ONLITE central CPS
Installation instruction
Legal notes
Trademarks
ONLITE® is a registered trademark of Zumtobel Lighting GmbH, Dornbirn.
Copyright
Copyright © 2008 Zumtobel Lighting GmbH
All rights reserved.
Manufacturer
Zumtobel Lighting GmbH
Schweizerstraße 30
A-6850 Dornbirn/Austria
Tel. +43-(0)5572-390-0
Fax +43-(0)5572-22826
luxmate@zumtobel.com
www.zumtobel.com
Document number
CPS_MA_25.06.08 en
1
Contents
Contents
1
1
3
2
Introduction and safety regulations
1.1
General information
3
1.2
Safety and danger notes
4
1.3
Designated use
5
1.4
Notes on illustrations and block diagrams
6
Installing the switch cabinet
2.1
3
7
System types
7
2.1.1 Compact station CPS K
7
2.1.2 Main station CPS H
8
2.2
Installation
9
2.3
Preliminaries
Installation
10
11
3.1
Connecting the relay outputs
11
3.2
Connecting the ONLITE central CPS Remote Interface
12
3.3
Connecting the line monitors
13
3.3.1 Connecting the line monitors in a circuit monitored sub distribution
13
3.3.2 Connecting the line monitors in a single monitored sub distribution
13
3.4
14
Connecting the emergency circuits
3.4.1 Connecting the emergency ciruits in a circuit monitored sub distribution 14
3.4.2 Connecting the emergency ciruits in a single monitored sub distribution 15
2
4
3.5
Connecting the 230 V AC / 400 V AC voltage supply
16
3.6
Installing and connecting the batteries
17
3.6.1 Connecting the batteries of an ONLITE central CPS K system
(compact station)
17
3.6.2 Connecting the batteries of an ONLITE central CPS H system
(main station)
19
3.6.3 Possible set-ups for battery sets
20
Connecting external sub distributions
22
4.1
Connecting the system bus
22
4.2
Connecting the voltage supply
24
5
Switching on the system
25
6
Completing the installation
26
Appendix
A
27
Technical Data
27
A.1 General
27
A.2 Compact station CPS K
27
A.3 Main station CPS H
28
A.4 Sub station CPS U
29
B
Fuses
29
C
HANDLING INSTRUCTIONS FOR SEALED
VENT-REGULATED LEAD ACID BATTERIES
31
C.1 Safety instructions
31
C.2 Storage instructions
32
C.3 Commissioning
32
C.4 Operating regulations
32
C.5 Charging, discharging
33
C.6 Battery service and maintenance
34
C.7 Warranty
35
C.8 Table of torques for the battery connectors
35
3
1 Introduction and safety regulations
1.1
General information
Validity and technical state of this installation instruction
This installation instruction is valid for the following ONLITE central CPS devices:
Type
Order number
ONLITE central CPS K (compact station)
22 154 689
ONLITE central CPS H (main station)
22 154 690
ONLITE central CPS U E00 (substation in E0 version)
22 154 691
ONLITE central CPS U E30 (substation in E30 version)
22 154 692
ONLITE central CPS BS (battery cabinet)
22 154 693
ONLITE central CPS BG (battery rack)
22 154 694
ONLITE central CPS Touch PC
22 161 687
ONLITE central CPS Remote Interface
22 154 740
Hardware version: B
Signs and symbols used in the documentation
The following signs and symbols are used in this documentation:
Symbol
Description
p
One step text instructions in instructions for action are marked with p. The
individual steps of multiple step instructions for action are numbered.
a
Indicates the result for the action step after several action steps. These results
are marked with an a symbol at the beginning of the line.
V
Requirements which need to be checked before operation are highlighted with
V.
i
Notes are marked with the symbol i.
d
Warning notes are marked with the symbol d. Warning notes also contain the
source of the danger as well as the consequence of the danger.
Warning notes are combined with the following signal words:
Danger: Warns of damage to persons (death or severe injury).
Caution: Warns of damage to persons (death or severe injury) which are
dependent on further actions.
Warning: Warns of material damages.
4
Who may perform the installation?
The installation may only be performed by suitably qualified professional electrical specialists
who have been briefed on local and operational conditions.
1.2
Safety and danger notes
The central battery system ONLITE central CPS is part of the emergency and general lighting
system and consequently part of a building's safety equipment. Installation and
commissioning of the system must be performed with the appropriate care and precision.
d
Danger
Please note that the luminaires are supplied with 216 V DC in case of emergency
operation. Mortal danger by electrical shock!
d
Danger
Only qualified electrical specialists may perform work on the 230 V mains. Wiring of
current-carrying lines as well as signal and control lines must be done in accordance
with the relevant guidelines and standards. National guidelines and regulations
applicable in the country in which the system is being installed and operated have to
be observed.
d
Danger
Improper use of the batteries or battery-powered parts of the system can cause risk of
injury or mortal danger from high current or arcs that can occur briefly on battery
discharge.
