2008 12 18 Retrofit A Procedure Rev 05

Proprietary Information of:
Title:
Document No.
Rev.
Retrofit A Procedure
045781
05
RETROFIT A
FOR ACU AND HEX CABINETS
INTENDED FOR
Alcatel-Lucent Description PSU cabinet PO16 Alcatel-Lucent P/N Power-One P/N Power-One Description
1AF11757AAAA
1-148306
PODS 16.48-8000 HEX VENT
PSU cabinet POB16
1AF11757AAAB
1-148306G
PODS 16.48-8000 HEX VENT
PSU cabinet POB16A ACU Batt cabinet BCAB2
1AF11757ABAB
1-154483G
PODS 16.48-8000 ACU VENT
1AF14355AAAB
1-154484G
BATT CAB ACU VENT
HEX Cabinet Type of Document: Rework Instruction ISO Std: 4.2.3
Air Conditioned Cabinet Department: PS Engineering Page 1 of 56
Title:
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CONTENTS
1. Purpose 2. Definitions 3. Sequence of Actions 4. List of Items and relation to referenced documents 5. Action Lists 6. Maintenance 7. Detailed Action Lists
Ax.1 Ax.2 Ax.3 Ax.4 Ax.5 Ax.6 Ax.7 Ax.8 Ax.9 Ax.10 Ax.11 Ax.12 Ax.13 Ax.14 Ax.15 Ax.16 Ax.17 Preparation: AC off, breakers off Disconnect the Battery terminals and isolate the lug ends Remove the (Narada) batteries and their venting Kits Replace the dummy panels with the Lateral Filter Panels. Install the Modification Kits. Refurbishment and AC-DC cabling inspection Install the battery terminal protection covers 2 warning labels in position Install the Fiamm Batteries Prepare and Install the Battery Ventilation Kits from Fiamm Install the Battery Temperature sensor Install 1 to 3 pcs of the 2.6m symmetry cables in the system cabinet Air con system: rewire the door alarm and the air conditioning alarms Commission the system Update the controller firmware and the software configuration Fill in and sign the Checklists, Store documentation and Stick the retrofit A label
3 3 3 4 5 8 9 9 9 10 12 15 19 24 25 26 28 32 33 34 38 40 45 45 46 53 54
Supplement A Supplement B Supplement C
Software Configuration Battery Discharge Currents Check Lists
Type of Document: Rework Instruction
ISO Std: 4.2.3
Department: PS Engineering
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1. Purpose
This retrofit A instruction is for the specific purpose as a guideline in modifying the above listed outdoor power systems, either equipped with a Heat Exchanger or an Air Conditioner, in order to install all elements for the Retrofit A program that includes lateral filter panels, an updated configuration and supports up to 3 x FIAMM FFT160 battery strings inside the system cabinet. There is no difference between the software, just that an Air Condition failure causes an Air condition alarm and the HEX failure causes a Hex alarm.
2. Definitions
Live procedure: Retrofit A procedure A0: for cabinets in the field with Live upgrade. Passive Procedures: Retrofit A procedure A1: for cabinets in the field with Narada batteries, drilled venting holes. Retrofit A procedure A2: for cabinets in the field with Fiamm batteries, sealed. Retrofit A procedure A3: for cabinets in the warehouse.
3. Sequence of actions
Advice: Do up a training for the installers before the retrofit procedure
1. Alcatel-Lucent creates part numbers for all items involved. 2. Alcatel-Lucent orders the correct amount of items into the hub of Marly. 3. Power One delivers all goods to hub Marly. Retrofit A procedures 4. The goods are shipped into the countries for the different projects. 5. The goods are shipped to the individual sites. 6. Retrofit A procedure is started.
ISO Std: 4.2.3
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4. List of Items and relation to referenced documents
ISO Std: 4.2.3
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5. Action Lists
Remark 1: Rectifier and controller swap processes for systems in operation with non IP55 period under control of ALU. Remark 2: The procedures A1.6 A1.7 A1.8 and A1.10 can be combined by a step by step installation per battery shelf, battery string with ventilation Kit and terminal protection on the side. Cover the battery terminals where needed in order to avoid any risk of short circuit.
The installation can be done either live (rectifiers providing load current) or passive (AC switched off). In all cases the battery breakers must be switched off. LIVE PROCEDURE Retrofit A procedure A0: for well trained and experienced installers only
A1.1 A1.2 A1.3 A1.4 A1.5 A1.6 A1.7 A1.8 A1.9 A1.10 A1.11 A1.12 A1.13 A1.14 A1.15 A1.16 A1.17 On every step consider the risks and verify if the action to be taken can cause any short circuit. Use insulated tools and professional equipment only. Keep AC Power switched on (in the switchboard). Open the system cabinet (and/or Battery cabinet). Switch off the battery breakers, keep the load breakers ON and the main switch ON.. Disconnect the battery terminals and isolate the battery cable lug ends When equipped with Narada: Remove the batteries and their venting Kits completely, or When equipped with Fiamm without venting Kits installed, remove the batteries except the bottom row. Replace the blind panels (with the drilled holes) by the Lateral Filter Panels. Install the Modification Kits when not installed yet but installation of 3 Fiamm batteries needed. Cover the battery terminals of a string before inserting a sheet metal above that string. Refurbish, i.e. clean and inspect the cabinet. Check electrical connections and cabling. Install the battery terminal protection covers. Check if 2 warning labels are in position, otherwise stick warning labels to their intended position. Install the Fiamm Batteries Prepare and install the Battery Ventilation Kits from Fiamm. See recommended tube lengths Install the Battery Temp sensor Install 1 to 3 pcs of the 2.6m symmetry cables in the system cabinet Option 4B: when 4 batteries: install 1 pce of a 5m symmetry cable in the battery cabinet Air conditioning system: rewire the door alarm and the air conditioning alarms Commission the system (during this procedure the battery breakers will be switched on) Update the controller firmware and the software configuration Fill in and sign the checklists and put the documentation in the document holder and Stick the retrofit A label on top of or near the system type label
ISO Std: 4.2.3
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PASSIVE PROCEDURES Retrofit A procedure A1, Replace Narada Battery Strings

