bundle and reinstall using cable boot plates.
Use tie-wraps inserted through slots in cable boot spine to close the boot shut.
Fill boot with sealant to completely seal the cable entry.
Rear View
Fig. 27 : Cable Cones
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8. AC POWER
8.1 Safety Precautions
DANGER
Risk of Electrical Shock, General
•
•
•
•
All ground connections must be installed and verified, prior to connecting
any power cables (AC or DC) and turning-up of enclosure.
Before installation, the AC grounding electrode system must be bonded to
an AC main service power neutral/ground bus. Contact your local power
company or local practices for information about codes or restrictions for
your installation.
When connecting any discrete power connection, make the connection first
with the ground/return and break last with ground/return.
Remove rings, metallic wrist bands, or bracelets, etc.
DANGER
Risk of Electrical Shock, AC
•
•
Proper actions, include, but not limited to:
— Verify before contacting the enclosure that no current leakage or ground
fault condition is present.
— Verify a proper ground is in place.
— Verify for AC hook-up, all enclosure circuit breakers are OFF and the
utility incoming feed is OFF.
Use a trained licensed electrician.
DANGER
Electrical Hazard
Observe all safety precautions as specified by local building codes and the
National Electrical Code (NEC). All procedures should be performed by a
licensed electrician. If local building codes specify procedures different from
those in this section, follow local codes.
8.2 Enclosure AC Schematic
The complete system schematics are included with each enclosure, and the AC Schematic is
posted on the door.
Page 56 of 148
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8.3 Grounding the Enclosure
ALERT
Grounding should be accomplished according to local practices and in accordance with the latest NEC codes.
All enclosure grounding and ground ring must be installed prior to turn up of enclosure.
•
•
•
The internal enclosure frame and all attached equipment are factory grounded to the
Enclosure Master Ground Bar.
A 2 AWG lead is factory connected from the Enclosure Master Ground Bar to a Ground
Ring Termination block located at the lower rear of the enclosure.
The external enclosure shell is internally grounded to the Ground Ring Termination block.
The enclosure should be grounded to an external ground ring using a #2 AWG solid wire. The
resistance of the ground ring, as verified with a Megger, shall be less than 25 ohms. Refer to
Section 6.3, Site Ground for supporting information.
Procedure
Step 1:
Connect the Ground Ring Termination block to site ground per local practices.
Refer to Fig. 28 for location. The Ground Ring Termination block is equipped with
1
/4-20 studs on 5/8” centers for installation of customer provided lugs. Refer to
Table D for recommended lugs. Recommended wire size is 2 AWG.
Rear
Ground Ring Termination
(1/4-20 Studs on 5/8” centers)
Fig. 28 : Enclosure Ground Ring Termination Location
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8.4 AC Input Connections
DANGER
Adhere to Section 8.1, Safety Precautions.
The enclosure requires separate AC feeds for the rectifier shelf, GFCI outlet, and Battery
Heater Control Unit. These AC feeds are connected to a terminal block located in an AC Input
Junction Box.
Make connections per the current edition of the American National Standards Institute (ANSI)
approved National Fire Protection Association's (NPFA) National Electrical Code (NEC), and
applicable local codes.
The following procedure shall be performed by a trained electrician.
Procedure
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Step 7:
Step 8:
Page 58 of 148
Use a non-contact voltage detector to verify the enclosure is safe.
Verify that the enclosure is properly grounded.
Verify that all breakers feeding the enclosure and all breakers within the enclosure
are in the OFF position.
Refer to the schematic drawings shipped with your enclosure for a detailed AC
wiring diagram. See also Fig. 31.
Remove the rear access panels. See Section 5.6, Removing/Installing Rear Access
Panels.
Determine the AC cabling route into the enclosure for your installation site. There
are knockouts located on the lower rear access panel and also knockouts on the rear
enclosure floor. Each conduit knockout has been assigned a specific use. Refer to
Fig. 29. Refer also to Section 6.8.1, Cabinet Conduit Entry Options.
Pull the AC Power and Ground Cables into the enclosure. Refer to Fig. 29, Fig. 30,
and Fig. 31.
Note: All green/yellow terminals are bonded to the DIN rail the terminal
block is mounted to. The customer is expected to provide ground
wires per the circuit diagrams provided.
A. You will need eight (8) separate 208Vac or 240Vac 30A branch circuits to feed
the rectifier shelf.
B. You will need one (1) 120Vac 20A circuit to feed the GFCI outlet circuit.
C. You will need one (1) 120Vac 15A circuit to feed the Battery Heater Control
Unit.
Connect the above feeds per Fig. 31. Strip the leads before inserting into terminal
block. Torque screw to 1.5N-m to 1.8N-m or 13 in-lbs to 16 in-lbs. Test the lead
connection by gently pulling on it.
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Step 9:
460-200-051
Version C, November 22, 2013
After cables are installed, refer to Section 7., Sealing Equipment Compartment
Cable Entries and seal all cable gromments and cones.
Removable Panels
Rear
AC Input
Channel
AC
Utility
2” Conduit
Knockouts
OSP
Cables
AC
Utility
2” Conduit
Knockouts
OSP
Cables
Fig. 29 : AC Input Channel and Knockout Locations
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AC Terminal
Blocks
Cut-out for
AC Junction Box
cables
AC Junction Box
removable cover
Fig. 30 : AC Input Channel Covers and Terminal Block Location
Page 60 of 148
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Fig. 31 : AC Input Terminations Location
460-200-051
Version C, November 22, 2013
NOTE:
1. Torque screws 1.5Nm to 1.8Nm or 13in-lbs to 16in-lbs.
SEE NOTE 1
AC WIRING AND GROUNDING
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9. DC POWER
9.1 Safety Precautions
DANGER
Risk of Electrical Shock, General
•
•
•
•
All ground connections must be installed and verified prior to connecting
any power cables (AC or DC) and turning-up of enclosure.
When connecting any discrete power connection, make the connection first
with the ground/return and break last with ground/return.
Remove rings, metallic wrist bands, or bracelets, etc.
Do not install equipment showing any physical damage.
DANGER
Risk of Electrical Shock, DC
•
•
•
An OFF Battery Switch / Breaker does not isolate the batteries, nor do the
batteries have a protective fuse. Thus, handle accordingly and use only
insulated tools when working around batteries or any DC potential.
In addition, be sure that all connection points have been de-energized.
GMT fuses can produce sparks during interruption or clearing of a fault, so
only use BUSSMAN GMT fuses provided with safety caps.
9.2 General
Refer to Section 6.3, Site Ground and Section 8.3, Grounding the Enclosure for information on
Site and Enclosure ground respectively.
9.3 DC Power Cabling Color Scheme
On the enclosure, the DC Power Cabling color scheme is:
•
BLK is return and BLU is –48Vdc Power.
Page 62 of 148
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9.4 Emerson NetSure™ 512NGBB DC Power System
The enclosure includes a NetSure™ 512NGBB DC Power System with Integrated Distribution
(582137000ZZ001) and controller configuration (555878). This power system includes:
•
•
•
•
•
•
•
Up to sixteen (16) PCU (rectifier) mounting positions.
Up to twelve (12) converter mounting positions.
Battery Low Voltage Disconnect.
A battery temperature probe attached to the top of a battery during battery installation (see
Section 12.4.3, VRLA Battery Installation and Connection).
A two-row distribution panel equipped with 41 (-48V) breaker mounting positions, 6 GMT
fuse positions, and 16 (+24V) breaker mounting positions.
Two (2) of the 48V breaker positions are used and 1 GMT position is used.
Use 90o lug adapter P/N 545405 when installing wires larger than 10 AWG on the upper
-48V or +24V row. Adapters are not needed for the return bus.
Refer to Fig. 32 for an illustration of the NetSure™ 512NGBB DC Power System
(582137000ZZ001).
2-Row Distr. Cabinet
Top Distr. Row
Bottom Distr. Row
ACU+ Controller
Module Mounting Shelf(s)
Front View
Rectifier
Mounting Positions
Converter
Mounting Positions
Rectifier or Converter
Mounting Positions
Fig. 32 : NetSure™ 512NGBB DC Power System (582137000ZZ001)
9.4.1 NetSure™ 512NGBB DC Power System Controller Factory Settings
The power system’s controller factory settings are documented in a configuration document
(C-drawing) that is furnished with the power system.
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9.4.2 Rectifier Local Indicators
Location and Identification: Refer to Fig. 33.
Description: There are three (3) indicators located on the Rectifier’s front panel. The functions
of these indicators are as shown in Table E.
Note: AC Voltage must be present at the input terminals.
Power Indicator (Green)
Protection Indicator (Yellow)
Alarm Indicator (Red)
Fig. 33 : Rectifier Local Indicators Locations
TABLE E - Rectifier Local Indicators
Indicator
Normal State
Fault State
Off
Power
(Green)
On
Off
Flashing
Alarm
(Red)
No input voltage.
Internal input fuse open.
On
Flashing
Protection
(Yellow)
Fault Cause
The Rectifier Module is being identified by
the Controller.
AC input under/over voltage.
PFC output under/over voltage.
High temperature.
Moderate load sharing imbalance.
Loss of communication with the Controller
(the rectifier can provide power).
On
Severe load sharing imbalance.
Rectifier Module output disabled for any
reason, including overvoltage shutdown
and internal output fuse open.
Rectifier addresses contradictory.
Flashing
Faulty fan (Rectifier Module shuts down).
Off
9.4.3 Converter Local Indicators
Location and Identification: Refer to Fig. 34.
Description: There are three (3) indicators located on the Converter’s front panel. The
functions of these indicators are as shown in Table F.
Note: DC voltage must be present at the Converter Module output terminals (from
battery or an operating Converter Module) or DC voltage at the input terminals.
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Power Indicator (Green)
Protection Indicator (Yellow)
Alarm Indicator (Red)
Fig. 34 : Converter Local Indicators Locations
TABLE F - Converter Local Indicators
Indicator
Normal State
Fault State
Off
Power
(Green)
On
Alarm
(Red)
No input voltage.
Internal input fuse open.
On
Flashing
Protection
(Yellow)
Fault Cause
Off
The Converter Module is being identified
by the Controller.
DC input under/over voltage.
High temperature.
Moderate load sharing imbalance.
Flashing
Loss of communication with the Controller
(the converter can provide power).
On
Severe load sharing imbalance.
Converter Module output disabled for any
reason, including overvoltage shutdown.
Off
Flashing
Faulty fan (Converter Module shuts
down).
9.4.4 ACU+ Local Indicators, Menu Navigation Keys, and LCD Display
Location and Identification: Refer to Fig. 35.
Description: There are three (3) indicators, four (4) menu navigation keys, and an LCD display located on the
ACU+ Controller’s front panel.
Refer to Table G for the function of the indicators.
Refer to Table H for the function of the menu navigation keys.
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Note: When the LCD is lit, if no button is pushed for 8 minutes, the backlight of the LCD
display extinguishes and the ACU+ Controller returns to the Main Screen. Press
any key to re-activate the LCD display.
Minor Alarm
Indicator (Yellow)
Status
Critical or Major
Indicator
Alarm Indicator
(Green)
(Red)
M820D
10/100M Ethernet
Port (RJ-45)
ESC
ENT
USB
Port
Menu Navigation Keys
Fig. 35 : ACU+ Local Indicators and Menu Navigation Keys Locations
TABLE G - ACU+ Local Indicators
Indicator
Page 66 of 148
Normal State
Fault State
Status
(Green)
On
Off
No input power to the ACU+ Controller.
Minor Alarm
(Yellow)
Off
On
The system has one or more active Minor
alarms. Alarm conditions are
programmable.
Critical/Major
Alarm (Red)
Off
On
The system has one or more active
Critical or Major alarms. Alarm conditions
are programmable.
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TABLE H - ACU+ Local Menu Navigation Keys
Key Symbol
Key Name
ESC
Escape
ENT
Enter

Up

Down
Function
Press this key to go back to a previous
menu or to cancel setting a parameter.
Press this key to go forward to the next
menu, to select a parameter to edit, or to
validate a parameter setting change.
 
Press
or
to scroll through the menus
or to change the value of a parameter.
Press any key to silence an audible alarm.
9.4.4.1 Controller Local Menu Navigation
To Select a Sub-Menu:
Press the up or down arrow keys to move the cursor up and down the list of sub-menus in the
menu screen (selects the sub-menu), then press ENT to enter the selected sub-menu.
To Enter a Password:
If a password screen opens, a password must be entered to allow the User to make adjustments.
To enter a password, with the cursor at the User Name field (default is "Admin"), press the
down arrow key to move cursor down to the password line. Press ENT. "0" is highlighted. Press
the up arrow key once to change the "0" to"1" (default password is "1"), then press ENT twice.
(Note: If you have been assigned a unique User Name and password, follow this procedure to
enter these.)
To Change a Parameter:
Press the up or down arrow keys to move the cursor up and down the list of parameters in the
menu screen (selects the parameter to change), then press ENT to change the selected
parameter. The parameter field highlights. Press the up or down arrow keys to change the
parameter value. Press ENT to confirm the change.
9.4.5 Rectifier High Voltage Shutdown and Lockout Restart
Remove the rectifier, wait 30 seconds or more (until the LEDs on the rectifier extinguish), then
re-insert the rectifier.
The rectifier can also be restarted from the ACU+ LCD or WEB Interface menu (via the
Rectifier Reset command, found in the Manual menu in the LCD menus or under the Rectifier
Control Tab in the WEB Interface).
9.4.6 Converter High Voltage Shutdown and Lockout Restart
Remove the converter, wait 30 seconds or more (until the LEDs on the converter extinguish),
then re-insert the converter.
The converter(s) can also be restarted from the ACU+ LCD or WEB Interface menu (via the
Over Volt Reset command, found in the Manual menu in the LCD menus or under the
Converter Control Tab in the WEB Interface).