Ensure that the batteries are connected to the correct poles!
d
Danger
Non-authorised or non-professional system installation and handling may result in
outages of the safety equipment. This implies immediate danger for people and the
security equipment itself. In addition, damages to machines and plants as well as loss
of productions are possible consequences at production sites.
d
Caution
Non-authorised or non-professional system installation and handling may result in
damages of the batteries. The contained electrolyte sulphuric acid is extremely caustic
and can lead to heavy injuries!
5
1.3
d
Caution
Only luminaires with an operation voltage of 230 V AC (50 / 60 Hz) and 230 V DC
may be connected to the outputs for the emergency lighting end circuits of the
ONLITE central CPS system. Disregarding the instructions may result in damages to
system and luminaires.
d
Caution
Short circuits and incorrect polarity may damage the batteries or parts of the system.
d
Caution
Pay attention to the line lengths of the output circuits. The maximum length of 300 m
may not be exceeded. Disregarding the instructions may result in outages of the
emergency lighting, because the proper communication between the system
components is not guaranteed.
d
Caution
The batteries may not be stored without maintaining for longer than 3 months.
Disregarding the instructions may result in damages to the batteries. When storing the
batteries without conservation charging, the battery capacity decreases up to the
defect of the battery.
Designated use
The central battery system ONLITE central CPS is designed for controlling and monitoring an
emergency lighting system. Any use in excess thereof is not allowed.
The adjustment and operation of the system is restricted to authorised technical staff.
Personal dangers may occur in case of
•
•
improper use
disregarding the safety regulations
The central battery system ONLITE central CPS and connected parts of the system may only
be operated if all system components are in perfect technical condition and in compliance with
•
•
•
•
the safety and danger notes contained in this installation instruction,
the operating and safety instructions stipulated by the system operator,
the commissioning notes and instruction manual supplied with the central battery system
ONLITE central CPS,
the technical data listed in the appendix.
Failures which cannot be removed by acknowledging are to be reported to the responsible
service person.
Operating and safety regulations arise from this installation instruction as well as from
organisational instructions and from general as well as technical guidelines and regulations for
accident prevention.
6
The manufacturer will not assume warranty or liability for consequential damages that occur
due to:
•
•
•
•
1.4
improper use
disregarding the regulations
unauthorised modifications or modifications made by technically non-competent persons
to device connections and settings of the ONLITE central CPS system
the use of not allowed or unsuitable system parts
d
Danger
Also pay attention to all laws, standards and guidelines applicable in the country in
which the system is being operated.
d
Caution
Verify whether electrical installations comply with the application environment. Special
environmental conditions (e.g. areas subject to explosion hazards or areas with an
aggressive atmosphere) require special equipment and installations.
d
Caution
Verify whether all used ballasts and luminaires fulfil the requirements of an emergency
lighting system and the operation at an ONLITE central CPS system.
d
Caution
If mains, which supplies the ONLITE central CPS system, is interrupted longer than
three days, the battery has to be disconnected to prevent from deep discharge and
thus damage of the battery.
Notes on illustrations and block diagrams
Illustrations and block diagrams in these installation instruction are partly for demonstration
purposes only. Drawings and plans that were especially created for the emergency lighting
system and are in accordance with local requirements must be observed.
7
2 Installing the switch cabinet
i
2.1
2.1.1
The ONLITE central CPS systems shown in this installation instruction can differ in
the modular design on delivery.
Special features of customer-specific systems are described in the project
documentation which must be ordered separately.
System types
Compact station CPS K
The following figure shows an ONLITE central CPS K system with one circuit monitored sub
distribution and one individually monitored sub distribution.
1
4
(1) Charging unit LE
(2) Circuit monitored sub distribution S
(3) Individually monitored sub distribution E
(4) Battery compartment
2
3
8
2.1.2
Main station CPS H
The following figure shows an ONLITE central CPS H system with two circuit monitored sub
distributions.
1
2
3
(1) Charging unit LE
(2)/(3) Circuit monitored sub distributions S
Flange plate for connection cables
The connection cables are routed into the cabinet through the drillings in the flange plate on
top of the cabinet (see following figure). The flange plate contains rubber bushings for different
cable diameters (8 mm to 44 mm). Each switch cabinet has three flange plates.
9
2.2
Installation
The switch cabinets of the ONLITE central CPS system must only be installed on flat surfaces
providing enough carrying capacity. Enough space must be provided to the sides and the back
of the cabinets to provide sufficient work space for the installation and future maintenance
work. Ensure that the doors of the switch cabinet can be opened completely.