A1.1 A1.2 A1.3 A1.4 A1.5 A1.6 A1.7 A1.8 A1.9 A1.10 A1.11 A1.12 A1.13 A1.14 A1.15 A1.16 A1.17 Switch off all AC Power. Open the system cabinet (and/or Battery cabinet). Switch off the breakers. Disconnect the battery terminals and isolate the battery cable lug ends. Remove the Narada batteries and their venting Kits. Replace the blind panels (with the drilled holes) by the Lateral Filter Panels. Install the Modification Kits when not installed yet but installation of 3 Fiamm batteries needed. Refurbish. For example, clean and inspect the cabinet. Check electrical connections and cabling . Install the battery terminal protection covers. Check if 2 warning labels are in position, otherwise stick warning labels to their intended position. Install the Fiamm Batteries Remark: cover the battery terminals of a string before inserting a sheet metal above that string. Prepare and install the Battery Ventilation Kits from Fiamm. See recommended tube lengths Install the Battery Temp sensor, preferably on the second row of batteries. Install 1 to 3 pieces of the 2.6m symmetry cables in the system cabinet Option 4B: when 4 batteries: install 1 piece of a 5m symmetry cable in the MIDI battery cabinet Air conditioning system: rewire the door alarm and the air conditioning alarms Commission the system Update the controller firmware and the software configuration Fill in and sign the checklists and put the documentation in the document holder and Stick the retrofit A label on top of or near the system type label
Retrofit A procedure A2, Retrofit a sealed cabinet with Fiamm Batteries