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10. OSP CABLES
10.1 General
DANGER
Risk of Electrical Shock, OSP Cables
If joint buried cables are used, check the cable sheath for voltage in accordance
with local standards. If voltage is detected, do not proceed with the installation.
Contact the supervisor and do not proceed until the voltage hazard is
eliminated.
Note: The following steps are recommendations only, and are perform in conjunction
with procedures and training that adhere to local practices.
Note: The following MOP assumes the undressed cables have been pulled into the
enclosure and sealed.
10.2 Sealing Cable Entries
After cables are installed, refer to Section 7., Sealing Equipment Compartment Cable Entries
and seal all cable gromments and cones.
10.3 Installing OSP Cables
OSP cables are run as illustrated in Fig. 36. Pass the cables through the cable boot openings
and run exposed within the center section of the cable entry compartment to the external
conduits. The center cable entry compartment provides tie-wrap lances to tie off the cables to
the compartment back panel.
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OSP
Cables
Equipment
Compartment
can also be
used for
OSP cables
reserved for
battery cables
Rear
Removable
Lower
Rear Cover
OSP
Cables
2” Knockout
2” Knockout
Cabinet Base
Fig. 36 : Routing OSP Cables
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11. ALARM WIRING
11.1 Connecting External Alarms
Alarm blocks are provided for the following purposes.
•
•
Enclosure Alarms
“Bunching” of Alarms from Adjacent Enclosures
Refer to Fig. 37 for locations. The alarm blocks are quick connect (IDC Type) feed through
type. The alarm blocks accept a wire size in the range of 16-24 AWG, solid or stranded. Wire
should NOT be stripped before inserting into block. A small #1 flat blade screwdriver is
required to activate the terminal before inserting the wire.
11.1.1 Enclosure Alarms
Environmental and power system alarms are processed by the ACU+. Refer to Fig. 37 for
location and alarm schedule.
11.1.2 “Bunching” of Alarms from Adjacent Enclosures
Additional alarm blocks are provided for “bunching” of alarms from adjacent enclosures.
Refer to Fig. 38 for a proposal on how to use the bunching blocks.
When connecting alarms from adjacent enclosures, the following material is suggested for use:
•
12 Pair Cable, approximately 25 feet,
16-24 AWG, Solid or Stranded, Color-Coded Cable
11.1.3 Typical Battery Alarm Wiring
Refer to Fig. 39.
Note: Battery breaker alarms are processed through the NetSure Power System and are
output as a critical alarm.
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TABLE BELOW
Note: Terminate equipment wires on
right side of block.
ALARM BLOCK
Fig. 37 : Local Alarm Block Schedule (cont’d on next page)
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1
2
ALARM INTERCONNECT
BLOCK
Notes:
1. Blocks 11 and 16 are grounded.
2. When adding battery cabinet alarms
for temp, fan and intrusion, move the
red bridge grounding jumper in the
right column from B to A.
3. As battery strings are installed, remove
the corresponding bridge in the right
column only.
Fig. 37: Local Alarm Block Schedule (cont’d from previous page)
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The above example shows four (4) discrete alarms being tied
together in series. If any one opens, it means there is an
open circuit across Alarm Out.
Fig. 38 : Typical Bunching Block Jumper Wiring
TYPICAL BATTERY STRING
WHT/ ORG
TO ALARM
INTERCONNECT
BLOCK
ORG/ WHT
Fig. 39 : Typical Battery Alarm Wiring
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12. BATTERIES
12.1 Safety Precautions
DANGER
Risk of Electrical Shock, General
•
•
•
•
•
All ground connections must be installed and verified prior to connecting
any power cables (AC or DC) and turning-up of enclosure.
When connecting any discrete power connection, make the connection to
the ground/return first.
When disconnecting any discrete power connection, remove the connection
to the ground/return last.
Remove rings, metallic wrist bands, or bracelets, etc.
Do not install equipment showing any physical damage.
DANGER
Risk of Electric Shock
•
•
•
•
•
The DC bus is powered by DUAL power sources – Rectifiers and DC
Batteries.
To properly work on the system, de-energize by disconnecting BOTH power
sources. Even with the batteries turned off by using a local battery (circuit
breaker) disconnect, batteries are still “LIVE” and hazardous, including a
voltage >50VDC, and a source of high short circuit current.
Use extreme caution around the batteries and terminals.
Do not smoke.
Remove all jewelry, use proper Personal Protective Equipment (PPE), and
use only insulated tools.
WARNING
Risk of Chemical Exposure
•
•
A battery can present harmful chemicals. Refer to the Battery Installation
Manuals and MSDS supplied with the batteries. Work in a ventilated area
and follow all safety procedures.
At a minimum, wear safety glasses and gloves when working with batteries.
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WARNING
Risk of Hazardous Substances
After handling of the enclosure or any such component; such as batteries,
cables, busbars, etc., always wash hands immediately after.
WARNING
Risk of Explosion
For safety reasons, never restrict or block the airflow through the door or entry
panel ventilation openings.
WARNING
Risk of Injury, Lifting Batteries
Batteries are heavy, use appropriate techniques and assistance when handling.
CAUTION
Prevent Equipment Damage, Proper Handling.
Do not stack batteries or lay them on their side.
CAUTION
Prevent Equipment Damage, Maintain Ventilation
To optimize the service life of this equipment, make sure there are no
obstructions in front of the ventilation openings.
NOTICE
Follow all battery manufacturer's and locally approved safety procedures and
wear appropriate safety gear when handling the batteries and connecting them.
12.2 Battery Compartment Cooling and Heating
The Battery Compartment is cooled through a Battery Compartment ventilation fan.
The battery ventilation fan is controlled by the ECU (Environmental Control Unit). Refer to
Section 14.4.2, Battery Compartment Thermal Components for operating parameters.
Three (3) 120Vac powered battery heater pads are also factory installed (one per battery shelf).
All three battery heater pads operate on a single 15A, 120VAC circuit, as shown in Fig. 31.
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IF BATTERY STRING #2 or #3 is not installed, to save energy, DISCONNECT the
appropriate cable from the battery heater at the Battery Heater Control Unit. Refer to Battery
Heater Control Unit wiring diagram in Fig. 40.
Fig. 40 : Battery Heater Control Unit Wiring Diagram
The thermostat control to automatically turn on/off the battery heaters is via a 1/2" diameter
disc type thermostat located on a bracket attached to the bottom battery tray. The heater’s
thermal set points are ON at +5ºC (+40ºF) and OFF at +15ºC (+60ºF).
There is a momentary toggle switch on the bottom of the Battery Heater Control Unit to test
the operation of the heater pads. Test by pressing the toggle switch for approximately 1 minute,
then feel the heater pad surfaces to verify they are warm to the touch. Replace the heater pad
if it doesn’t get warm during the test. Note that a supplemental 10A input fuse is located inside
the Battery Heater Control Unit (located in the Equipment Compartment, see Fig. 9) that may
be open. Check that fuse before replacing heater pad.
12.3 Battery Compartment
12.3.1 Cabling
One set of 2 AWG (+) and (-) battery cables are provided for each of the three (3) battery trays.
Battery intercell connectors are not supplied with the enclosure, and need to be ordered with
the batteries.
12.3.2 Battery Disconnect
A battery disconnect circuit breaker (100A) is provided in the Equipment Compartment for
each of the three (3) Battery Compartment’s battery trays.
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12.3.3 Anti-Oxidant
Before making any connection, ensure that all contact surfaces have been cleaned and coated
with a thin coat of NO-OX-ID-A, or other equivalent anti-oxidant compound.
12.3.4 Physical Battery Placement
Fig. 50 illustrates the typical placement of batteries in one of the three (3) battery trays.
12.3.5 Physical Size of Battery Tray
The free space available for batteries in each of the three (3) battery trays:
•
•
•
21.85" (555 cm) wide for all four batteries
26.3" (668 cm) deep
12.75" (323.85 cm) high.
12.4 VRLA Batteries
12.4.1 Supported VRLA Batteries
The enclosure can be equipped with three (3) 48Vdc battery strings, providing emergency
backup power in the event that AC service is lost. Each string consists of four 6-cell 12V
modules.
The system will support the batteries listed in Table I, at a minimum.
Note: The battery shelves are configured for GNB 155 Ah batteries. Battery shelves may
be reconfigured for different battery types and sizes by removing or adding left
and right side battery tray shims. See Fig. 41 and Table I below.
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Detail A
3 Shims (left side)
3 Shims (right side)
see Detail A
Fig. 41 : Power and Battery Cabinet Battery Tray Shim
TABLE I - Supported VRLA Batteries
Battery
CD TEL12-210F
DEKA 12AVR170ET
EnerSys SBS 190F
FIAMM UMTX 180FT
GNB
M12V180FT
Northstar
NSB 180FT
Amp Hours
per String @
8 hrs
Dimensions (inches)
HxWxD
Qty of Battery
Tray Shims
Recommended
(Left and Right
Side)
202 Ah
170 Ah
190 Ah
180 Ah
12.6 x 4.9 x 22
12.6 x 4.9 x 22.1
12.64 x 4.96 x 21.97
12.5 x 4.9 x 22
3 Right, 3 Left
NA
1 Right, 1 Left
1 Right, 1 Left
180 Ah
12.6 x 4.9 x 22
NA
179Ah
12.60 x 19.6 x 22.6
3 Right, 3 Left
12.4.2 Reconfiguring Battery Trays for Use with VRLA Batteries
Note: The battery shelves are factory configured for use with Northstar
NSB 180FT. To reconfigure the battery shelves for use with other VRLA
batteries as listed in Table I, perform the procedures below.
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Note: The following procedure will be used for installing batteries for the middle and
bottom trays of the cabinet. Refer to “Procedure - Topmost VRLA Battery Tray”
on page 82.
• Procedure - Middle and Bottom VRLA Battery Trays
Step 1: Loosen and set aside the 1/4"-20 hex bolts (8 places) to remove the battery retaining
bracket. Refer to Fig. 42.
Step 2: Loosen and set aside the 1/4"-20 hex bolts (4 places) to remove the front battery
holding bracket. Refer to Fig. 42.
Step 3: Loosen two 3/8" captive fasteners to release the battery tray from the battery frame.
Refer to Fig. 43.
Front battery
holding bracket
Battery
retaining bracket
1/4”x 1.25” hex bolts
and washers
(4 places)
1/4”x 0.5” hex bolts
and washers
(8 places)
Fig. 42 : Removing the Battery Holding and Retaining Brackets
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Captive
fasteners
Fig. 43 : Disengaging the Battery Tray from the Battery Frame
Step 4:
Pull the battery tray to the front by 15 inches and engage the locking pin to secure
the open position. Refer to Fig. 44.
Locking pin
locked position
Fig. 44 : Locking the Battery Tray to Open Position
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Step 5:
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Lay the first VRLA battery in the middle initially, then push to the leftmost side of
the tray. Place the second battery at the rightmost part. Place the two remaining
batteries in the middle.
first battery
second battery
Fig. 45 : Placing the VRLA Batteries
Step 6:
Step 7:
Re-install the battery holding bracket to secure the batteries in the tray.
The cabinet is shipped with two (2) sets each with three (3) shims per side of the
battery tray. Use the recommended number of battery shims required for your
battery. Refer to Table I, “Supported VRLA Batteries,” on page 78 for the complete
list per battery model.
Step 8: Re-install the battery retaining bracket and secure with the previously removed
hardware.
Step 9: Dis-engage the battery tray’s locking pin. Refer to Fig. 53.
Step 10: Slide the battery-occupied tray back to its original position and secure by tightening
the loosened captive screws.
Note: Refer to the following procedure for installing batteries on the topmost
tray.
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Front battery
holding bracket
Shims placed on each side
of tray if necessary
Fig. 46 : Securing the Batteries with Battery Holding Bracket and Shims
• Procedure - Topmost VRLA Battery Tray
Step 1: Loosen and set aside the 3/8" hex bolts and washers (4 places) to remove the top
battery frame support. Refer to Fig. 47.
Step 2: Follow the similar procedure in Step 1 to Step 10 from “Procedure - Middle and
Bottom VRLA Battery Trays” in placing the topmost batteries.
Step 3: Re-install the top battery frame removed in Step 1 and secure with the same
hardware.
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Top battery
frame support
Fig. 47 : Placing VRLA Batteries on Topmost Battery Tray
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Fig. 48 : Battery Shelf Configuration for NorthStar Red Batteries
Page 84 of 148
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12.4.3 VRLA Battery Installation and Connection
ENCLOSURE IS PRE-WIRED FOR -48VDC BATTERY INSTALLATION ONLY.
The Battery Compartment holds twelve (12) 12Vdc 180 Ah (minimum) front post batteries.
Cabling in the enclosure is provided and pre-wired for three (3) -48VDC battery strings only
(twelve [12] batteries total).
Note: The enclosure is not shipped with batteries installed. The batteries are to be
installed in the field.
DANGER
ELECTRICAL HAZARD. Risk of serious injury and/or equipment damage.
Exercise extreme care when handling the batteries and connecting them to the
string. Two people are recommended for lifting and placing batteries. Wear
heavy gloves and safety glasses while lifting the batteries. Handle each battery
ONLY by its lifting slot. Keep hands well away from the connector posts.
Arcing is possible during battery connection procedures. Use heavy gloves
during all procedures involving the batteries to avoid potential injury. Do not
wear rings, metallic wrist bands or bracelets when working on batteries. Do not
allow metal objects to rest on the batteries or to fall across the terminals.
Make sure the battery disconnect breakers are set to “OFF”.
Refer to:
•
•
The schematic drawings shipped with your enclosure for a wiring diagram.
The battery vendor’s documentation set for installation and testing instructions of the
string.