The connections for the power supply of the ONLITE central CPS system must be provided by
the customer according to the technical data given in appendix A and the wiring diagrams.
i
We recommed to ensure at least 1 m free work space on each side of the switch
cabinet. The switch cabinet dimensions are listed in appendix A of this installation
instruction.
10
2.3
Preliminaries
Before installing the ONLITE central CPS system, open the following fuses:
•
•
•
Main fuses: -2F1, -2F2, -2F10.2 and -2F10.2
Battery fuses: -2F4, -2F5, -2F6 and -2F7
Outgoing fuses in the individual sub distributions: F1 to F20, both for phase L (red labelled
fuses) and for the neutral wire N (blue labelled fuse).
If the battery case (ONLITE central CPS K) or the battery cabinets (ONLITE central CPS H)
contain any batteries, you have to remove them prior to installation. In this case, also note the
instructions described in chapter "Handling instructions for sealed vent-regulated lead acid
batteries" (see chap. C on page 31).
i
Already installed and connected batteries must be removed taking into account the
battery installation order.
11
3 Installation
Connecting the relay outputs
Connection of the relay outputs has to be performed in accordance with the schematic
drawing shown below and the plans and drawings valid for the conditions at the installation
site. The charging unit of the ONLITE central CPS system provides five potential-free relay
outputs which can be used either as normally closed or normally open contact each.
1. Route the connection cables into the cabinet through the flange plate at the top side of the
switch cabinet (see chap. 2.1.2 on page 8).
2. Connect the relay outputs to the terminal block -2X4 of the charging unit relay module (see
following figure).
Ö6 C6 S6
Ö7 C7 S7 Ö8 C8 S8
Relay output 8
Ö5 C5 S5
Relay output 7
Ö4 C4 S4
Relay output 6
0V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Relay output 5
2
-2x4
Relay output 4
1
24 V DC
-2x5
Internal signal
voltage supply
3.1
i
The relay outputs are implemented potential-free. If a signal voltage is required, the
internal 24 V DC voltage supply is provided at terminal block -2X5. The 24 V DC
voltage must be wired to the middle contact (Common) of the corresponding relay.
d
Danger
Leave no connection cables temporarily loose and unsecured.
12
Connecting the ONLITE central CPS Remote Interface
Connection of the ONLITE central CPS Remote Interface (Art. No. 22 154 740) has to be
performed in accordance with the schematic drawing shown below and the plans and
drawings valid for the conditions at the installation site.
d
Danger
Comply with the national regulations and guidelines for indicating and signalling when
using a remote switch or remote indicator for emergency lighting systems.
The ONLITE central CPS Remote Interface is powered by the internal 24 V DC voltage supply
of the ONLITE central CPS system.
d
Caution
Do not use an external 24 V DC voltage supply. Disregarding the instructions may
result in outages of the emergency lighting because the proper communication
between the system components may not be guaranteed.
Connect the ONLITE central CPS Remote Interface as follows:
Battery
operation
Rel5
Rel6
S5-
Failure
Mains
operation
S5+
Rel7
Block system
0V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
-2x4
2x5
24V
Free
Free
Fan error message
Maintained light On/Off
Free
OFF
ONLITE central CPS
Remote Interface
S2
S3
S4
S5
S6
S7
3.2
Ö4 C4 S4
Ö5 C5 S5
Ö6 C6 S6
Ö7 C7 S7 Ö8 C8 S8
13
3.3
3.3.1
Connecting the line monitors
Connecting the line monitors in a circuit monitored sub distribution
Connect the line monitors to the input terminals S1 to Sx of the circuit monitored sub
distribution (depending on the configuration of the ONLITE central CPS system).
The terminal block is labelled -4X1 (see following figure).
3.3.2
Connecting the line monitors in a single monitored sub distribution
Connect the line monitors to the input terminals S1 to Sx of the single monitored sub
distribution (depending on the configuration of the ONLITE central CPS system).
The terminal block is labelled -5X1 (see following figure).
14
3.4
3.4.1
Connecting the emergency circuits
d
Caution
Note the line length limitation of the output circuits. The maximum length of 300 m
may not be exceeded. Disregarding the instructions may result in outages of the
emergency lighting because the proper communication between the system
components is not guaranteed.
d
Caution
Connect the luminaires to the emergency circuits according to the specifications of the
luminaires manufacturer. Disregarding the instructions may result in damages to the
system and luminaires.
Connecting the emergency ciruits in a circuit monitored sub
distribution
A maximum of 20 emergency circuits can be connected to each sub distribution. Each circuit
is fused by two outgoing fuses.
1. Route the connection cables into the cabinet through the flange plate at the top side of the
switch cabinet.