Initial condition: Fiamm venting Kits are not installed yet: A2.1 A2.2 A2.3 A2.4 A2.5 A2.6 A2.7 A2.8 A2.9 A2.10 A2.11 A2.12 A2.13 A2.14 A2.15 A2.16 A2.17 Switch off all AC Power. Open the system cabinet (and/or. Battery cabinet). Switch off the breakers. Disconnect the battery terminals and isolate the battery cable ends, except for the bottom row Remove the Fiamm batteries except for the bottom row Replace the blind panels with holes by the Lateral Filter Panels. Check electrical connections and cabling. Install the battery terminal protection covers. Check if 2 warning labels are in position, otherwise stick warning labels to their intended position. Re-install the Fiamm batteries Remark: cover the battery terminals of a string before inserting a sheet metal above that string. Install the Battery Ventilation Kits from Fiamm. See the recommended tube lengths Install the Battery Temp sensor, preferably on the second row of batteries. Install 1 to 3 pieces of the 2.6m symmetry cables in the system cabinet option 4B: when 4 batteries: install 1 piece of a 5m symmetry cable in the MIDI battery cabinet Air conditioning system: rewire the door alarm and the air conditioning alarms Commission the system Update the controller firmware and the software configuration Fill in and sign the checklists and put the documentation in the document holder and Stick the retrofit A label on top of or near the system type label
ISO Std: 4.2.3
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Initial condition: Fiamm venting Kits are already installed: Symmetry measurement tbd A2.1 A2.2 A2.3 A2.4 A2.5 A2.6 A2.7 A2.8 A2.9 A2.10 A2.11 A2.12 A2.13 A2.14 A2.15 A2.16 A2.17 Switch off all AC Power. Open the system cabinet (and/or Battery cabinet). Switch off the breakers. Disconnect the battery terminals and isolate the battery cable ends except for the bottom row. Remove the Fiamm batteries, except for the bottom row. Replace the blind panels with holes by the Lateral Filter Panels Check electrical connections and cabling. Install the battery terminal protection covers. Check if 2 warning labels are in position, otherwise stick warning labels to their intended position Re-install the Fiamm batteries. Remark: cover the battery terminals of a string before inserting a sheet metal above that string. Replace the straight tube connections between blocks by 18cm connections Install the Battery Temp sensor, preferably on the second row of batteries. Install 1 to 3 pieces of the 2.6m symmetry cables in the system cabinet Option 4B: when 4 batteries: install 1 piece of a 5m symmetry cable in the MIDI battery cabinet Air conditioning system: rewire the door alarm and the air conditioning alarms Commission the system Update the controller firmware and the software configuration Fill in and sign the checklists and put the documentation in the document holder and Stick the retrofit A label on top of or near the system type label
Retrofit A procedure A3, Warehouse upgrades

A3.1 A3.2 A3.3 A3.4 A3.5 A3.6 A3.7 A3.8 A3.9 A3.10 A3.11 A3.12 A3.13 A3.14 A3.15 A3.16 A3.17 Switch off all AC Power. Open the system cabinet (evt. Battery cabinet). Switch off the breakers. Replace the blind panels with holes by the lateral filter panels Check electrical connections and cabling. Install the battery terminal protection covers. Check if 2 warning labels are in position, otherwise stick warning labels to their intended position. Check if the Battery Temp sensor is present inside the cabinet. Add 1 piece of the 2.6m symmetry cables into the system cabinet Air conditioning system: rewire the door alarm and the air conditioning alarms Commission the system Update the controller firmware and the software configuration Fill in and sign the checklists and put the documentation in the document holder and Stick the retrofit A label on top of or near the system type label
Internal Battery cable Kits

A4.12 Add 1 piece of the 2.6m symmetry cables to the cable Kit
External Battery cable Kits

A5.12 Add 1 piece of the 5 m symmetry cables in the external cable Kit
ISO Std: 4.2.3
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6. MAINTENANCE
Documentation: Instruction manual 043527, Battery maintenance or supplier engineering manual Instruction manual 043536, Battery maintenance or supplier engineering manual Objects for maintenance: Batteries, Battery Ventilation Kits, Fans (HEX/ACU , rectifiers), Filters, Cabinet, openings and door, etc. Recommended intervals of site survey: Batteries need maintenance intervals normally once per year, as this is stated explicitly by Fiamm. It is advised especially during start up phases to visit sites more frequently, to see how a site develops in temperature, water, dust, sand penetration, lightning protection devices etc. And if all screws still are tightened well enough especially for installed cables. Recommended is do a first site / battery inspection after 2-3 months, then after a period of 6-9 months and then every 6 to 12 months whatever the specific site requires or allows. Sites that show specific abnormal performance should be visited more often. This battery inspection can be combined to inspect and/or clean all other objects inside the cabinet.
ISO Std: 4.2.3
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7. Detailed Action Lists