Follow all safety precautions and notices as listed in the battery vendors documentation set.
Perform the following procedure to install batteries into the enclosure.
CAUTION
Provide Most Stable Loading
If only one (1) battery string is installed, install batteries in the bottom battery shelf.
If two (2) battery strings are installed, install batteries in the bottom two battery shelves.
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Procedure
Step 1:
If not done already, open the front door and ensure all battery disconnect circuit
breakers are in the “off” position. See Fig. 49.
Battery Disconnect
Circuit Breakers
Fig. 49 : Battery Disconnect Circuit Breaker Locations
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Step 7:
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Using a Digital Multimeter (DMM), measure the battery voltages to make sure all
batteries are in good condition. A good battery will indicate approximately
12.5Vdc. Per internal battery procedures, replace any battery measured at less than
11.0Vdc.
If necessary, remove all the connecting hardware from the battery terminals.
Coat all battery terminals with an anti-oxidation compound.
Locate the interconnect busbars, covers, and lug bolts in the battery kit.
Remove battery restraint brackets from the battery trays and set them aside for reuse
later. It is suggested that activities be performed on a tray-by-tray basis to reduce
potential for misplacing hardware.
Ensure cables will be in an accessible position after batteries are installed.
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Step 8:
Install the batteries into each
battery tray of the Battery
Compartment. Refer to Step
5 on page 81. Ensure the
battery lifting handle straps
are kept clear of the battery
shelf "clamps" front and
back.
Step 9: Secure batteries within the
battery tray with the
previously removed restraint
brackets.
Note: Install the Battery
Charge Temperature
Compensation Probe
as the batteries are
front
Top View
being cabled. See
Battery Tray
Fig. 51 for probe
Fig. 50 : Battery Placement
location.
in Battery Trays
Note: Coat all battery
interconnect busbars
with an anti-oxidation compound as the next steps are performed.
Step 10: For each battery tray, connect a battery interconnect busbar between the left two
batteries as shown in Fig. 51.
Note: When ordered, batteries are generally shipped with battery
interconnect busbars. The battery interconnect busbars are
approximately 3.25" inches in length.
Step 11: For each battery tray, connect a battery interconnect busbar between the middle two
batteries as shown in Fig. 51.
Step 12: For each battery tray, connect a battery interconnect busbar between the right two
batteries as shown in Fig. 51.
CAUTION
To prevent arcing, the positive (+) battery cables must be connected to the positive (+) battery terminals and the negative (-) battery cables must be connected
to the negative (-) battery terminals.
Step 13: For each battery tray, locate the pre-wired positive (+) battery cable (originating
from the power system’s Battery Return Busbar). Connect this cable to the positive
(+) battery terminal of the fourth battery (right most). See Fig. 51 and Fig. 52.
Step 14: For each battery tray, ensure the battery disconnect circuit breaker is in the “OFF”
position before performing the next step. See Fig. 49.
Step 15: For each battery tray, locate the pre-wired negative (-) battery cable factory
(originating from the respective battery disconnect circuit breaker). Connect this
cable to the negative (-) battery terminal of the first battery (left most). See Fig. 51
and Fig. 52.
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Step 16: Using a torque wrench, tighten all battery hardware per manufacturer's
specifications.
Step 17: Install the covers on the batteries.
Step 18: Close the front door.
Note: Battery temperature probes are
located near battery strings #1 and #3 only.
BLUE
Fig. 51 : VRLA Typical Battery Wiring
Fig. 52 : Typical Battery Connection
(rear of power system)
Page 88 of 148
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12.5 SAFT Batteries
The cabinet also accommodates SAFT 80-94793-01 batteries. The following is a procedure on
how to configure the battery trays for use with SAFT Batteries.
12.5.1 Reconfiguring Battery Trays for Use with SAFT Batteries
Note: The battery shelves are factory configured for use with Northstar
NSB 180FT. To reconfigure the battery shelves for use with SAFT batteries,
perform the procedures below.
Note: The following procedure will be used for installing batteries for the all trays in the
cabinet.
• Procedure - Middle and Bottom SAFT Battery Trays
Step 1: Loosen two 3/8" captive fasteners to release the battery tray from the battery frame.
Refer to Fig. 53.
Step 2: Pull the battery tray to the front by 9.75 inches and engage the locking pin to secure
the open position. Refer to Fig. 53.
Locking
pin
Locked position of
locking pin
Captive
fasteners
Fig. 53 : Pulling out Battery Tray by 9.75 inches and Securing Open Position
Step 3:
Loosen the 1/4"-20 hex bolts (8 places) to release the front battery holding bracket
and the shims. Refer to Fig. 54.
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Front battery
holding bracket
Removed
shims
Fig. 54 : Removing the Battery Holding Bracket and Shims
Step 4:
Loosen the 1/4"-20 hex bolts (4 places) to remove the battery retaining bracket and
heater pad assembly.
Battery retaining bracket
and heater pad assembly
Fig. 55 : Removing the Rear Battery Holding Bracket and
Battery Heater Pad assembly
Step 5:
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Place the SAFT batteries in the battery tray as shown in Fig. 56.
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Fig. 56 : Placing the SAFT Batteries
Step 6:
Step 7:
Dis-engage the locking pin. Refer to Fig. 53.
Slide in the battery-occupied tray and tighten the captive screws to secure.
12.5.2 SAFT Battery Installation
The battery compartment can hold three (3) strings of 180 AMP-hrs SAFT batteries (P/N
80-94793-01).
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Refer to the generic battery string diagram below.
Fig. 57 : SAFT Batteries String
Note: Black dot in each connection indicates positive terminal.
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DANGER
ELECTRICAL HAZARD. Risk of serious injury and/or equipment damage.
Exercise extreme care when handling the batteries and connecting them to the
string. Two people are recommended for lifting and placing batteries. Wear
heavy gloves and safety glasses while lifting the batteries. Handle each battery
ONLY by its lifting slot. Keep hands well away from the connector posts.
Arcing is possible during battery connection procedures. Use heavy gloves
during all procedures involving the batteries to avoid potential injury. Do not
wear rings, metallic wrist bands or bracelets when working on batteries. Do not
allow metal objects to rest on the batteries or to fall across the terminals.
Make sure the battery disconnect breakers are set to “OFF”.
Prepare the following tools and equipment needed for installing the batteries:
•
•
•
•
•
•
•
Insulated torque wrench (100in-lbs),
Insulated socket 100mm & 3/8" (to fit torque wrench),
Multimeter,
Flat wrench and socket wrench set (3/8" or 14mm needed),
Standard Telecom tools, snips and wrenches,
Electrician’s tape, and
Cable ties.
Preparations to be considered before installation:
•
•
•
•
•
Open the battery compartment and extend the shelf to its full position. Lock in place using
the provided latches.
Before installing the battery string, check the battery cabinet power cables polarity. Using
a digital multimeter (DMM), make sure the -48VDC & +0VDC are properly installed and
labeled.
Once the polarity has been verified, make sure the battery power leads are de-energized
before working on the battery compartment (turn off circuit breakers). Using a DMM,
measure the battery power cables: Voltage reading should be +0VDC.
Properly insulate the battery power cables prior to installing the batteries.
Batteries should be installed one level at a time.
Refer to:
•
•
•
•
The schematic drawings shipped with your enclosure for a wiring diagram.
The battery vendor’s documentation set for installation and testing instructions of the
string.
Follow all safety precautions and notices as listed in the battery vendors documentation
set.
Refer to the following steps in installing SAFT NiCd batteries into the enclosure battery
tray.
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CAUTION
Provide Most Stable Loading
If only one (1) battery string is installed, install batteries in the bottom battery shelf.
If two (2) battery strings are installed, install batteries in the bottom two battery shelves.
Procedure
Step 1:
Step 2:
Stage the battery blocks in front of the cabinet, as shown in Fig. 58. Follow the
block orientation and polarity as shown in Fig. 58.
Place the battery (+) end (block A) with a bar code (shown in Fig. 59) to the
rightmost front position.
I
G
J
H
F
E
D
B
C
A
Fig. 58 : SAFT Block Mapping Diagram
Step 3:
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Remove all block-end covers (front and back) to access battery block terminals.
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Exposed terminals
after removing the
block end-covers
Fig. 59 : Removing Block-end covers to Expose Terminals
Step 4:
Measure and record on the SAFT Installation Instruction Sheet 80-94793-01 I/O
sheet all block voltage readings.
Step 5: Remove all end-terminal bolts and wave washers used to connect the blocks and
apply No-Ox to terminals surface.
Step 6: Prepare installation for rear batteries - blocks B, D, F, G and I.
Step 7: Temporarily insulate each cable either using the tube provided or electrician’s tape
end to prevent accidental electrical shock.
Step 8: Connect each of the three long cables to the (-) terminals of blocks B and D, as well
as to the (+) terminal of block I. Refer to Fig. 58.
Note: Torque at 96 in-lbs and apply No-Ox to all exposed metal surface.
Step 9: Connect one of the short cables to the (+) terminal of block F. Refer to Fig. 58.
Note: Torque at 96 in-lbs and apply No-Ox to all exposed metal surface.
Step 10: Re-install block-end covers when connections are completed.
Step 11: Place blocks B, D, F, G and I inside the battery shelf., as shown in Fig. 60.
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G
F
D
B
Connect this short
cable to block G
Fig. 60 : Placing Blocks B, D, F, G and I on Battery Shelf
Step 12: Connect the short cable from terminal F to terminal G.
Note: Torque at 96 in-lbs and apply No-Ox to all exposed metal surface.
Step 13: Install block-end cover for newly connected terminals.
Step 14: Push block B, D, F, G and I to the back of the battery shelf.
Step 15: Place blocks A, C, E, H and J in the battery shelf. Refer to the block diagram in
Fig. 58.
Note: Keep battery handles upright for easier installation.
Step 16: Insert the provided spacer (foam material) between blocks E and F.
Note: Torque at 96 in-lbs and apply No-Ox to all exposed metal surface.
Step 17: Connect the blocks B to A, D to E, H to G, and J to I using the interconnecting straps,
bolts and wave washers previously removed.
Step 18: Connect block F to E using the short cable, and secure with the bolt and wave
washer.
Step 19: Using a DMM, measure voltage between the (+) terminal of block A and the cable
coming connected to block B. Reading should be equal to the sum of the two
blocks’ total voltage.
Step 20: Measure voltage between the (+) terminal of block C and the cable coming
connected to block B. Reading should be 0VDC.
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B
B
Step 21
Step 20
C
C
A
A
Fig. 61 : Measuring Voltage between (+) Terminal and Cable
Step 21: Connect the cable from (-) terminal of block B to the (+) terminal of block C.
Note: Torque at 96 in-lbs and apply No-Ox to all exposed metal surface.
Step 22: Re-install the block-end covers.
Step 23: Repeat Step 19 through Step 22 to connect block D to block E, and block I to block
H. Once done with connecting all blocks, battery string assembly is competed.
Step 24: Using a DMM, measure voltage between the (+) terminal of block A and the (-) of
block J. Reading should be equal to the sum of voltage of all battery blocks
previously noted in the I/O sheet.
Block J
(-) terminal
Block A
(+) terminal
Fig. 62 : Measuring Voltage between (+) Terminal and Cable
Step 25: Tuck the cables using wire ties as required.
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Step 26: Release the battery shelf locking latches.
Step 27: Push the shelf inside the cabinet.
Step 28: Install the battery shelf hardware to secure shelf into the cabinet.
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13. INITIAL POWER UP
13.1 Safety Precautions
DANGER
Risk of Electrical Shock, General
•
All ground connections must be installed and verified prior to turning-up of
enclosure.
DANGER
Risk of Electrical Shock, AC
•
Proper actions, include, but not limited to:
— Verify before contacting the enclosure that no current leakage or ground
fault condition is present.
— Verify a proper ground is in place.
CAUTION
Prevent Equipment Damage, from Condensation
•
•
Until the enclosure is turned up for service, the bags of desiccant shipped
with the enclosure must remain in the enclosure to prevent condensation.
Once service is in-place, remove the desiccant.
13.2 Prerequisite
All procedures and safety notices previous to this section have been observed, with the respect
to the installation of the enclosure, ground, AC power, DC power, and batteries.
Similarly, all procedures and safety notices accompanying other installed equipment have been
observed.
The enclosure now has a protected connection into the local utility power.
13.3 Initial Power Up Sequence
Checks
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Use Non-Contact Voltage Detector to verify enclosure is not unsafe.
Verify all battery disconnect circuit breakers located in the Equipment
Compartment are Off.
Verify all other breakers inside the Equipment Compartment are Off.
Verify no open power leads are present.
Verify all cables and connections are secure.
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Step 6:
Step 7:
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Verify any installed battery, including proper matching of polarity.
Ensure the alarm block bunching clips are set correctly in the alarm block for the
battery shelves being used.
Final Set-Up
Step 8:
Install the rectifier and converter modules into the NetSure™ 512NGBB DC Power
System as follows.
Rectifier modules can be installed in any of the four (4) far left mounting positions
of each module mounting shelf (as viewed from the front). Converter modules can
be installed in any of the three (3) far right mounting positions of each module
mounting shelf (as viewed from the front). See Fig. 63.
Note: Each rectifier and converter module locks into the module mounting
shelf by means of a latch located on the bottom of the module. The
latch and module handle are interactive. Pushing the handle up into
the module's front panel causes the latch to extend to the locking
position; pulling the handle down out from the module's front panel
causes the latch to retract. See Fig. 63.
WARNING
To prevent damage to the latching mechanism, ensure the handle is in the open
position when installing or removing a module. NEVER hold the handle in the
closed position when installing a module into a shelf.
A. Unpack the modules.
B. Note the model number located on the front of each module. Model numbers
starting with the letter "R" are rectifier modules. Model numbers starting with
the letter "C" are converter modules.