2. Connect each emergency circuit to the terminal blocks -4X2 and the PE terminal block in
the switch cabinet of the ONLITE central CPS system or the external sub distribution (as
shown in the following figure).
PE
(yellow/green)
N (blue)
L (red)
15
3.4.2
Connecting the emergency ciruits in a single monitored sub
distribution
A maximum of 20 emergency circuits can be connected to each sub distribution. Each circuit
is fused by two outgoing fuses.
1. Route the connection cables into the cabinet through the flange plate at the top side of the
switch cabinet.
2. Connect each emergency circuit to the terminal blocks -5X1 (DALI terminals and PE
terminal block) and -5X2 in the switch cabinet of the ONLITE central CPS system or the
external sub distribution (as shown in the figure below).
i
For connecting the emergency circuits of a single monitored sub distribution a 5-pin
cable is used because two DALI connections D1 and D2 must be wired additionally to
the voltage supply.
N (blue)
L (red)
PE
(yellow/green)
DALI connection D1 and D2
(brown/grey)
16
3.5
Connecting the 230 V AC / 400 V AC voltage supply
The ONLITE central CPS system is powered by the general 230 V AC / 400 V AC mains or in
emergency operation by the batteries (battery cabinet or battery rack) or an emergency
generator.
Before connecting the voltage supply, ensure that
•
•
the system and the supply lines are switched dead,
the fuses 2F1, 2F2, 2F10.1 and 2F10.2 are opened (removed).
d
Danger
When disregarding the preliminaries there is a risk of mortal danger due to live parts!
Proceed as follows to connect the ONLITE central CPS system to 230 V AC / 400 V AC
mains:
1. Switch the system dead by opening the external main switch and protect the system
against re-engagement.
2. Route the connection cables into the cabinet through the flange plate at the top side of the
switch cabinet.
3. Connect the 230 V AC / 400 V AC mains and the earth wire to the screw terminals L1, L2,
L3, N and PE of the terminal block -2X1 of the ONLITE central CPS switch cabinet.
PE
i
L1
L2
L3
N
When connecting the 400 V AC voltage supply, please note that the phasing (L1-L3)
corresponds to a clockwise rotating field. For this purpose a phase sequence indicator
must be used.
17
3.6
Installing and connecting the batteries
Before connecting the batteries, ensure that
•
•
•
3.6.1
no persons work on the installation,
all mounting and installation works are completed,
the battery fuses -2F4, -2F5, -2F6 and -2F7 have been removed. Two fuses for each sub
distribution are installed.
d
Danger
When disregarding the preliminaries there is a risk of mortal danger by electrical
shock!
d
Danger
Comply with the valid accidental regulations and wear protective clothes and
protective goggles.
d
Caution
Also note the maximum admissible torques for battery connectors (see chap. C.8 on
page 35).
Connecting the batteries of an ONLITE central CPS K system
(compact station)
The battery set for an ONLITE central CPS K (compact station) consists of 18 batteries
connected in series (see chap. A.2 on page 27). The voltage of the battery set (system
voltage) is 216 V DC.
i
We recommend the following battery set-up in the compact cabinet switch:
When arranging the batteries, the first battery has to be installed in the rear row and
the last battery in the first row. This way, access to the battery connectors is easier
and additionally the risk of danger is reduced.
The batteries of the battery sets from 24 Ah to 75 Ah are installed on two levels. The
first nine batteries have to be installed on the floor board, the other nine batteries on
the grating supplied with the system (see chap. 3.6.3 on page 20).
i
In the switch cabinet of the compact station CPS K, the battery cabling is already
connected to the fuses -2F4 and -2F5. The other two cable ends are ready for
connection and can be found in the battery compartment.
Proceed as follows to connect the batteries of a compact station CPS K:
V Prepare the bridges, pole covers and numbering stickers supplied with the system.
18
1. Connect the blue labelled cable to the negative pole (-) of battery 1.
Rear side of the ONLITE central CPS switch cabinet
Floor board
2. Install one of the supplied bridges between the positive pole (+) of battery 1 and the
negative pole (-) of battery 2 and fix it accordingly.
3. Repeat step 2. for the other batteries until all batteries are connected in series.
4. Connect the red labelled cable to the positive pole (+) of battery 18. The second end of the
cable is already connected to fuse -2F5.
a The batteries are connected.
19
3.6.2
Connecting the batteries of an ONLITE central CPS H system (main
station)
An ONLITE central CPS H (main station) can be powered with 216 V DC either by a battery
cabinet or a battery rack. The connection cables to the batteries must be provided by the
customer.
V The connection cables to the batteries are available.
1. In the switch cabinet of the main station, connect the connection cables (+) and (-) to the
terminals + and - of terminal block -2X1.
i
Mark the connection cables at both ends with a red and blue labelling ring to ensure
proper connection.