On this and the following pages you will find each of the 16 sections outlined for every individual action needed for retrofitting the cabinets, from replacing Narada batteries until warehouse upgrades. Actions can be done individually and separate but can also be combined when having some experience. Retrofit A procedure Ax.
Ax.1 Preparation: AC off, breakers off Passive procedure (standard)

1. 2. 3. Switch off all AC Power Open the system cabinet (evt. Battery Cabinet). Switch off all breakers, including battery breakers.
Warning! IT IS STRONGLY RECOMMENDED TO TURN OFF THE AC MAINS AND BATTERY CIRCUIT BREAKERS TO THE POWER SYSTEM BEFORE PERFORMING THIS INSTALLATION.
Live procedure (for trained and experienced installers only)

L1 L2 L3 AC Power ON (external switch board), Open the system cabinet (evt. Battery Cabinet). Switch OFF the Battery breakers. Main switch ON (63A 3p breaker). Load Breakers ON.
Ax.2 Disconnect the Battery terminals and isolate the lug ends
Tools:
l l Socket wrench set, insulated, various sizes; Screwdriver set, cross, insulated.
Procedure:
1. 2. 3. 4. Disconnect the positive + cable to the positive pole of the battery string.. Detach plastic pole protection caps to all battery poles. Disconnect the negative - cable to the negative pole of the battery string. Isolate the end e.g. with tape. Repeat steps 1 to 3 to disconnect battery cables for other battery branches in combination with the removal of the battery (next section) ISO Std: 4.2.3 Department: PS Engineering Page 9 of 56
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Ax.3 Remove the (Narada) batteries and their venting Kits.