C. Place the module into an unoccupied mounting position without sliding it in
completely. Rectifier modules can be installed in any of the four (4) far left
mounting positions of each module mounting shelf (as viewed from the front).
Converter modules can be installed in any of the three (3) far right mounting
positions of each module mounting shelf (as viewed from the front). See
Fig. 63.
D. Loosen the captive screw on the module's handle. Pull the handle down out
from the module's front panel (this will also retract the latch mechanism). See
Fig. 63.
E. Push the module completely into the shelf.
F. Push the handle up into the module's front panel. This will lock the module
securely to the shelf. Tighten the captive screw on the handle.
G. Repeat the above steps for each module being installed in the system.
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H. After the modules are physically installed in the mounting shelf(s), they are
ready for operation immediately after power is supplied to them.
Module
Mounting
Shelf(s)
Front View
Rectifier
Mounting Positions
Converter
Mounting Positions
Rectifier or Converter
Mounting Positions
Rectifier
Converter
Captive Screw
Captive Screw
Handle
Latch
Handle
Latch
Fig. 63 : Installing Rectifier and Converter Modules
Step 9:
Replace the rear access panels. See Section 5.6, Removing/Installing Rear Access
Panels. If the bonding cable to the bottom rear access panel was removed (see
Section 6.8.1, Cabinet Conduit Entry Options), re-connect the bonding cable to the
bottom rear access panel at this time.
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Power Up
Step 10: Enable Utility Power into the enclosure by closing the external overcurrent
protective devices supplying AC input to the enclosure.
• Use Non-Contact Voltage Detector to verify enclosure is not unsafe.
• Allow rectifiers and ECU a few minutes to complete start-up sequence.
Step 11: The ACU+ goes through an initialization routine as follows. Refer to Fig. 35 for
locations of the ACU+ local indicators and navigation keys. Refer also to
Section 9.4.4.1, Controller Local Menu Navigation.
Note: The initialization routine takes several minutes. During that time
various alarm indicators may illuminate on the ACU+ front panel and
an audible alarm may sound. Disregard all alarms. An audible alarm
can be silenced at any time by momentarily depressing the ENT key
on the ACU+ Controller.
A. After the ACU+ is powered on, the display alternates between the "Emerson
Network Power" screen and a screen displaying "Advanced Control Unit Plus
Version ***** Starting….
B. Next, the language screen appears. Press the up or down arrow key to select the
desired language. Press the ENT key to confirm the selection. If no key is
pressed within 10 seconds, the ACU+ selects the displayed language
automatically.
English
C. As initialization continues, the Main screen is displayed, but with zero volts.
Initialization is not complete.
0 9:18:36
F lo a t Charge
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0.0V
0.0A
Auto
N o Alm
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D. When initialization is complete, the Main screen displays voltage and current
normally, and no alarms are active.
0 9:20:21
F lo a t Charge
5 4.4 V
34A
Auto
N o Alm
E. System information is displayed in multiple screens. Repetitively press the up
or down arrow key to view other system information screens one by one.
F. From the Main screen, press ENT to go to the "Main Menu" screen.
M A IN M E N U
S ta tus
Settings
ECO Mode
Manual
Quick Setting
G. From the Main Menu, select a submenu by repetitively pressing the up or down
arrow key. The selected submenu will be indicated by the cursor. Press ENT to
open the submenu.
Note: Repeatedly press the "ESC" key to return in reverse order level by level
from any submenu until the Main screen appears.
H. The DC Power System controller has been factory programmed to customer
operational DC and alarm setpoints. For more information, refer to customer
site documentation. It is not recommended that the settings be field modified
without proper approval. Refer to the configuration drawing (C-drawing)
supplied with your power system documentation for factory settings of
adjustable parameters.
Step 12: Refer to Fig. 64 and program the NetSure™ 512NGBB DC Power System for the
batteries installed.
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Main Screen
###A
09:20:20
##.#V
No Alm
Float Charge
Auto
ENT
ESC
To Select a Sub-Menu:
Press
or
to move cursor in
menu screen (selects menu item).
Main Menu
Main Menu
S tatu s
Settings
ECO Mode
Manual
Quick Setting
Press ENT to enter selected sub-menu.
To Change a Parameter:
Press
or
to move up and
down list of parameters.
or
to change highlighted value.
Press ENT to highlight selected parameter.
Press
Press ENT to make the change.
Press ESC to cancel the change.
ENT
Setting Battery Capacity Parameter
ESC
Select User
Admin
Enter Password
*
ENT
* Note: Use or to move the cursor
to the Select User field. Press ENT
to select a different User if required.
To select a User, press ENT
to highlight the Select User field,
and use or to select a User.
Press ENT to select the User displayed
in the Select User field. Note that only
Users programmed into the ACU+ are shown.
Users are programmed via the Web Interface.
Use or to move the cursor
to the Enter Password field.
Press ENT to enter a password.
To enter password, press ENT
to highlight bit, and use or
to choose character. Press ENT
to accept and move to the
next character. Press ENT again
to accept password.
1. From the MAIN SCREEN (the beginning screen), press ENT.
ESC
Battery
Basic
Charge
Settings
Alarm Setting
Power System
Capacity
Temp Comp
Test
ESC
Rectifier
ENT
BattFuseUnit
Battery 1
Battery
DC
LVD
AC
EIB
SMDU
Converter
SMTemp
Communication
Controller
2. In the MAIN MENU, press the DOWN ARROW to move the cursor to SETTINGS. Press ENT.
3. In the PASSWORD SCREEN, enter the ADMIN password (default is 1). The SETTINGS MENU is displayed.
4. In the SETTINGS MENU, repeatedly press the DOWN ARROW to move the cursor to BATTERY. Press ENT.
4. In the BATTERY MENU, repeatedly press the DOWN ARROW to move the cursor to BATTERY #. Press ENT.
5. In the BATTERY # MENU, the cursor should be on RATED CAPACITY. Press ENT.
7. Press the UP and DOWN arrows until the system’s battery capacity is displayed. Press ENT to change the
setting to the displayed value. The value that needs to be entered is the sum of the capacity of the strings
installed (i.e. three strings of 155 Amp-hr batteries has a capacity of 465).
8. Repeatedly press ESC until the MAIN SCREEN is displayed.
Fig. 64 : Programming the Battery Capacity into the ACU+ Controller
ENT
Battery 1
Rated Capacity
600.0 Ah
ESC Shunt Current
800.0 A
Shunt Voltage
25.0 mv
(50.0-50000.0)
(50.0-50000.0)
(1.0-150.0)
ENT
ACU+ Front Panel
ESC
Menu Navigation Keys
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Step 13: Program the following parameters into the controller (navigate the ACU+ menus as
shown in the previous step).
A. Date: Main Menu / Settings / Controller / Date
B. Time: Main Menu / Settings / Controller / Time
C. IP Communications Parameters (IP address, subnet mask address, gateway
address): Main Menu / Settings / Communication
Note: To take full advantage of NiCad batteries, temperature compensation
should be disabled by setting the Temperature Compensation Sensor
to None. The LVD’s in the plant should also be set to the minimum
value. LVD 1 is disabled and LVD 2 is the battery LVD and is for the
LVBD (Low Voltage Battery Disconnect)
D. Temperature Compensation Sensor: Main Menu / Settings / Battery / Temp
Comp / TempComp Sensor (see note above)
E. LVD 1: Main Menu / Settings / LVD / LVD Unit / LVD1 / LVD1 Volt (see note
above)
F. LVD 2: Main Menu / Settings / LVD / LVD Unit / LVD2 / LVD2 Volt (see note
above)
Battery Backup Online
Step 14: Verify DC rectifiers battery settings are in accordance to installed battery
requirements.
Float Voltage: Main Menu / Settings / Battery / Charge / Float Voltage
Equalize Voltage: Main Menu / Settings / Battery / Charge / EQ Voltage
Battery Capacity: Main Menu / Settings / Battery / Battery 1 / Rated Capacity
• Refer to battery documentation.
Step 15: Close the battery disconnect circuit breakers located in the Equipment
Compartment for shelves with batteries installed. Ensure the battery breaker for any
unused battery shelf(s) is in the OFF position.
Step 16: Verify battery state, as per manufacturer’s instructions. Refer to battery
manufacturer’s documentation for any battery tests.
• Returning to the DC Rectifier System, verify battery profile.
• Verify, as required, battery temperature monitor probe is connected.
Step 17: All DC circuit breakers are ON, verify all rectifier system alarms have been cleared.
ACU+ Alarm Relay Check
Step 18: To verify operation of the external alarm relays, use the ACU+ alarm relay test
feature. Refer to the ACU+ Instructions (UM1M820BNA) for instructions in using
this feature.
Note: The relays are preprogrammed for specific functions. Refer to the configuration
drawing (C-drawing) supplied with your system for your system's specific
configuration.
Checking System Status
Step 19: Monitor DC rectifiers; have rectifier alarms cleared?
• If not, refer to DC Rectifiers Documentation.
• DC System’s alarms will be present until all DC distribution breakers and fuses
are closed “ON”.
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Step 20: Monitor ECU. Power on and have all ECU alarms cleared? If not, refer to
Section 14., ECU (Environmental Control Unit) and Thermal Components.
Step 21: Observe the status of the indicators located on the ACU+, rectifiers, and converters
(if furnished). If the system is operating normally, the status of these is as shown in
Table J.
TABLE J - Power System Status and Alarm Indicators
Component
ACU+
Rectifier
Modules
Converter
Modules
Indicator
Normal State
Status
(Green)
On
Minor
(Yellow)
Off
Critical or Major
Alarm (Red)
Off
Power
(Green)
On
Protection
(Yellow)
Off
Alarm
(Red)
Off
Power
(Green)
On
Protection
(Yellow)
Off
Alarm
(Red)
Off
Final Steps
Step 22: If any ACU+ Controller configuration settings were changed, refer to the ACU+
Instructions (UM1M820BNA) and save a copy of the configuration file. This file
can be used to restore the ACU+ Controller settings, if required, at a later date.
Note: Note that provided on a USB drive furnished with the system is an
ACU+ configuration drawing (C-drawing) and the ACU+
configuration files loaded into the ACU+ as shipped.
Step 23: Verify all rectifier and converter modules and the ACU+ are fully seated, latched,
and the latch handle screws secured.
Step 24: Close and secure the front door.
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14. ECU (ENVIRONMENTAL CONTROL UNIT)
AND THERMAL COMPONENTS
14.1 ECU Description
The enclosure is divided up into two (2) separate environmental compartments: Equipment
Compartment and Battery Compartment. The Equipment Compartment is equipped with a
Heat Exchanger. The Battery Compartment is equipped with a ventilation fan. Each
compartment contains its own set of thermal components, each controlled independently by the
Environmental Control Unit (ECU). Besides controlling all enclosure compartments thermal
components, the ECU also provides the following functions:
•
•
•
monitoring for thermal system component failure (fans and thermistors),
high and low temperature alarming,
and intrusion alarming (audible and extended relay contacts).
Refer to Fig. 65A for an illustration of the ECU used in this enclosure.
THE ECU USED IN THIS ENCLOSURE IS POWERED BY -48VDC.
THE ECU REQUIRES -48VDC INPUT POWER. THERMAL SYSTEM IN ENCLOSURE
REQUIRES -48VDC INPUT POWER CONNECTION TO ECU. OBSERVE PROPER
POLARITY TO ECU INPUT POWER CONNECTION:
•
•
BLUE WIRE (Distribution Side of Power Connector) / RED WIRE (ECU Side of Power
Connector): -48VDC (BATTERY)
BLACK WIRE (Distribution Side and ECU Side of Power Connector):
+48VDC (BATTERY RETURN / GROUND)
Note: Power cable and appropriate circuit breaker for the ECU are provided with the
enclosure and factory connected.
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14.2 Overview Diagrams
ECU (Environmental Control Unit)
(see next sheet for connections)
Heat Exchanger
(mounted on front door)
Equipment
Compartment
(Heat Exchanger)
Battery
Compartment
(Ventilation Fan)
Battery Compartment Fan
(mounted on rear of cabinet)
Fig.65A : ECU and Thermal Components Overview Diagram (cont’d on next page)
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14.3 ECU Power Connector
The ECU power connectors are located below and to the left of the ECU.
The ECU power connectors are pre-connected at the factory. These connections should only
be temporarily broken and made during a service event.
Audible Alarm
Cutoff / Maintenance / Reset
Pushbutton
Red LED Display,
Status and Error Codes
(Three Digit)
Battery Ventilation
Fan Thermistor
External
Alarms Out
Heat Exchanger
Internal Fan #1 (5A)
Intrusion
Alarms In
Heat Exchanger
Internal Fan #2 (5A)
Heat Exchanger
Internal Fan #3 (5A)
Heat Exchanger
External Fan #1 (5A)
Not Used
Heat Exchanger
External Fan #2 (5A)
Heat Exchanger
External Fan #3 (5A)
Battery Vent
Fan (3A)
black
red
black
blue
BLUE / RED is -48Vdc
BLACK is Return.
Fig.65B : ECU and Thermal Components Overview Diagram (cont’d from previous page)
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14.4 Thermal Components and ECU Operation
14.4.1 Equipment Compartment Heat Exchanger Thermal Components
The HX (Heat Exchanger) is a closed loop cooling unit with three (3) fans in the internal loop
and three (3) fans in the external loop. The internal and external fans are the same part number.
The inner and outer loop fans operate independently of each other. The use of multiple fans
provides redundancy and the failure of any fan will result in a small but acceptable reduction
in the thermal performance. The HX fans (internal and external loops) are turned off if the
equipment door or rear panel alarm switch is activated.