2. Now, connect the blue labelled cable to the negative pole (-) of the first battery.
3. Insert the supplied bridges between the positive pole (+) of battery 1 and the negative pole
(-) of battery 2 and fix it accordingly.
4. Repeat step 3. for the other batteries until all batteries are connected in series.
5. Connect the red labelled cable with the positive pole (+) of the last battery and terminal (+)
of the terminal block -2X1.
20
3.6.3
Possible set-ups for battery sets
The following figures show set-up illustrations for the individual battery sets.
Battery set 17 Ah
Rear side of switch cabinet
Floor board
21
Battery sets from 24 Ah to 75 Ah
Rear side of switch cabinet
Floor board
Supply line (-)
from charging unit
Supply line (+)
from charging unit
Grating
Rear side of switch cabinet
22
4 Connecting external sub distributions
4.1
Connecting the system bus
The components of an ONLITE central CPS system communicate via the system bus (LON).
For the system bus connection cables of the type JY (St)Y2x2x0.8 must be used.
Two cables are required, where two cable wires are used for data exchange and two cable
wires provide the 24 V DC-voltage supply.
Connect the wires to the bus terminals which are mounted on the terminal block -4X2 (see the
following figure).
i
The bus system can be configured in line topology or free topology. Please observe
the maximum cable lengths of 900 m (line topology) and 500 m (free topology).
1
2
3
Description of the system bus components
Designation
Function
(1) 24 V voltage supply
Terminals for the 24 V DC voltage supply of the system
bus (core colours: re/bk)
(2) System bus (LON)
Terminals for the data connection of the system bus
(core colours: ye/wh)
(3) System bus connector
Connector for plugging in the Touch PC (control unit)
23
Examples of the possible system topologies
Line topology
- two terminators
- max. bus length 900 m
- cable type: JY (St)Y2x2x0.8
Free topology
- one terminator
- max. bus length 500 m
- cable type: JY (St)Y2x2x0.8
i
Depending on the used topology, the terminators of the ONLITE central CPS system
must be installed and checked.
When using the line topology, two terminators are required. In that case, one
terminator is installed and connected in the cabinet of the main station CPS H or
compact station CPS K ex factory. The second terminator must be connected to the
bus terminals of the most remote located sub distribution (see chap. 4.1 on page 22).
When using the free topology, only one terminator is required in the main station
CPS H or compact station CPS K. This terminator ist already installed and connected
ex factory.
24
4.2
Connecting the voltage supply
Up to seven (CPS H) or six (CPS K) external sub distributions can be connected to an
ONLITE central CPS system.
Two outgoing fuses are available for each sub distribution in the switch cabinet of the
ONLITE central CPS system. The power supply lines for the sub distributions must be wired
directly to the outgoing fuses.
Description of the outgoing fuses
External sub distribution
Fuse label
UV03
4F103+ and 4F103-
UV04
4F104+ and 4F104-
UV05
4F105+ and 4F105-
UV06
4F106+ and 4F106-
UV07
4F107+ and 4F107-
UV08
4F108+ and 4F108-
UV09 (only CPS H)
4F109+ and 4F109-
i
The cable types and line cross sections required for the voltage supply of the sub
distributions can be found in the overall connecting diagram of your
ONLITE central CPS system.
For a permissible voltage drop also the distance and connected load are to be
considered during line dimensioning.
25
5 Switching on the system
Perform the following checks and works while mains supply is switched off before
switching on the ONLITE central CPS system:
•
•
Check all works done and compare the established connections with the given plans and
drawings.
Make sure that all connections are firm.
d
•
Danger
When checking the battery connectors there is a risk of mortal danger.
Use only insulated tools. Wear rubber gloves, protective goggles and protective
clothes (incl. safety shoes) and take off metallic objects e.g. watches and jewellery.
Remove all unused cables, insulation and fixing materials, tools and packaging.
To switch on the ONLITE central CPS system, proceed as follows:
1.
2.
3.
4.
Switch on the external main switch.
Check the voltage supply at the terminals L1, L2, L3 and N of the terminal block -2X1.
Check the rotational direction of the voltage supply.
Check whether all outgoing fuses of the circuits (F1 - F20 blue, F1 - F20 red) in the sub
distributions are opened.
5. Reinstall the fuses 2F1, 2F2, 2F10.1 and 2F10.2.
d
Danger
The System is now connected and energised. Mortal danger by electrical shock.
6. Close the first fuse in the first sub distribution (outgoing fuse F1).
a All luminaires installed in this circuit are switched on (status "ON").
7. Check whether the number of switched on luminaires and their installation location comply
with the given plan.
8. If the number of luminaires and their installation location is correct, switch off the circuit by
opening the fuse.