1. Disassemble the battery ventilation kit when Narada batteries installed. i) Pull out the ventilation assembled with 4 three-way plugs from the ventilation outlet at the back of each battery respectively.
ii)
Disconnect the ventilation assembly firmly to the ventilation tube from the cable entry.
iii) iv)
Uninstall these shorter ventilation tubes from each end of the three-way plug; Uninstall the stopple to the left end of the leftmost three-way plug.
ISO Std: 4.2.3
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2. Detach inter-block connections between the battery blocks. 3. Remove battery blocks on the battery shelf. The batteries should be handled according to the battery manufacturers recommendations.
Similar procedure when Fiamm batteries are installed without venting Kits: Take out the batteries. Be aware that the batteries are high energy and avoid any short circuit with a live part (isolate live parts with tape or whatsoever).
ISO Std: 4.2.3
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Ax.4 Replace the dummy panels (with/without drilled holes) with the Lateral Filter Panels.
Part List:
l l l Plate; Cover of air filter Air filter box
Tools:
l l Socket wrench set, insulated, various sizes; Screwdriver set, cross, insulated.
Procedure:
1. 2. Loosen and remove the nut and washer on the top of the lifting brackets to remove the lifting brackets from the bolt. Unlock the cabinet top lid by turning the lock handle clockwise.
3. 4.
Lift the lid carefully and keep it in position using the lid support on the right side. Remove the dummy panel on the right side of the cabinet.
5.
Install the air filter box with three screws. Note that the three screws should be assembled in the leftmost, middle and rightmost screw holes of air filter box.
ISO Std: 4.2.3
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6.
Install the cover of air filter. Ensure the cover and air filter box are matched well.
7.
Place the plate on the top of the air filter box, and assemble Socket wrench set, insulated, various sizes; two M4 screws to another two screw holes to fix it.
ISO Std: 4.2.3
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8.
Follow the steps 5 to 7) to install another Lateral Filter Kit on the left side of the cabinet.
ISO Std: 4.2.3
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Ax.5 Install the Modification Kits. REWORK INSTRUCTION TO FIT 3 X FIAMM FFT160 BATTERY STRINGS
FOR
Alcatel-Lucent Description PSU cabinet PO16 PSU cabinet POB16 PSU cabinet PO16A PSU cabinet POB16A (with Air con) PSU cabinet PO16A cab battery with aircon Alcatel-Lucent P/N 1AF11757AAAA Power-One P/N 1-148306 Power-One Description PODS 16.488000 HEX PODS 16.488000 HEX PODS 1364 Alcatel ACU PODS 16.488000 ACU Battery Shelf Spacing New Battery shelf to fit 3 x FFT160 New Battery shelf to fit 3 x FFT160 New Battery shelf to fit 3 x FFT160 New Battery shelf to fit 3 x FFT160 No new shelf required, ensure shelves are at 8U pitch Kit required for 3 x FFT160 1-155854-G
PPRD and Air Guide Move PPRD to top position and install air guide (HEX) Move PPRD to top position and install air guide (HEX) PPRD in top position, no change (Never Shipped) PPRD in top position, no change
1AF11757AAAB
1-148306G
1-155854-G
1AF11757ABAA
1-151258G
1-155865-G
1AF11757ABAB
1-154483G
1-155865-G
1AF14355AAAB
1-154484G
PODS 1364 ACU Battery
N/A, no PPRD
None
Purpose:
This rework instruction is for the specific purpose to modifying the above outdoor power systems in order to be able to install 3 x FIAMM FFT160 battery strings. The use of this instruction requires an upgrade kit (PowerOne part number 1-155854-G, and 1-155865-G) which includes the parts indicated below.
Parts List
1 -155854-G: 1 x new battery shelf 1 x new air guide assembly 8 x M6 screw 8 x M5 screw 1 -155865-G: 1 x new battery shelf 8 x M6 screw
ISO Std: 4.2.3
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Tool List
The following tools are required to perform this upgrade: Insulated screwdriver set Small slotted Medium slotted Medium Phillips Medium Torx
Insulated side cutters (to cut cable ties)
Procedure:
When not installed yet but installation of 3 Fiamm batteries needed inside the cabinet: make sure original battery strings were taken out. 1. 2. If the 4U power shelf is not installed in the upper most rack unit position, then move the shelf up 1U to the top position. Check that all attached cables have enough slack in order to move the shelf. Remove the mounting screws and carefully move the shelf to the top mounting position. Re-install the mounting screws. Move the middle battery shelf up 1U (So that the bottom shelf has an 8U pitch, see figure followed).
3.
Replace the top battery shelf with the new one provided at 8U (less ~12mm) pitch from the middle battery shelf (the position can be confirmed as 2 screw holes will be visible immediately above the shelf instead of 1 as seen on the bottom and middle shelf. Fasten the battery shelf with four M6 screws by torque 6Nm.
ISO Std: 4.2.3
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Battery Shelf M6 Screw
4.
Remove the cable tie bar on rear wall inside cabinet (See figure below).
Metal piece to be discarded for battery fitting Replace the air guide with the new one (not apply to kit 1-155865-G!) Remove the old air guide subassembly from the heat exchanger. Place the new air guide to the position as indicated in Figure 4. Fasten it with the provided four M5 screws with torque 3Nm. Type of Document: Rework Instruction ISO Std: 4.2.3 Department: PS Engineering 5.
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Air Guide Subassembly
M5 Screw
ISO Std: 4.2.3
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Ax.6 Refurbishment and AC-DC cabling inspection