ECU Control of the Equipment Compartment Thermal Components
The enclosure has a typical ambient operating temperature range of -40°C (-40°F) to +46°C
(+115°F). The range of operating temperature for the equipment to be housed in the enclosure
is -40°C (-40°F) to +65°C (+149°F). The purpose of the heat exchanger is to remove heat
dissipated from equipment while maintaining equipment inlet air temperature. By controlling
enclosure air temperature, the ECU maximizes electronic equipment life. In addition, the ECU
limits acoustic noise by reducing fan speeds when possible.
Equipment Compartment Temperature Sensors
The main Equipment Compartment thermistor determines the Cabinet Air Temperature (TCab).
Fan Speed Control Scheme for Heat Exchangers
Refer to Table K.
•
•
•
•
The speeds of internal and external loop fans are controlled identically in most cases
except where the internal fans reach an upper RPM limit before the external fans and where
the start and stop points differ.
All internal fans run at the same airflow which translates to the same speed for identical
fans from the same vendor.
All external fans run at the same airflow which translates to the same speed for identical
fans from the same vendor.
The internal temperature values determine internal and external maximum fan speeds and
the enclosure set point temperature. The control setting state is defined as the present set
of maximum speeds and setpoint. The controller shall vary the speed of the fans between
minimum and maximum fan speed for that combination using Integral-Proportional (I-P)
control, to maintain TCab (Cabinet Air Temperature) at the Set Point Temperature.
Fan Start/Stop Temperatures: To reduce cycling that might occur when cooling is turned
on or off, specific start stop points are selected for both the internal fans and external fans.
These points are based on the potential drop in internal enclosure temperature as cooling
begins or temperature rise as cooling ends. This selection has to be balanced with the desire
not to run the fans continuously.
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TABLE K - Heat Exchanger Fan Speed Limits - Increasing Thermal Energy
TCab
Condition Required to Progress to this
State from Lower State
Control Setting State
Max Internal
Fan RPM
Max External Fan
RPM
Set Point
Temperature
INT FAN
STATE
EXT FAN
STATE
TCab
FANS ON
MINIMUM
FANS ON
MINIMUM
TCab ≥ -40°C
(-40°F)
FANS ON
+20°C
(+68°F) I-P
CONTROL
FANS ON
+20°C
(+68°F) I-P
CONTROL
TCab ≥ +20°C
(+68°F)
3000
3000
+20°C (+68°F)
FANS ON
+30°C
(+86°F) I-P
CONTROL
FANS ON
+30°C
(+86°F) I-P
CONTROL
TCab ≥ +30°C
(+86°F)
3250
4250
30°C (+86°F)
FANS ON
MAXIMUM
FANS ON TCab ≥ +65°C
(+149°F)
MAXIMUM
Fan Full Speed
Fan Full Speed
N/A
1200 Internal fans 1200 External fans
never shut off
never shut off
N/A
Note: At startup, fans begin in the "fans on maximum" state.
Note: At change of state, fans may momentarily stop.
Fig. K - Heat Exchanger Fan Speed Limits - Decreasing Thermal Energy
TCab
Condition Required to Progress to this
State from Higher State
Control Setting State
INT FAN
STATE
EXT FAN
STATE
TCab
Max Internal
Fan RPM
Max External Fan
RPM
Set Point
Temperature
FANS ON
MAXIMUM
FANS ON
MAXIMUM
N/A
Fan Full Speed
Fan Full Speed
N/A
FANS ON
+30°C
(+86°F) I-P
CONTROL
FANS ON
+30°C
(+86°F) I-P
CONTROL
TCab ≤ +65°C
(+144°F)
3250
4250
+30°C (+86°F)
FANS ON
+20°C
(+68°F) I-P
CONTROL
FANS ON
+20°C
(+68°F) I-P
CONTROL
TCab ≤ +20°C
(+68°F)
3000
3000
FANS ON
MINIMUM
FANS ON
MINIMUM
TCab ≤ +10°C 1200 Internal fans
(+50°F)
never shut off
+20°C (+68°F)
1200 External
fans never shut
off
N/A
14.4.2 Battery Compartment Thermal Components
The vented Battery Compartment consists of the following thermal components.
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Battery Compartment Thermistor.
Battery Compartment ventilation fan which is mounted on a rear removable panel (at the
back of the Battery Compartment). The battery ventilation fan is accessible for
maintenance from within the cable entry compartment. The fan provides air pressure to
draw air from a rear air vent into the Battery Compartment and then out the front door to
cool the compartment. The ECU controls whether the fan is operating or not; and the speed
of the fan to maintain an internal temperature of approximately +25°C (+77°F). The vent
fan does not turn “on” unless the compartment temperature reaches +20°C (+68°F).
Battery Compartment Temperature Sensors
The Battery Compartment thermistor (J4 - Thermistor #4) determines the Battery
Compartment Temperature (TBat). This thermistor controls the battery compartment vent fan.
There is another thermistor (J3 - Thermistor #3) located on a bracket attached to the bottom
battery tray to monitor battery heater pad temperature.
Note: The battery heater pads themselves are not controlled by the ECU, but by a
separate battery heater control circuit.
Fan Speed Control Scheme for the Battery Compartment
This compartment consists of one fan. The controller varies the speed of the fan between
minimum and maximum fan speed for that combination using Integral-Proportional (I-P)
control, to maintain TBat at the Set Point Temperature. See Table L.
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TABLE L - Battery Vent Fan Speed
TBat
Condition Required to Progress to this
State from Lower State
Control Setting State
FAN
STATE
TBat
Max Fan RPM
Set Point
Temperature
FAN OFF
N/A
Off
N/A
FAN ON
MINIMUM
TBat ≥ +20°C (+68°F)
1500
N/A
FAN ON
+25°C
(+77°F) I-P
CONTROL
TBat ≥ +25°C (+77°F)
5000
+25°C (+77°F)
FANS ON
MAXIMUM
TBat ≥ +75°C (+167°F)
Fan Full Speed
N/A
TBat
Condition Required to Progress to this
State from Higher State
Control Setting State
FAN
STATE
TBat
Max Fan RPM
Set Point
Temperature
FANS ON
MAXIMUM
N/A
Fan Full Speed
N/A
FAN ON
+25°C
(+77°F) I-P
CONTROL
TBat ≤ +70°C (+158°F)
5000
+25°C (+77°F)
FAN ON
MINIMUM
TBat ≤ +20°C (+68°F)
1500
N/A
FAN OFF
TBat ≤ +15°C (+59°F)
Off
N/A
Note: At startup, fans run full speed 30-45 seconds to detect fan failure.
14.4.3 Temperature Alarm Setpoint Summary
See Table M.
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TABLE M - Temperature Alarm Setpoint Summary
Port
Temp Input
Description
Alarm Hi
Alarm Lo
LED
Display
Remote Alarm
J1
Cabinet Air 1
+63°C (+145°F)
retires at +60°C
(+140°F)
Not Used
E07
Temperature
Alarm Relay
J2
Not Used
Not Used
Not Used
Not Used
Not Used
J3
Battery
Heater Plate
+65°C (+149°F)
retires at -49°C
(-56°F)1
Not Used
E09
Temperature
Alarm Relay
J4
Battery Fan
+55°C (+131°F)
retires at 52°C
(127°F)1
Not Used
E10
Temperature
Alarm Relay
1
This large hysteresis effectively creates a latch that must be cleared by reset.
14.4.4 Failure Modes
In general, the application accounts for single points of failure. Failures cause the compartment
to enter a system fault mode. Operation in fault mode depends on the type of fault and is given
in Table N.
Thermistor Failure Open or Short
Compartment enters fault mode.
Fan Speed Low
A fan alarm is detected when a fan is commanded to run at a specified RPM and the actual
RPM detected is not within an acceptable tolerance. Compartment enters fault mode.
TABLE N - Fault Conditions
Fault Condition Summary
Loss of Thermistor
Description
Heat
Exchanger
Fans
Battery
Fan
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Fan
Failure
High
Temp
Cabinet
Air 1 (J1)
Battery
Heater
Plate (J3)
Battery
Compartment
(J4)
Remaining
fans
All fans
operate
full speed
normally
Fans
operate
normally
Fans
operate
normally
Fans
operate
normally
Fan
operates
normally
Fan
operates
normally
Fan set
to full speed
Fan set to
full speed
Fan set to
full speed
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14.5 ECU User Interface
14.5.1 Initial Start-Up Sequence
When power is first applied to the ECU, the ECU goes through the following Start-Up
sequence.
Start-Up Sequence
Step 1:
Step 2:
Step 3:
Product Code # and Firmware Code (Revision) # displays.
All fans run at full speed for approximately 30 seconds to detect any fault
conditions, then normal operation resumes.
UP displays if everything is operating as expected.
or
Continuous cycle of error codes if any faults detected.
14.5.2 ECU Display Codes
Note: NORMAL OPERATION OF THE ECU LED DISPLAY IS "UP".
TABLE O - ECU Display Codes
Code 1
Description
ECU External Alarm
UP
Controller OK
--
PC
Product Code
--
xxx
Product Code
(follows PC)
(xxx = 000-999)
(In this enclosure it is 019.)
--
FC
Firmware Code (Revision)
--
N.N.N
Firmware Code (Revision)
(follows FC)
(N = 0-9)
--
d01
Door Open (software does not
treat as alarm resulting in a system
fault condition)
Intrusion Alarm
d02
Door Ajar (software does not treat
as alarm resulting in a system fault
condition)
Intrusion Alarm
d03 (followed by
minutes
remaining in
maintenance
mode or
seconds
remaining if less
than 1 minute)
Maintenance Mode
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TABLE O - ECU Display Codes
E01
TH1 (Thermistor) Fail (J1) Cabinet Air 1
(Note: E07 inhibited)
HVAC Major Alarm
E03
TH3 (Thermistor) Fail (J3) Battery Heater Plate
(Note: E09 inhibited)
HVAC Major Alarm
E04
TH4 (Thermistor) Fail (J4) Battery Ventilation
HVAC Major Alarm
E07
High Temperature (Equipment
Compartment) (inhibited by E01)
Temperature Alarm
E09
High Temperature (Battery Heater)
(inhibited by E03)
Temperature Alarm
F01
Internal HX Fan #1 Fail (J16) 2
HVAC Major Alarm
F02
Internal HX Fan #2 Fail (J17) 2
HVAC Major Alarm
F03
Internal HX Fan #3 Fail (J20) 2
HVAC Major Alarm
F04
External HX Fan #1 Fail (J14) 2
HVAC Major Alarm
F05
External HX Fan #2 Fail (J15) 2
HVAC Major Alarm
F06
External HX Fan #3 Fail (J18) 2
HVAC Major Alarm
F07
Battery Fan Fail (J19) 2
HVAC Major Alarm
1
Display cycles continuously through all active messages.
2
Fan fail alarms are latched until controller is reset.
All other alarms are retired when the alarm condition is removed.
14.5.3 External Alarms
The ECU provides the following external alarms. Refer also to the Section 11.1, Connecting
External Alarms.
•
•
•
Intrusion Alarm: Activates if the front door is opened or the top rear access panel is
removed.
High / Low Temperature Alarm: Activates during a high or low temperature condition
in either the Equipment and/or Battery Compartment.
HVAC Major Alarm: Activates if any of the following conditions occur.
— One or more fans failed.
Note that an unplugged fan will not alarm unless the ECU tells it to turn ON.
— A Thermistor failed or is open.
— ECU board communications failure.
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14.5.4 Intrusion Alarm
Whenever the front door is opened or top rear access panel removed; an intrusion alarm
activates. The intrusion alarm...
•
•
•
•
•
Displays Code d01 (Door Open) on the ECU LED display.
Activates an audible alarm.
Activates an external intrusion alarm, if connected to an alarm sending device.
Turns all fans off (if there are no alarms).
Starts an intrusion alarm timer (30 minute timer).
To Disable Audible Alarm
To disable the audible alarm, momentarily depress the Audible Alarm Cutoff / Maintenance /
Reset pushbutton located on the ECU. See Fig. 65A for location. This cancels the intrusion
alarm and restarts the intrusion alarm timer, providing the enclosure temperature in any
compartment is less than its high temperature alarm limit.
Intrusion Alarm Timer
If the door is not closed or access panel not replaced before the 30 minute timer expires (or 30
minutes elapse after depressing the Audible Alarm Cutoff pushbutton), the following occurs.
•
•
•
•
•
Code d02 (Door Ajar) displays on the ECU LED display.
Audible alarm (if silenced) re-activates.
External intrusion alarm (if silenced) re-activates.
All fans turn on.
Thermal control is restored.
14.5.5 Maintenance Mode
The system can be placed into the Maintenance Mode to perform such tasks as fan
replacement. To enter the Maintenance Mode, open the front door and depress the Audible
Alarm Cutoff / Maintenance / Reset pushbutton located on the ECU for more than 5 seconds
but less than 10 seconds. See Fig. 65A for location. The following occurs.
•
•
•
•
The system is placed into the Maintenance Mode for 60 minutes.
The audible alarm is turned off.
All thermal devices are turned off.
Code d03 (Maintenance Mode) displays on the ECU LED display, along with a count
down of the minutes remaining.
Note: The display continues to cycle through all other active messages.
Note: When the time remaining is down to 1 minute or less, the audible buzzer will beep
as a warning that this mode will be exited and the fans may start. The display
continues to cycle through all active messages.
Manually Exiting Maintenance Mode
Maintenance Mode can be exited by closing the door or by depress the Audible Alarm Cutoff
/ Maintenance / Reset pushbutton for more than 10 seconds.
Resetting the Maintenance Mode
To reset the Maintenance Mode for another 60 minutes, depress the Audible Alarm Cutoff /
Maintenance / Reset pushbutton for more than 5 seconds but less than 10 seconds.