9. Repeat the luminaires check for all sub distributions and circuits.
26
6 Completing the installation
After having finished the luminaires check of the individual circuits and successfuly compared
the installation with the plans, the installation work can be completed.
Perform the following steps to complete the installation:
1. Open all outgoing fuses (F1 up to F20 max.) in the sub distributions (also connected
external sub distributions).
a The luminaires connected to these circuits are switched off.
2. Remove the fuses 2F103+ and 2F103- up to 2F109+ max. and 2F109- of the connected
external sub distributions.
3. Remove the battery fuses 2F4, 2F5, 2F6 and 2F7.
4. Reinstall the fuse elements 2F1, 2F2, 2F10.1 and 2F10.2.
5. Switch the system dead by opening the external main switch and protect the system
against re-engagement.
a The system is now out of operation.
27
Appendix
A
A.1
A.2
Technical Data
General
Circuit monitored
Individually monitored
Circuits
0 - 20
0 - 20
Number of luminaires
0 - 400
400
Max. power (W)
4700
4700
Max. power per circuit (W)
1300
1300
Fuse per circuit (A)
10
10
Outgoing terminals (mm²)
4
4
Digital inputs
8 - 16
8 - 16
Compact station CPS K
Dimensions (H x W x D)
1800 x 850 x 600 mm
Total power
7 - 30 kVA
Outgoing circuits to UVS
0 - 8 pcs.
Fuse protection UVS
up to 35 A
Outgoing terminals UVS
16 mm²
Battery voltage (18 blocks)
216 V DC
Max. battery capacity
17 - 75 Ah
Ethernet port
1 pcs.
Potential-free outputs
5 pcs.
Set of batteries available for the compact station CPS K:
Set of batteries
Weight (kg)
Total weight (kg)
17 Ah
107
257
24 Ah
162
312
28 Ah
175
325
28
Set of batteries
Weight (kg)
Total weight (kg)
33 Ah
211
361
45 Ah
267
417
55 Ah
324
475
75 Ah
432
582
i
A.3
The total weight results from the weight of the set of batteries and the switch cabinet.
Main station CPS H
Dimensions (H x W x D)
1800 x 850 x 600 mm
Total power
7 - 30 kVA
Max. outgoing circuits
3 x 20 pcs.
Outgoing circuits to UVS
0 -9 pcs.
Fuse protection UVS
up to 35 A
Outgoing terminals UVS
16 mm²
Battery outgoing terminals
35 mm²
Max. battery capacity
17 - 75 Ah
Ethernet port
1 pcs.
Potential-free outputs
5 pcs.
Battery cabinets available for the main station CPS H:
Set of batteries
Dimensions
(H x W x D) in mm
Weight set of
batteries (kg)
Total weight (kg)
33 Ah
1600 x 600 x 600
211
331
45 Ah
1600 x 600 x 600
267
387
55 Ah
1600 x 600 x 600
324
444
75 Ah
1600 x 600 x 600
432
552
80 Ah
1800 x 850 x 600
472
612
90 Ah
1800 x 850 x 600
540
680
100 Ah
1800 x 850 x 600
540
680
120 Ah
1800 x 950 x 600
679
829
134 Ah
1800 x 950 x 600
765
915
150 Ah
1800 x 1100 x 600
836
996
29
Set of batteries
Dimensions
(H x W x D) in mm
Weight set of
batteries (kg)
Total weight (kg)
190 Ah
1800 x 1800 x 600
1800 x x600 x 600
1167
1367
1297
200 Ah
1800 x 1800 x 600
1800 x x600 x 600
1206
1406
1336
i
A.4
The total weight results from the weight of the set of batteries and the switch cabinet.
Sub station CPS U
The substation models CPS U E00 and CPS U E30 are available.
B
Dimensions (H x W x D) in mm
Weight (kg)
CPS-U E00
800 x 300 x 140
15
CPS-U E30
909 x 407 x 364
75
Fuses
Charger module:
Designation
Value
Type
Description
2F1
*a
time-lag
Mains supply L1
2F2
*1
time-lag
Mains supply L2
2F3
*1
time-lag
Mains supply L3
2F4
*1
time-lag
Battery (+)
2F5
*1
time-lag
Battery (-)
2F6
*1
time-lag
Battery (+)
2F7
*1
time-lag
Battery (-)
2F8
*1
time-lag
Battery (+)
2F9
*1
time-lag
Battery (-)
2F10.2
*1
time-lag
Charging unit
2F10.2
*1
time-lag
Charging unit
2F11
3.15
time-lag
Mains monitoring L1
2F12
3.15
time-lag
Mains monitoring L2
30
Designation
Value
Type
Description
2F13
3.15
time-lag
Mains monitoring L3
2F14
6.3
time-lag
Switching module
2F15
6.3
time-lag
Switching module
2F16
3.15
time-lag
Measuring module LE
2F17
6.3
time-lag
Mains switch-over
2F18
6.3
time-lag
Mains switch-over
2F19
6.3
time-lag
Mains switch-over
3F81
3.15
time-lag
Bus supply
3F82
3.15
time-lag
Bus supply
*a These values depend on the system type. A valid list for your system can be found on the
inside of the switch cabinet door.