Purpose
l l To clean the outdoor cabinets following the pacification and temporarily degraded IP rating of the cabinet. Inspection of cabling
Tools:
l l l l Vacuum cleaner Cloth and detergent for cleaning metal surfaces Power-One Lateral Ventilation Kit (Power-One part number 1-156613-G) Standard set of screwdrivers
Safety Alerts! The use of Valve Regulated Lead Acid (VRLA) batteries means high energies inside the cabinet. Be aware and avoid any possible short circuit. When doing the live procedure special attention must be made for the cleaning procedure
Procedure:
1. 2. 3. 4. Have the cabinet door and top lid open for access. Remove any temporary ventilated panel(s) previously mounted according to procedure 3BK 17442 0004 RJZZA Revision 01a. Clean the area around the left and right panel openings. Inspect the cleanness of the Power-One lateral ventilation kit according to the installation procedure delivered with the kit.
5. 6.
Clean distribution front panels using the cloth, then remove the front panels Use the vacuum cleaner to remove dust or other objects from the distribution. ISO Std: 4.2.3 Department: PS Engineering Page 19 of 56
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WARNING! Metal parts should not be entered into the distribution. Use a brush tip with plastic housing on the vacuum cleaner and proceed with care. WARNING! Avoid bodily contact with distribution bus bars and cabling.
Clean all parts of the distribution.
7. 8.
Remove one rectifier and wait until it has shut down (fan will stop and LED will die out). Inspect rectifier visually and the vacuum cleaner gently to remove any unwanted objects and/or dust. Cloth may be used for rectifier front grid and metal cover but not for the rear.
Rectifier Front: Vacuum cleaner around fans, then use cloth to thoroughly clean the surface.
ISO Std: 4.2.3
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Rectifier Rear: Gentle use of vacuum cleaner to release dust from internal components and connector. Use dry cloth to clean rear, top and sides are cleaned with a wet cloth.
9.
Use the cloth to clean the rectifier backplane surfaces that are revealed when the rectifier is being removed.
Area behind rectifier to be cleaned (also clean side walls where applicable). Note: Shown here with three rectifiers removed, rectifiers should be removed one by one.
10. Gently use the vacuum cleaner to clean the rectifier backplane area. 11. Remark: Live procedure: put in back the rectifier taken out and wait until switched on. There is a redundancy of 1 rectifier in the system. Verify how many rectifiers can be taken out maximally without endangering the BTS operation. Do not go beyond this amount. For the passive procedure it does not matter. Type of Document: Rework Instruction ISO Std: 4.2.3 Department: PS Engineering Page 21 of 56
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WARNING! Metal parts should not be entered into the rectifier backplane. Use a brush tip with plastic housing on the vacuum cleaner and proceed with care. WARNING! Avoid bodily contact with rectifier backplane.
Rectifier backplane area behind rectifier to be cleaned. Note: Shown here with three rectifiers removed, rectifiers should be removed one by one.
12. Repeat steps 7 - 11 for each rectifier (one by one). Also perform the same operation for rectifier positions with dummy panels (dummy panels to be cleaned in the same way as rectifier fronts). 13. Remove the PCC and the vacuum cleaner gently to remove any unwanted objects and/or dust. Cloth may be used for controller front but not for the PCB.
Clean the PCC front, first with the vacuum cleaner and then using the cloth.
ISO Std: 4.2.3
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Pull out the controller to access the rear. Gently use the vacuum cleaner on the internal components and connector. Clean the cover using the cloth.
14. Perform visual inspection of cabinet inner surfaces (including but not limited to walls, Heat Exchanger (ACU) element and cabinet bottom) for dirt, water, insects or any other unwanted objects. Use vacuum cleaner and cloth to clean all cabinet inner surfaces described above.
AC/DC cabling screw terminal inspection

15. Visual inspection of wire harness assembling in back of rectifier shelf. As the blanking plates in cabinet top are removed and replaced for degassing reason, opportunity shall be taken to check whether all the AC harness contacts are equally plugged on backplane. A mirror helping visual access may be needed. No further tools or efforts considered. (take a photograph with a digital camera or mobile phone).
16. Verify proper tightening of screw contacts in DC-MCB (battery and load high current wires) by means of a screwdriver. 17. It can be refrained from manual check of connector retention in backplane. However, when any damage occur during AC/DC service life, e.g. backplane connector loosen by unplugging a rectifier (connector comes out with rectifier) entire shelf must be replaced Type of Document: Rework Instruction ISO Std: 4.2.3 Department: PS Engineering Page 23 of 56
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Ax.7 Install the battery terminal protection covers.