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14.5.6 Resetting the ECU
To reset (restart) the ECU, open the front door, listen for the audible alarm and then depress the
Audible Alarm Cutoff / Maintenance / Reset pushbutton located on the ECU for more than 10
seconds. See Fig. 65A for location. If display starts to countdown from 60, then Maintenance
mode was activated and unit was not reset. Close door and reopen, listen for alarm and hold
reset button for more than 10 seconds.
Note: The ECU is also reset if a hard power down (remove 48Vdc) and power up occurs.
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15. MAINTENANCE, TROUBLESHOOTING, AND
REPLACEMENT PROCEDURES
15.1 Enclosure Identification
Prior to contacting Emerson for support and/or replacement parts, note the enclosure part
number, serial number and test date which can be found on the ID label located on the inside
of the front door.
15.2 Routine Maintenance
15.2.1 Battery Compartment Ventilation Openings
At each visit, verify that there is no obstruction outside the enclosure blocking the Battery
Compartment ventilation openings. At 1 to 5-year intervals, based on the location and
environmental conditions, use clean compressed air to blow out the dust accumulation from
the Battery Compartment ventilation openings in the door shroud, door, and back panel.
15.2.2 Heat Exchanger Maintenance
At each visit, verify that there is no obstruction outside the enclosure preventing ventilation,
and that all fans are clean and operating normally. At 1 to 5-year intervals, based on the location
and environmental conditions, use clean compressed air to blow out the dust accumulation
from the external loop heat exchanger core per the following procedure. Also blow out the dust
accumulation from the Heat Exchanger ventilation openings in the door shroud.
Although not a mandatory preventative maintenance measure, replace the external fans at
5-year intervals, particularly if the enclosure is operating under extreme environmental
conditions. See Section 15.4.3, Heat Exchanger Fan Replacement for a procedure.
External Loop Heat Exchanger (Hx) Maintenance Procedure
To clean the external loop HX, Emerson advises to remove the external loop fan assembly per
the “Replacing an External Fan” procedure in Section 15.4.3, Heat Exchanger Fan
Replacement. Then using clean compressed air (DO NOT USE WATER OR SOLVENTS),
clean the fins of the HX. Normal compressed air is OK to use, provided that the hose is kept
far enough away from the exterior loop fins, so that the air velocity on the fins doesn’t cause
the fins to deflect past their elastic limit. That is, they can deflect, but not permanently be bent.
You can also use a clean vacuum cleaner with the hose reversed to provide an air stream.
15.2.3 DC Power System Maintenance
The following maintenance routines should typically be performed every six to 12 months.
Note that some of these procedures could cause service interruptions. Make sure that the
batteries are fully charged and capable of maintaining the load before performing any of these
procedures.
Every Six Months:
•
•
clean ventilation openings on rectifiers, converters, and controller,
measure and record output voltage,
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inspect all installer's connections.
Every 12 Months:
•
•
•
check major/minor alarms,
check and adjust output voltage,
check and adjust high voltage shutdown set point.
15.2.4 Battery Maintenance
Battery life is determined by a variety of factors, including the technology deployed, the
charge/discharge cycle history, operating temperature, peak current draw, etc. Battery string
replacement is governed by carrier policies, but should be performed regularly at the end of the
expected lifetime of the battery.
Battery health should be checked at regular intervals per battery manufacturer’s instructions,
which should include a verification of the float voltage and open circuit voltage.
The furnished Power System’s controller includes a set of Battery (Plant) Tests to validate
batteries. If the carrier wishes to use these tools, refer to Section 9., DC Power.
Battery Maintenance Procedure
Step 1:
Step 2:
Step 3:
Step 4:
Make sure that the batteries and battery area are clean and dry.
Inspect the battery terminals. Make sure that the battery terminals are clean and the
connections are tight. If necessary, clean and tighten the terminals in accordance
with local practices, using approved cleaning solution. Reapply antioxidant
compound (NO-OX-ID-A or equivalent).
In high discharge rate applications, or in areas subject to high vibration, periodically
check battery terminal tightness.
Note: Tighten all battery terminal adapter post nuts to the torque
specifications specified by the battery manufacturer only.
Keep records of battery and cell voltages as required by battery manufacturer and
local practices to monitor long-term changes in battery condition. To ensure battery
warranty protection, keep any additional records as required by the battery
manufacturer. Refer to the Battery Installation and Maintenance Record supplied
with the batteries.
15.2.5 Battery Replacement
The following considerations must be taken when replacing a battery:
•
•
•
•
•
•
•
•
•
Follow all previously stated warnings and precautions.
Review all documentation, including the battery manufacturers instructions and MSDS.
Never mix different battery technologies, manufacturers, or models within the enclosure.
Before proceeding, isolate the battery from the DC Power Plant (open the connecting
circuit breaker).
Though isolated, potential for hazardous current remains, act accordingly.
The removal procedure is the inverse of an installation.
Any and all spillage must be dealt with completely and immediately.
To install the replacement, follow the previous installation and battery manufacturer’s
instructions.
Ensure to re-apply NO-OX-ID-A (or approved equivalent) on all terminals and lugs.
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15.2.6 Freezing Rain and Ice
The two primary issues with freezing rain and ice are:
•
•
Blocked ventilation, which can impose personnel hazards and potential risk to equipment
damage.
Difficulty of access to the inside of the enclosure.
— The selected lock hasp has been designed to minimize hidden ice build-up and provide
for the removal of ice.
Ice will often break in sheets, so the use of a soft mallet or hand onto a surface will create the
stress cracks necessary to push the ice off.
In the unlikely event of a severe freezing rain, immediately followed by severe drop in
temperature, the ice may be extremely thick and hard. In this case, it is recommended a tent be
used to isolate the enclosure and an external, no spark heat source, be used to warm the
enclosure.
Ice and snow should be removed from the front door and all ventilation areas.
Practices and tools to avoid include:
•
•
•
•
use of salt,
use of ice scraper, screwdrivers or other tools that would dig into the ice and ultimately into
the metal surface,
use of an open flame, or any device that may create an open spark, and
use of de-icing fluid(s).
15.3 Troubleshooting
15.3.1 DC Power System
15.3.2 Rectifier Fault Symptoms and Troubleshooting
The fault indicators that can be displayed by the rectifier are as follows. Refer to Table P for
a list of possible causes and corrective actions.
•
•
•
•
•
Power Indicator (Green) OFF
Protection Indicator (Yellow) ON
Protection Indicator (Yellow) Flashing
Alarm Indicator (Red) ON
Alarm Indicator (Red) Flashing.
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TABLE P - Rectifier Troubleshooting
Symptom
Power
Indicator
(Green) Off
Protection
Indicator
(Yellow) On
Protection
Indicator
(Yellow)
Flashing
Alarm
Indicator
(Red) On
Alarm Indicator
(Red) Flashing
Possible Cause(s)
Suggested Action(s)
No input voltage.
Make sure there is input voltage.
Internal input fuse open.
Replace the Rectifier Module.
AC input voltage outside the normal
range.
Correct the AC input voltage to within
the acceptable range.
PFC over-voltage.
Replace the Rectifier Module.
Moderate load sharing imbalance.
Replace the Rectifier Module.
Rectifier Module not inserted into the
slot completely.
Remove and properly insert the
Rectifier Module.
1. Fan rotor blocked.
1. Remove any object that may be
blocking the fan.
2. Ventilation blocked (inlet or outlet).
2. Remove any object that may be
blocking the inlet or outlet.
3. Ambient temperature too high or
Rectifier Module inlet too close to a
heat source.
3. Lower the ambient temperature or
relocate the heat source.
Rectifier Module communication
failure.
Check the communication cables.
Remove and properly insert the
Rectifier Module.
Output over-voltage shutdown.
Severe load sharing imbalance.
Internal output fuse open.
Remove the Rectifier Module from its
shelf and then reinstall after 30
seconds. If Rectifier Module fails to
start or shuts down again; replace the
Rectifier Module.
Rectifier Module addresses
contradictory.
Replace the Rectifier Module.
Fan not operating (Rectifier Module
shuts down).
Replace the Rectifier Module.
The fault indicators that can be displayed by the converter are as follows. Refer to Table Q for
a list of possible causes and corrective actions.
Power Indicator (Green) OFF
Protection Indicator (Yellow) ON
Protection Indicator (Yellow) Flashing
Alarm Indicator (Red) ON
Alarm Indicator (Red) Flashing.
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Higher
State
Rectifier Module over-temperature protection, which could be caused by:
15.3.3 Converter Fault Symptoms and Troubleshooting
•
•
•
•
•
Lower
State
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TABLE Q - Converter Troubleshooting
Symptom
Power
Indicator
(Green) Off
Protection
Indicator
(Yellow) On
Protection
Indicator
(Yellow)
Flashing
Alarm
Indicator
(Red) On
Alarm Indicator
(Red) Flashing
Possible Cause(s)
Suggested Action(s)
No input voltage.
Make sure there is input voltage.
Internal input fuse open.
Replace the Converter Module.
DC input voltage outside the normal
range.
Correct the DC input voltage to within
the acceptable range.
Moderate load sharing imbalance.
Replace the Converter Module.
Converter Module not inserted into
the slot completely.
Remove and properly insert the
Converter Module.
Higher
State
Converter Module over-temperature protection, which could be caused by:
1. Fan rotor blocked.
1. Remove any object that may be
blocking the fan.
2. Ventilation blocked (inlet or outlet).
2. Remove any object that may be
blocking the inlet or outlet.
3. Ambient temperature too high or
Converter Module inlet too close to a
heat source.
3. Lower the ambient temperature or
relocate the heat source.
Converter Module communication
failure.
Check the communication cables.
Remove and properly insert the
Converter Module.
Output over-voltage shutdown.
Severe load sharing imbalance.
Remove the Converter Module from
its shelf and then reinstall after 30
seconds. If Converter Module fails to
start or shuts down again; replace the
Converter Module.
Converter Module addresses
contradictory.
Replace the Converter Module.
Fan not operating (Converter Module
shuts down).
Replace the Converter Module.
Refer to Section 9., DC Power for information on troubleshooting the rectifiers, converters,
and controller.
15.3.4 Batteries
Refer to the appropriate battery manufacturer’s maintenance manual for information on
troubleshooting battery problems.
15.3.5 Environmental Control Unit (ECU)
The following provides information to verify and troubleshoot the enclosure's Environmental
Control Unit (ECU), heat exchanger (HX), fans, and associated cabling.
The following documents, tools, and parts are required:
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system SD and J drawings (which ship with the enclosure),
digital multimeter, 0-60Vdc and continuity (Ohmmeter),
replacement parts as needed.
The troubleshooting person needs to be able to locate:
•
•
the ECU, HX, fans, and associated cabling,
the rectifiers, converters, and the DC distribution panel.
Note: Important! All procedure should be done in keeping with safe and local practices.
ECU Display Codes
Refer to Table O for a list of codes that the ECU may display.
ECU Door “Ajar” Alarm - d02
When “d02” displays on the ECU, there is a door intrusion condition. Two scenarios cause d02
to be displayed.
•
•
A door or panel is left open for more than 30 minutes (a normal condition).
A broken door intrusion switch or an open in the door intrusion switch wiring (a fault
condition).
Scenario 1 (Normal Condition)
No troubleshooting required. A door or panel was simply left open for more than 30 minutes.
Close the door or panel, or momentarily depress the Audible Alarm Cutoff / Maintenance /
Reset pushbutton located on the ECU to cancel the intrusion alarm and silence the audible
alarm for another 30 minutes.
Scenario 2 (Fault Condition - Broken Door Intrusion Switch
or an Open in the Door Intrusion Switch Wiring)
If the door and all panels have been closed and there is an audible alarm active, you have a
broken door intrusion switch or an open in the door intrusion switch wiring.
When you open the front door and observe the ECU, you will see the d02 code displayed. This
also indicates that there is a wiring issue with the intrusion switches somewhere.
If you momentarily depress the Audible Alarm Cutoff / Maintenance / Reset pushbutton
located on the ECU, the ECU displays “UP” and the audible alarm ceases, but there is still a
problem and the alarm will activate again in 30 minutes.
Check for a broken door intrusion switch or an open in the wiring. See Fig. 66 for wiring
illustration.
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TOP ACCESS PANEL
FRONT DOOR
Fig. 66 : Enclosure Intrusion Switch Wiring
(two intrusion switches wired in series, each switch provides a close loop circuit
when the door or panel is closed, opening a door or removing a panel opens the circuit)
Recommended Practice to be Performed after a Door or Panel is Open
To check for a broken door intrusion switch or an open in the wiring, perform the following
procedure whenever a door or panel has been opened.
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
As a final check, before leaving the site, ensure all panels are properly closed.
With the front door open, d01 or d02 should be displayed on the ECU.
Pull the front door intrusion switch out. This places this switch in the disabled
position.
Observe that “UP” is displayed on the ECU. This confirms that the other switches
and door intrusion wiring has no open conditions.
Close the front door.
15.3.6 Fan Alarm Test Procedure
This test method is to validate alarms back to the NOC during the initial commissioning, and
is not intended for routine maintenance.
•
•
Refer to Fig. 65A for location of ECU temperature sensor and fan ports.
Field technician requires a 10k Ohm ECU Temp Sensor Bypass Resistor Plug using AMP
Parts 172165-1 (Connector, Qty 1) and 770904-3 (Pins, Qty 2) and a 10k Ohm Resistor.
— This 10k Plug simulates a Temp Sensor setting for a warm summer day, which drives
the Heat Exchanger (HX) Fans. Please note that HX Fans at this speed is barely audible
and may be masked by the noise of other equipment.
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After power is completed and the heat exchanger (HX) fans have settled down to the
operating speed, fan operation is as follows.
— If the internal temperature is below 10°C, fans will be idle at 1200 rpm.
or
If the equipment door is open and bypass is not enabled, the HX fans will be off.