Module for circuit monitoring (UV S):
Designation
Value (A)
Type
Description
F1 to F20
6.3
time-lag
Outgoing fuses per circuit
Module for individual monitoring (UV E):
Designation
Value (A)
Type
Description
F1 to F20
6.3
time-lag
Outgoing fuses per circuit
31
C
C.1
C.1.1
HANDLING INSTRUCTIONS FOR SEALED VENTREGULATED LEAD ACID BATTERIES
Safety instructions
Electrolyte maintenance / Valve Regulation
The sealed battery blocks are maintenance free only as related to the electrolyte. This
presents a safety hazard and voids the warranty and inevitably leads to the destruction of the
battery. Nevertheless, the battery system requires regular inspections and service (see
chap. C.6 on page 34).
d
C.1.2
Caution
Risk of damage
Do not attempt to remove the vents (valves) from the battery or add water.
Precaution-, safety- & disposal notices
Symbol
Description
Observe handling instructions.
Wear full eye protection and protective clothing.
Do not smoke or introduce sparks in the vicinity of the battery.
Danger of Explosion and Fire. Battery systems present a risk of electrical high
short circuit currents. Therefore remove all personal metal objects, use
insulated tools, do not lay metal tools and hardware on top of the batteries,
observe circuit polarities, do not make or break live circuits.
Any gelled or liquid emissions from a VRLA battery is electrolyte which
contains dilute sulphuric acid which is harmful to the skin and eyes; is
electrically conductive; and is corrosive.
If electrolyte contacts the skin, wash immediately and thoroughly with water. If
electrolyte enters the eyes, wash thoroughly for 10 minutes with clean water
or a special neutralising eye wash solution and seek immediate medical
attention.
Individual batteries may be heavy. Exercise care when handling and moving
batteries. Mount on secure surface.
32
Symbol
Description
Lead acid batteries are to be recycled. Batteries contain lead and dilute
sulphuric acid. Dispose of in accordance with Federal, State and local
regulations. Do not dispose of in a landfill, lake or other unauthorised location.
Please contact the supplier or manufacturer if in doubt about disposal.
C.2
Storage instructions
Store batteries in a clean, dry cool but frost free area away from radiant heat sources.
Elevated storage temperatures increase the selfdischarge rate of the batteries and reduce the
storage time between required freshening charges. Batteries in storage should be given a
freshening charge every 6 months or when the open circuit voltage declines to 12.5 V,
whichever case occurred first. (see chap. C.5.1 on page 33).
C.3
Commissioning
The ideal operation temperature is 20 °C. Higher temperatures shorten the overall battery life,
lower temperatures reduce the operating time (capacity). The battery blocks must be placed in
such a way that the temperature between the blocks and the ambient temperature does not
differ by more than 3 °C. Prior to initial operation please check the following points: check
batteries for damage, check circuit polarity, torque the connection hardware to that specified
(see chap. C.8 on page 35), use optional plastic or rubber pole caps.
Proceed as follows to commission the batteries:
1. Connect the battery output cables to the DC load/charger circuit with the load/charger
fuse, circuit breaker or disconnect in the OPEN condition.
2. Switch on the charger and recharge accordingly (see chap. C.5.1 on page 33).
C.4
Operating regulations
i
The regulations IEC 896-2 (EN 60896-2) and/or any relevant state or individual local
laws and regulations regarding the operation of stationary battery systems must be
observed.
33
C.5
C.5.1
Charging, discharging
Charging
A charger with IU-charging characteristics should be used. Depending on the type of system
charging can be done in the following modes of operation:
•
Continuous battery power supply and buffer mode
In this case the system, the DC-source and the battery are permanently in parallel mode.
The charging voltage is same as the battery voltage and as the system voltage.
In continuous battery power supply mode the DC-source is always capable of supplying
the maximum power for the system as well as for the battery charging. The battery only
supplies the power, if the DC-source fails. The charging voltage setting is 2.3 V DC / cell at
20 °C multiplied by the number of cells (+/- 1 %), with measurement taken at the end poles
of the battery.
In buffer mode the DC-source is not capable of always supplying the maximum system
power. which is sometimes higher than the power supply possible from the DC-source.
During these periods the battery supplies the energy. As the battery is not fully charged
permanently, the charging voltage has to be set user related to 2.3 – 2.4 V DC / cell.