Purpose:
The Battery Terminal Protection Cover is made of plastic and used for the isolation of the cabinet inner sheet metals so both negative battery terminal and cable lug can not touch the cabinet thus avoid a short circuit of the battery.
Part List:
Battery Terminal Protection Cover (Part Number: 1-157166-G)
Tools:
Screwdriver set, cross, insulated.
Procedure:
1. Place the Battery Terminal Protection Cover (see in the figure followed) at the corresponding place. The location where the Battery Terminal Protection Cover should be placed at is at the left side of the cabinet and verified with the dimension of the battery. The battery negative terminal lies at the middle of the Battery Terminal Protection Cover would be better.
2.
Fix the Battery Terminal Protection Cover with two M6 screws.
ISO Std: 4.2.3
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Ax.8 2 Warning labels in position If NOT: stick warning labels to their intended position.
Purpose:
Reminding the installer to pay attention to two WARNING labels pasted on the document holder and the left inner side of the cabinet when installing the battery ventilation kit. If no WARNING label is found, paste the supplied labels to the corresponding position. See figure below.
Procedure:
Check if 2 warning labels are in position; otherwise stick warning labels to their intended position.
ISO Std: 4.2.3
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Ax.9 Install the Fiamm Batteries.

The battery cables for one cable string are delivered as a default configuration. The battery cables of the system can be ordered according to your requirements. The battery cables are connected to the systems battery circuit breakers at delivery. The + cable is connected to the positive bus bar of the system, and the -cable to the negative battery breaker. You only need to connect the other end of the cable to the corresponding - or + pole of battery string.
WARNING: Always lift each single cell/block from underneath or whenever available by the lifting handles. Never apply force to, or drop anything on the terminal posts: doing so the threads or the sealing of the terminal posts may be damaged. WARNING: Improper handling of batteries can result in the batteries shortcircuiting, which can result in serious injury due to high energy levels. Operation to the battery must be restricted to qualified personnel only. WARNING: Ensure that the battery circuit breakers are off.
1. 2. 3. Measure the individual battery blocks: Well charged Fiamm FFT/UMTB blocks will show ca.12.75V DC Advice: access and installation of batteries is easiest when the shelves above the strings are removed
Place battery blocks on the battery shelf. The batteries should be handled and installed always according to the battery manufacturers recommendations. 4. It is strongly advised to keep an equal distance between battery blocks of 5 mm -15 mm for proper ventilation. 5. Prepare and Install the battery ventilation Kit. See section Ax.10 6. Remove the isolation from the lugs and connect the negative - cable to the negative pole of the battery string. Tighten the connection to a torque of 5 Nm -6 Nm. Remove the isolation from the lug. Connect the positive + cable to the positive pole of the battery string. Tighten the connection to 5 Nm -6 Nm. Attach plastic pole protection caps to all battery poles. Warning: the battery cables do have 90degr lugs 7. Attach inter block connections between the battery blocks. 8. Attach the symmetry cable to the midpoint of the string. Measure the voltage: should be ca. 25.5V, depending on the individual block voltages. See section Ax.11 9. Put proper covers onto the battery poles. 10. Put the next battery shelf above the just installed battery string into position and mount it: check that the negative pole underneath is isolated and you can not cause a short circuit. Repeat steps 1 to 10 for each battery string. 11. For the upper of the first two rows of battery strings: attach the battery temperature sensor. See section Ax.12
ISO Std: 4.2.3
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Options for the mounting of the 90degr angled battery lug sized 25/8:
A: On the top of the bloc by solid connectors
B1: On the front by a special L clamp
B2: There is also the possibility to turn the special clamp of 90 to connect end cable on the longer side of the battery.
ISO Std: 4.2.3
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Ax.10
Prepare and Install the Battery Ventilation Kits from Fiamm.
Purpose:
A battery ventilation kit must be attached to each battery string to allow Hydrogen to exit the cabinet.
WARNING: If batteries are installed in the cabinet, do not power up the system before ventilation kits are installed on all battery strings. Part List:
l l l 1 x single inlet plug with O-Ring seal 3 x double inlets plug with O-Ring seal 1 x PVC vent pipes, L=5 m
Tools: Procedure:
1. Cut the delivered 5 m battery tube into the following lengths: l 1.2 m for the bottom battery string l 1.7 m for the middle battery string (if installed) l 2.1 m for the top battery string (if installed) Select nipples with appropriate size to insert up to three ventilation tubes separately on the cable entry, and follow the steps to assemble the nipples and ventilation tubes: l Remove the appropriate number of nipples from the cable entry panel (according to the total number of battery strings being installed). l l l Cut an appropriately sized hole in the nipple to accommodate the ventilation tube. Push the ventilation tube(s) through the hole in the rubber nipple from the inside to the outside. Leave sufficient length of tubing outside the cabinet to prevent the tube from sliding back into the cabinet. Assemble the rest of the nipples and ventilation tubes if needed.
2.
ISO Std: 4.2.3
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3. 4. 5.
Install the nipples to the cable entry panel respectively. Position the tube(s) under the cabinet so that they are safe from vandalism and from soil entering and obstructing the tube(s), and have proper free air ventilation. The other end of the ventilation tube(s) need to be routed to the battery shelves inside the cabinet. l The shortest ventilation tube is routed to the bottom battery string, l the ventilation tube with middle length (if installed) is to the middle battery string, and l the longest ventilation tube (if installed) is for the top battery string. l
6.
From the remaining unused ventilation tubes, cut shorter tube pieces of appropriate lengths (recommended 18 cm) and install them to each end of the plug pieces into a ventilation assembly as shown in figure bellow.
CAUTION: Make sure the left most plug piece of the ventilation assembly must be the one with a blocked end in default.
CAUTION: Make sure the ventilation tubes are not obstructed, bent, blocked or damaged during installation.
ISO Std: 4.2.3
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7.
Connect the ventilation assembly to the tube from the cable entry.
CAUTION: Make sure that the O-Ring seal is fitted in each vent plug.
8. (When not done already, load the batteries onto the appropriate shelf and) Install the ventilation assembly with 4 plug pieces clamped firmly to the ventilation hole on the top of each battery respectively, keeping the ventilation tube in S-shape.
If a second and/or third battery string is to be installed in the system, install the battery shelf(s) and battery string into the cabinet and install the venting Kit as described before.
ISO Std: 4.2.3
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Ax.11
Install the Battery Temperature sensor