• Exception: If the ECU is reporting an over-temperature condition, fans will be
running at full speed.
Unplug the temperature sensor from the ECU J1 port.
— ECU should display the E01 error code.
— To this ECU alarm condition, the HX Fans will ramp up.
Connect the temporary 10k Plug into ECU J1 port.
— The fans will settle down to the 45 dBA sound level speed.
— Note the other internal equipment is likely louder than the HX Fans, and thus mask the
sound of the HX Fans.
— No error codes should be displayed on the ECU display.
Unplug the fan connected to the ECU J14 port.
— The ECU should display the F04 error code.
Reconnect the fan to the ECU J14 port.
— No error codes should be displayed on the ECU display.
Repeat the above 2 steps for all remaining fans (ECU ports J15 - J21).
— The ECU error codes should be F01 and Fxx, with xx being the next fan fail number.
Replace the temporary resistor plug in the ECU J1 port with the original temperature
sensor that was connected to this port before the procedure was started.
— During this change over, an error may temporarily be reported.
15.3.7 Battery Heater Pad Test Procedure
Refer to Section 12.2, Battery Compartment Cooling and Heating.
15.4 Replacement Procedures
15.4.1 DC Power System
15.4.1.1 Rectifier Replacement
Rectifier modules can be inserted or removed with power applied (hot swappable).
Note: Each Rectifier Module locks into a module mounting shelf by means of a latch
located on the bottom of the module. The latch and Rectifier Module handle are
interactive. Pushing the handle up into the module's front panel causes the latch
to extend to the locking position; pulling the handle down out from the module's
front panel causes the latch to retract. See Fig. 67.
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DANGER
Take care when removing a Rectifier Module that was in operation, as Rectifier
Module surfaces could be very hot.
WARNING
To prevent damage to the latching mechanism, ensure the handle is in the open
position when installing or removing a Rectifier Module. NEVER hold the handle
in the closed position when installing a Rectifier Module into a shelf.
Procedure
Note: Refer to Fig. 67 as this procedure is performed.
Step 1:
Performing this procedure may activate external alarms. Do one of the following. If
possible, disable these alarms. If these alarms cannot be easily disabled, notify the
appropriate personnel to disregard any alarms associated with this system while this
procedure is performed.
Step 2: Loosen the captive screw on the module's handle. Pull the handle down out from the
module's front panel (this will also retract the latch mechanism). See Fig. 67.
Step 3: Grasp the handle and pull firmly to remove the module from the shelf.
Step 4: Place the replacement Rectifier Module into the mounting position without sliding
it in completely.
Step 5: Loosen the captive screw on the module's handle. Pull the handle down out from the
module's front panel (this will also retract the latch mechanism). See Fig. 67.
Step 6: Push the module completely into the shelf.
Step 7: Push the handle up into the module's front panel. This will lock the module securely
to the shelf. Tighten the captive screw on the handle.
Step 8: Certain functions (i.e. rectifier current limit, rectifier addressing) may require
adjustment when adding or replacing a Rectifier Module. Refer to the Power
System documentation for instructions.
Step 9: After the Rectifier Modules are physically installed in the mounting shelf(s), they
are ready for operation immediately after power is supplied to them. Verify that the
Rectifiers are operating normally.
Step 10: Enable the external alarms, or notify appropriate personnel that this procedure is
finished.
Step 11: Ensure that there are no local or remote alarms active on the system.
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Rectifier
Captive Screw
Handle
Latch
Fig. 67 : Latch Mechanism on the Rectifier Module
15.4.1.2 Converter Replacement
Converter modules can be inserted or removed with power applied (hot swappable).
Note: Each Converter Module locks into a module mounting shelf by means of a latch
located on the bottom of the module. The latch and Converter Module handle are
interactive. Pushing the handle up into the module's front panel causes the latch
to extend to the locking position; pulling the handle down out from the module's
front panel causes the latch to retract. See Fig. 68.
DANGER
Take care when removing a Converter Module that was in operation, as
Converter Module surfaces could be very hot.
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WARNING
To prevent damage to the latching mechanism, ensure the handle is in the open
position when installing or removing a Converter Module. NEVER hold the
handle in the closed position when installing a Converter Module into a shelf.
Procedure
Note: Refer to Fig. 68 as this procedure is performed.
Step 1:
Performing this procedure may activate external alarms. Do one of the following. If
possible, disable these alarms. If these alarms cannot be easily disabled, notify the
appropriate personnel to disregard any alarms associated with this system while this
procedure is performed.
Step 2: Loosen the captive screw on the module's handle. Pull the handle down out from the
module's front panel (this will also retract the latch mechanism). See Fig. 68.
Step 3: Grasp the handle and pull firmly to remove the module from the shelf.
Step 4: Place the replacement Converter Module into the mounting position without sliding
it in completely.
Step 5: Loosen the captive screw on the module's handle. Pull the handle down out from the
module's front panel (this will also retract the latch mechanism). See Fig. 68.
Step 6: Push the module completely into the shelf.
Step 7: Push the handle up into the module's front panel. This will lock the module securely
to the shelf. Tighten the captive screw on the handle.
Step 8: Certain functions (i.e. converter current limit, converter addressing) may require
adjustment when adding or replacing a Converter Module. Refer to the Power
System documentation for instructions.
Step 9: After the Converter Modules are physically installed in the mounting shelf(s), they
are ready for operation immediately after power is supplied to them. Verify that the
Converters are operating normally.
Step 10: Enable the external alarms, or notify appropriate personnel that this procedure is
finished.
Step 11: Ensure that there are no local or remote alarms active on the system.
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Converter
Captive Screw
Handle
Latch
Fig. 68 : Latch Mechanism on the Converter Module
15.4.1.3 ACU+ Controller Replacement
WARNING
ACU+ CONTROLLER HANDLING
Installation or removal of the ACU+ Controller requires careful handling. To
avoid possibility of ACU+ Controller damage from static discharge, a static
wrist strap grounded through a one megohm resistor should always be worn
when handling the ACU+ Controller. ESD-protective packaging material must
also be used when carrying/shipping the ACU+ Controller.
Note: Depending on your network security settings, when you remove a device that is
connected to your network and assign the same IP address to the replacement
device, you may not be allowed to communicate with the replacement device
over the network. Contact your network administrator for assistance.
The ACU+ Controller is hot swappable. It can be removed and installed with the system
operating and without affecting the output bus.
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Procedure
Step 1:
Before performing this procedure, ensure the replacement ACU+ Controller
contains the same configuration file as the existing ACU+ Controller. Refer to the
Configuration Label on the side of the replacement ACU+ Controller for the
Configuration Part Number. If the existing Controller is operational, navigate the
menus to view its configuration file (MAIN SCREEN/ESC/ENT/ENT).
M820D
C o nfig ura tion F ile
P a rt N um ber L a b el
Fig. 69 : ACU+ Controller Configuration Label Location
Step 2:
Performing this procedure may activate external alarms. Do one of the following. If
possible, disable these alarms. If these alarms cannot be easily disabled, notify the
appropriate personnel to disregard any future alarms associated with this system
while this procedure is being performed.
Step 3: Connect an approved grounding strap to your wrist. Attach the other end to a
suitable ground.
Step 4: Loosen the captive fastener securing the latch mechanism to the front of the ACU+
Controller. Pull the latch mechanism away from the ACU+ Controller (this will
retract the latch mechanism located on the bottom of the ACU+ Controller). This
unlocks the ACU+ Controller from the shelf. Refer to Figure 70.
Step 5: Slide the ACU+ Controller completely from the shelf.
Step 6: Loosen the captive fastener securing the latch mechanism to the front of the
replacement ACU+ Controller. Pull the latch mechanism away from the ACU+
Controller (this will retract the latch mechanism located on the bottom of the ACU+
Controller).
Step 7: Slide the ACU+ Controller completely into its mounting position.
Step 8: Push the latch mechanism into the front panel of the ACU+ Controller, and secure
by tightening the captive fastener. This locks the ACU+ Controller securely to the
shelf.
Step 9: Wait for the Controller to finish booting and verify that the complete system
operates normally. Refer to Step 11 on page 102.
Step 10: Perform Step 12 on page 103 and Step 13 on page 105.
Step 11: Enable the external alarms, or notify appropriate personnel that this procedure is
finished.
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Step 12: Ensure that there are no local or remote alarms active on the system.
M820D
Captive Fastener
ESC
ENT
Latch Mechanism
Fig. 70 : Latch Mechanism on the ACU+ Controller
15.4.2 LED Light Replacement
Procedure
Step 1:
Step 2:
Unplug the LED unit that needs to be replaced.
Refer to Fig. 72 and remove the nut securing the LED unit that needs to be replaced.
LED LIGHT WIRING DIAGRAM
Light Switch
Fig. 71 : LED Light Wiring Diagram
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Reverse these steps to re-install the LED unit.
LED light fixture
Front door removed in
illustration for clarity.
LED light bracket
LED unit
Remove nut when replacing
LED unit
Fig. 72 : LED Light Replacement
15.4.3 Heat Exchanger Fan Replacement
DANGER
Electrical Hazard/Mechanical Hazard
Risk of electric shock or being cut by moving fan blades. Before replacing any
fan, disconnect power to the Environmental Control Unit (ECU).
You Will Need - To replace one of the heat exchanger’s fans, you will need the following tools.
•
•
•
Standard Telco Socket Wrench Set
Standard Mechanic Telco Tools
Replacement Fan
Replacing an Internal Fan
Perform the following steps to replace an internal heat exchanger fan. Refer to Fig. 73 as this
procedure is performed.
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Remove the padlock from the enclosure door, if present.
Open the enclosure door.
Secure the door in the open position with the wind latch.
Using the ECU Status, identify the fan to be replaced and its location.
Verify that the replacement fan is of the appropriate model.
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Step 6:
Step 7:
Step 8:
Step 9:
Step 10:
Step 11:
Step 12:
Step 13:
Step 14:
Step 15:
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Disable the HX fans by either...
A. Placing the ECU in maintenance mode. See Section 14.5.5, Maintenance Mode
for a procedure.
B. Placing the ECU circuit breaker in the DC distribution shelf into the “OFF”
position.
C. Temporarily disconnecting power to the ECU by separating the in-line
connectors in the ECU power cable.
Disconnect the defective fan’s power lead connector.
For proper orientation of the replacement fan, note the location of the fan wires and
the air flow arrows on the defective fan. Remove the two sets of screws and lock
washers securing the finger guard on the defective fan. Remove the two sets of
screws and lock washers securing the defective fan in place. Remove the fan and
discard. Save the fan mounting hardware for re-use.
Install the replacement fan and secure it in place using the hardware removed above.
Ensure the fan wires and air flow arrows match the orientation noted above.
Install the finger guard onto the new fan and secure it in place using the hardware
removed above.
Plug the connector of the replacement fan into the connector vacated when
disconnecting the defective fan. Verify that the connector is fully seated in the
mating connector.
Enable the HX fans by either...
A. Exiting the ECU maintenance mode. Maintenance Mode can be exited by
closing the door or by depress the Audible Alarm Cutoff / Maintenance / Reset
pushbutton for more than 10 seconds.
B. Placing the ECU circuit breaker in the DC distribution shelf into the “ON”
position.
C. Reconnecting power to the ECU by mating the in-line ECU power cable
connectors.
Monitor the ECU to make sure that the replacement fan is powered up and that it
initializes, calibrates, and goes into steady state.
Close the enclosure door on which the heat exchanger is mounted.
Replace the door padlock, if required.
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Screw with
Lock Washer
(6 places)
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Internal
Fans
Screw with
Lock Washer
(6 places)
Finger Guards
Air Flow
Inside View
of Front Door
Fig. 73 : Heat Exchanger Internal Fan Replacement
Replacing an External Fan
Perform the following steps to replace an external heat exchanger fan. Refer to Fig. 74A as this
procedure is performed.
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Remove the padlock from the enclosure door, if present.
Open the enclosure door.
Secure the door in the open position with the wind latch.
Using the ECU Status, identify the fan to be replaced and its location.
Verify that the replacement fan is of the appropriate model.
Disable the HX fans by either...
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A. Placing the ECU in maintenance mode. See Section 14.5.5, Maintenance Mode
for a procedure.
B. Placing the ECU circuit breaker in the DC distribution shelf into the “OFF”
position.
C. Temporarily disconnecting power to the ECU by separating the in-line
connectors in the ECU power cable.
On the inside of the front door, remove all bolts securing the Heat Exchanger’s
shroud (door top shroud) except for the middle outside one closest to the door
handle. This requires a 7/16 hex nut driver. From the front of the door, hold the
shroud while removing the last bolt securing the shroud. Set the shroud and
hardware safely aside.
Note: All three external fans will be removed as an assembly.
Step 8:
Step 9:
Step 10:
Step 11:
Step 12:
Step 13:
Step 14:
Step 15:
Step 16:
Step 17:
Step 18:
Step 19:
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Separate all external fan power connectors (ensure each half of the in-line external
fan power connectors are marked so the can be properly plugged back together).
Loosen (or remove if preferred) the bottom four nuts securing the fan assembly.
Requires 7/16 bit. See Fig. 74A.
Remove the top three screws and hardware securing the fan assembly. Requires
medium cross-blade screw driver. Save the plastic p-clips securing the fan cabling.
It may be necessary to cut one cable tie securing the cables. See Fig. 74A.
Remove the fan assembly by tilting the top of the assembly down, while lifting the
bottom from the bolts loosened above. Set the fan assembly on a suitable work area.
For proper orientation of the replacement fan, note the location of the fan wires and
the air flow arrows on the defective fan. Remove the two sets of screws and lock
washers securing the finger guard on the defective fan. Remove the two sets of
screws and lock washers securing the defective fan in place. Remove the fan and
discard. Save the fan mounting hardware for re-use.