•
Switch mode
In this mode the battery is switched of from the system when charged. The max. charging
voltage of the battery is 2.4 V DC / cell (boost charge). Charging must be monitored.
Should at this constant charging voltage the charge current fall to 0.5 A / 100 Ah then the
float charge mode must be activated.
•
Float charge mode
Equipment with IU charging characteristic should be used and set in such a way that the
voltage is 2.3 V DC / cell (+/- 1 %) at 20 °C. Should the battery temperature permanently
be higher or lower, the charging voltage has to be adjusted accordingly:
Charging voltage(> 20 °C) = 2,3 V DC / cell - 0,005 V * ∆T (∆T= Temperature difference to
20 °C)
Charging voltage(< 20 °C) = 2,3 V DC / cell + 0,005 V *∆T(∆T = Temperature difference to
20 °C)
Examples:
Temperature predominantly around 15 °C, charge voltage = 2.3 V DC / cell + 0.015 V DC /
cell = 2.315 V DC / cell.
Temperature predominantly around 30° C, charge voltage = 2.3 V DC / cell –
0.030 V DC / cell = 2.270 V DC / cell.
Charging currents
With float charge mode the charging currents are generally not restricted. With boost charge
mode 20-30 A per 100 Ah nominal capacity should not be exceeded.
Ripple current
During recharging up to 2.4 V DC / cell in the operation modes continuous battery power
supply and buffer mode an effective AC-current of up to 20 A per 100 Ah nominal capacity is
acceptable. After recharging and during float charge mode the ripple current must not exceed
5 A per 100 Ah of nominal capacity.
34
C.5.2
Discharging
The correct discharge rates are established through the capacities l(disc.) = QL/t. If no other
data is available, no more than the so established capacity may be used. To avoid deep
discharge and consequently the destruction of the battery, the battery must be shut off from
the user before reaching the run time related end point voltage:
Run time
End point voltage
>3h
1,80 V DC / cell
1-3h
1,75 V DC / cell
20 min. - 1 h
1,67 V DC / cell
< 20 min.
1,60 V DC / cell
d
C.6
C.6.1
Caution
Risk of damage
The system should be reconnected only after mains power supply has returned. After
discharge, including deep discharge, the battery has to be recharged immediately.
Battery service and maintenance
Battery care
The battery is to be kept clean and dry as to avoid stray current creepage. For cleaning, use
a cloth moistened in a solution of bicarbonate of soda and water or just plain water. Do not use
cleaners of unknown solutions such as window or glass cleaners and solvents.
C.6.2
Inspection of the battery system
It is advisable to perform the following checks and record the findings every 6 months:
•
•
•
•
Visual inspection of batteries for cleanliness, terminal damage, container or cover damage
and evidence of overheating.
Check of float charge voltage of the battery system and of each individual battery block.
Check of surface temperature of the battery blocks.
Check ambient temperature.
A regular annual check and recording of the findings is mandatory for the fulfilment of the
warranty conditions and comprises the following checks:
•
•
•
All connection hardware should be retorqued to the value indicated in § 1 with a calibrated
torque wrench.
Repeat the semi-annual checks.
Ideally measure the voltage of the battery system and of the individual blocks with the
charger switched off.
To be performed only in the presence of the system supplier or their authorised
representative:
•
Record the block voltages at service load (capacity test).
35
i
C.7
Tests are to be executed according to IEC 896-2 (EN 60896-2). In addition eventual
state or local regulations may have to be observed.
Warranty
Warranty claims are subject to proper service and maintenance. In support of claims the
following documentation has to be supplied: Detailed description of fault / damage, relevant
identification data and the last maintenance reports. Faulty batteries have to be returned for
fault analysis.
i
C.8
The warranty becomes void if these handling instructions are not observed: i.e. in the
case of too high ambient temperature, the batteries being left discharged for an
extended period, inadequate storage conditions, incorrect float charge setting, failure
to maintain the recommended service intervals and service instructions.
Table of torques for the battery connectors
Type
BSOL BTX
(LS)
Torque
(Nm)
Type
BSOL BTX
(LS)
Torque
(Nm)
Type
BSOL BTX
(LS)
Torque
(Nm)
12-17
6.2
12-33
8.5
12-120
12.4
12-17 LS
6.2
12-33 LS
8.5
12-120 LS
12.4
12-24
6.2
12-40
8.5
12-150
12.4
12-24 LS
6.2
12-45
8.5
12-150 LS
12.4
12-28
6.2
12-45 LS
8.5
12-190 LS
12.4
12-28 LS
6.2
12-55
8.5
12-200
12.4
12-55 LS
8.5
12-200 LS
12.4
12-60
8.5
12-75 LS
8.5
12-80
8.5
12-80 LS
8.5
12-90 LS
8.5
12-100
8.5
12-100 LS
8.5
12-134
8.5