Install the replacement fan and secure it in place using the hardware removed above.
Ensure the fan wires and air flow arrows match the orientation noted above.
Install the finger guard onto the new fan and secure it in place using the hardware
removed above.
Re-install the fan assembly. Tighten (or replace) the bottom set of nuts and replace
the top set of screws to secure the fan assembly.
Re-connect the power lead connectors for all external fans. Verify that the
connectors are fully seated in the mating connector.
Replace the heat exchanger’s shroud, and secure with the bolts and hardware
previously removed.
Enable the HX fans by either...
A. Exiting the ECU maintenance mode. Maintenance Mode can be exited by
closing the door or by depress the Audible Alarm Cutoff / Maintenance / Reset
pushbutton for more than 10 seconds.
B. Placing the ECU circuit breaker in the DC distribution shelf into the “ON”
position.
C. Reconnecting power to the ECU by mating the in-line ECU power cable
connectors.
Monitor the ECU to make sure that the replacement fan is powered up and that it
initializes, calibrates and goes into steady state.
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Step 20: Close the enclosure door on which the heat exchanger is mounted.
Step 21: Replace the door padlock, if required.
Removing Shroud
Remove these bolts
and rubber washers
Remove these bolts
and rubber washers
Remove these bolts
and rubber washers
Shroud
Outside View
of Front Door
Fig.74A : Heat Exchanger External Fan Replacement (cont’d on next page)
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Removing External Fan Assembly
Remove these bolts
and hardware
Loosen these bolts
Outside View
of Front Door
Remove the fan assembly by tilting
the top of the assembly forward,
while lifting the bottom from the
loosened bolts.
Outside View
of Front Door
Fig.74B : Heat Exchanger External Fan Replacement
(cont’d from previous page, cont’d on next page)
Page 138 of 148
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Removing Fans
External
Fans
Finger Guards
Screws with
lock washers securing
the fans and
the finger guards
Air Flow
Fig.74C : Heat Exchanger External Fan Replacement (cont’d from previous page)
15.4.4 Battery Vent Fan Replacement
DANGER
Electrical Hazard/Mechanical Hazard
Risk of electric shock or being cut by moving fan blades. Before replacing any
fan, disconnect power to the Environmental Control Unit (ECU).
You Will Need - To replace the battery vent fan, you will need the following tools.
•
•
Cross-blade Screw Driver
Replacement Fan
Procedure
Perform the following steps to replace a battery vent fan. Refer to Fig. 75 as this procedure is
performed.
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Remove the padlock from the enclosure’s front door, if present.
Open the enclosure’s door.
Secure the door in the open position with the wind latch.
Verify that the replacement fan is of the appropriate model.
Disable the battery vent fan by either...
A. Placing the ECU in maintenance mode. See Section 14.5.5, Maintenance Mode
for a procedure.
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Step 6:
Step 7:
Step 8:
Step 9:
Step 10:
Step 11:
Step 12:
Step 13:
Step 14:
Step 15:
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B. Placing the ECU circuit breaker in the DC distribution shelf into the “OFF”
position.
C. Temporarily disconnecting power to the ECU by separating the in-line
connectors in the ECU power cable.
Remove the top two rear access panels. See Section 5.6, Removing/Installing Rear
Access Panels.
Disconnect the defective fan’s power lead connector.
For proper orientation of the replacement fan, note the location of the fan wires and
the air flow arrows on the defective fan. Remove the two screws and hardware
securing the defective fan and fan guard in place. Remove the fan and fan guard.
Discard the fan. Save the fan guard and fan mounting hardware for re-use.
Install the replacement fan and saved fan guard and secure it in place using the
hardware removed above. Ensure the fan wires and air flow arrows match the
orientation noted above.
Plug the connector of the replacement fan into the connector vacated when
disconnecting the defective fan. Verify that the connector is fully seated in the
mating connector.
Enable the battery vent fan by either...
A. Exiting the ECU maintenance mode. Maintenance Mode can be exited by
closing the door or by depress the Audible Alarm Cutoff / Maintenance / Reset
pushbutton for more than 10 seconds.
B. Placing the ECU circuit breaker in the DC distribution shelf into the “ON”
position.
C. Reconnecting power to the ECU by mating the in-line ECU power cable
connectors.
Monitor the ECU to make sure that the replacement fan is powered up and that it
initializes, calibrates and goes into steady state.
Replace the top two rear access panels. See Section 5.6, Removing/Installing Rear
Access Panels.
Close the enclosure’s front door.
Replace the door padlock, if required.
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DC Bus Surge
Suppressor
location
Air Flow
Fig. 75 : Battery Vent Fan Replacement
15.4.5 Battery Heater Pad Replacement
You Will Need - To replace a battery heater pad, you will need the following tools.
•
•
•
Standard Telco Socket Wrench Set;
Standard Mechanic Telco Tools; and
Replacement Battery Heater Pad Assembly.
Procedure
Perform the following steps to replace a battery heater pad. Refer to Fig. 76 to Fig. 80 as this
procedure is performed.
Step 1:
Step 2:
Step 3:
Remove the padlock from the enclosure's front door, if present.
Open the enclosure's door.
Secure the door in the open position with the wind latch.
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Step 4:
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Pull the battery tray to the front by 15 inches and engage the locking pin to secure
the open position. Refer to Fig. 76 below.
Locking
pin
Locked position of
locking pin
Captive
fasteners
Fig. 76 : Pulling out Battery Tray by 9.75 inches and Securing Open Position
Step 5:
Remove the front battery retaining bracket from the tray by loosening the front two
/8" captive fasteners (2-places).
3
Captivated
Fasteners
Fig. 77 : Removing Battery Retainer from Battery Tray
Step 6:
Step 7:
Step 8:
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If batteries are present in the tray, place the Battery Disconnect circuit breaker to the
OFF position and then disconnect, remove, and store these in a safe place.
Separate the battery heater pad inline connector to disconnect the battery heater pad
wiring from the enclosure's wiring.
Disengage the battery try locking pin as shown in Fig. 76 and pull the battery tray
out of the enclosure. See Fig. 78.
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Step 9:
460-200-051
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Remove the screws (1/4-20) that secure the rear battery retaining bracket and heater
pad to the battery tray (4-places on one side only). Refer to Fig. 78.
Battery retaining bracket
and heater pad assembly
Fig. 78 : Removing the Rear Battery Holding Bracket and
Battery Heater Pad Assembly
Step 10: Carefully remove the battery heater pad, feeding the battery heater pad cable
through the opening in the battery tray.
Step 11: Carefully install the replacement battery heater pad in reverse order it was removed,
and secure with the 4 screws removed.
Step 12: Reinstall the battery tray into the cabinet and engage the locking pin in the trays
pulled out position. Refer to Fig. 76.
Step 13: Plug the battery heater pad in line cable into its mating connector found near the
battery tray and apply heat shrink tubing over these connectors.
Step 14: After replacing the Heater pad, lay the first VRLA battery in the middle initially,
then push to the leftmost side of the tray. Place the second battery at the rightmost
part. Place the two remaining batteries in the middle. Refer to Fig. 79.
first battery
second battery
Fig. 79 : Placing the VRLA Batteries
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Step 15: Replace the front battery retaining bracket to the tray with the hardware removed
above. Refer to Fig. 80.
Front battery
holding bracket
Shims placed on each side
of tray if necessary
Fig. 80 : Securing the Batteries with Battery Holding Bracket and Shims
Step 16: Disengage the battery trays locking pin and push it back into the cabinet.
Step 17: Reconnect the batteries, and then place the Battery Disconnect circuit breaker to the
ON position.
Step 18: Test the replacement battery heater pad by pressing the momentary toggle switch
located on the bottom of the Battery Heater Control Unit for approximately 1
minute, then feel the heater pad surface to verify it is warm to the touch.
Step 19: Close the enclosure's front door.
Step 20: Replace the door padlock, if required.
15.4.6 DC Bus Surge Suppressor Replacement
Procedure
Perform the following steps to replace a surge suppressor. Refer to Fig. 81 as this procedure is
performed.
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Page 144 of 148
Open the rear access panel. Refer to Section 5.6, Removing/Installing Rear Access
Panels on page 30 for the complete procedure.
Locate the surge suppressor on the top-right rear area of the equipment
compartment of the cabinet. See Fig. 81.
Remove the end clamp that secures the surge suppressor to the DIN rail. Set aside.
Remove the defective surge suppressor and replace with a new one.
Secure the new surge suppressor with the end clamp previously removed.
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460-200-051
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Wire per Fig. 81.
Fig. 81 : Surge Suppressor Replacement
Outside Plant Equipment
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16. ACCESSORIES AND REPLACEMENT PARTS
TABLE R - Accessories and Replacement Parts
Part Number
Description
F1010243
Pad-mount template (metal)
F1010279
Reusable mylar/film template
F1010598
Plinth
145400
ECU Fan Controller
P92538
Intrusion Switch and Light Switch
143136
LED Light Replacement - (1) LED Light
137974
48V Vent Fan 120mm
542352
Fan Finger Guard
130471
Thermistor Cable (Fan controller) J1
141001
Thermistor Cable (Fan controller) J3
141003
Thermistor Cable (Fan Controller) J4 Ext Air
P86845
Gore-Tex Patch - Hydrophobic Air Vent Patch
248611000
5A Fuse - 60VDC (G) Internal and External Fans
248610900
3A Fuse - 60VDC (BL) Vent Fan
141328
Door Handle (Front Swing Handle)
141569
Door Latch (Rear) w/o Padlock Hasp
145333
Battery Breaker 100 Amp
556263
Battery Shelf Shim/Spacer - (1) Shim/spacer
Battery Heater Pad
P66625
Battery Heater Pad Fuse 10amp
111062
Battery Heater T-Stat N/O Close 40°F Open 60°F
141552
Surge Suppressor Assembly, 30 DRM w/ Alarm, Raycap
1R482000E3
1M820DNAZZ006
MA4C5U31
555484
MA455U41
540973
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Rectifier
ACU+
IB2, Customer I/O Board, SCU
Can Interface Bus Board
EIB Alarm Board
MBD PWB Assembly
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NOTES
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Outdoor Enclosures
17. REVISION RECORD
Issue
Change
Number
(ECO)
A
RRM218313
New
B
RRM218724
Add plinth option.
C
RRM219629
Update breaker alarm interconnect.
Page 148 of 148
Description of Change
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NetPerform™ Optimization Services
At Emerson Network Power, we understand the importance of reliable equipment - its critical to both your business and your bottom line.
That is why we offer a wide array of services to meet all of your network infrastructure needs.
Customer Service (Pre-Shipment)
Email
CustomerService.ESNA@Emerson.com
Phone
1.800.800.1280 option 2
Pricing and availability [1,2], purchase orders, expediting requests
and order tracking. Ask for your company’s dedicated Customer Service
Associate.
Customer Support Center (Post-Shipment)
Email
ESNACustomerSupportCenter@Emerson.com
Phone
1.956.661.6867
After an order has shipped, contact our Customer Support Center
with related questions, concerns or claims.
Account Management
Email
AccountManagement.ESNA@Emerson.com
Phone
1.800.800.1280 option 3
Provides quotes and bid responses for custom configured [2] DC power
systems and outside plant enclosures for customers and channel partners
(Reps, VARs & Distributors).
Spare Parts
Email
DCpower.Spares@Emerson.com
OSP.Spares@Emerson.com
Phone
1.800.800.1280 option 5
Pricing and purchase orders for spare parts, including but not limited to
breakers, cables, fuses, rectifier fans, misc. breaker and fuse panels,
enclosure fans, doors and switches, etc.
DC Power Depot Repair
Email
DCpower.Repair@Emerson.com
Phone
1.800.800.1280 option 6
Creates and processes RMAs for depot repair and refurbishment.
Determines repair and refurbishment lead times and pricing based on
warranties/contractual agreements. Provides repair shipping information
and status.
Technical Support
Email
DCpower.TAC@Emerson.com
OSP.TAC@Emerson.com
Phone
1.800.800.5260
[1]
[2]
Answers technical product and system questions; determines status of
warranties and contractual agreements for repair.
Contact Account Management for custom-configurations.
Contact DC Power Spare Parts for parts and accessories.
For More Information
To learn more about service offerings from Emerson Network Power, please contact your sales representative,
call 1-800-800-1280 option 7, email ES.Services@Emerson.com or visit EmersonNetworkPower.com/EnergySystems.
The information contained in this document is subject to change without notice and may
not be suitable for all applications. While every precaution has been taken to ensure the
accuracy and completeness of this document, Emerson Network Power, Energy Systems,
North America, Inc. assumes no responsibility and disclaims all liability for damages resulting from use of this information or for any errors or omissions. Refer to other local
practices or building codes as applicable for the correct methods, tools, and materials to
be used in performing procedures not specifically described in this document.
The products covered by this instruction manual are manufactured and/or sold by Emerson
Network Power, Energy Systems, North America, Inc. This document is the property of
Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and
proprietary information owned by Emerson Network Power, Energy Systems, North
America, Inc. Any copying, use or disclosure of it without the written permission of Emerson
Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Names of companies and products are trademarks or registered trademarks of the
respective companies. Any questions regarding usage of trademark names should be
directed to the original manufacturer.
EmersonNetworkPower.com/EnergySystems (North America)
EmersonNetworkPower.eu/EnergySystems (EMEA)
© Emerson Network Power Energy Systems North America 2013.
Business-Critical Continuity ™, Emerson Network Power™, the Emerson Network Power logo, Emerson® and Consider it Solved are service marks and trademarks of Emerson Electric Co.
EnergyMaster™, eSure™, NetPerform ™, NetReach™, NetSpan™, NetSure™ and NetXtend™ are trademarks of Emerson Network Power Energy Systems North America.