The temperature sensor is used to measure the battery ambience temperature as the input to the controller. The controller will adjust the float charge voltage according to the input temperature and the preset temperature compensation factor. The temperature sensor is normally pre-routed in the cabinet and connected to the controller interface. The description presented is also valid for replacing a battery temperature sensor.
Terminal connections on the alarm interface board from left to right: J1 Symmetry J2 HEX-ACU/Symmetry J4 Temp sensor J6J7J8J9 Alarms 1..4
The sensor element is routed to the right side of the battery shelf and should be positioned in the middle of the upper of the first two rows of battery strings on top of a battery block.
ISO Std: 4.2.3
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Ax.12
Install 1 to 3 pcs of the 2.6m symmetry cables in the system cabinet

NOTE: Option 4B: when 4 batteries: install 1 piece of a 5m symmetry cable in the MIDI battery cabinet.
There are 4 inputs available for symmetry measurement. An example of the symmetry cable routing for the first, lowest positioned, string is shown in the figure below. See for the connections the section for the battery temperature sensor. Follow the steps below to connect the symmetry cable with the battery.
1. 2. 3.
Make sure the inter block connections between batteries are attached. See section Ax.9 Insert the separately supplied metal lug into the end of symmetry cable. Fix the symmetry cable lug onto the middle battery string of the battery branch.
For additional symmetry measurement of up to 3 additional battery strings, the symmetry cable is normally delivered with the battery cable kit option for additional battery strings. Connect the symmetry signal (1 wire) to the controller interconnection board as per previous section. Route the cable to the battery string using the pre-mounted symmetry cable as reference, and fasten the cable to the battery block as described above. Type of Document: Rework Instruction ISO Std: 4.2.3 Department: PS Engineering Page 33 of 56
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Ax.13
ACU System only: rewire the Door alarm and the ACU alarms
In the original ACU system the door alarms and ACU alarms are connected such that 2 symmetry alarms are available. After the rewiring and the upgrade 4 symmetry alarms can be used.
Original connections: inside the Power Cabinet

ACU alarms, original state (when battery cabinet present)
a. The alarm wire Power Cabinet ACU Alarm is connected to J1-3 on the external alarm interface
b. The alarm wire Battery Cabinet ACU Alarm is connected to J2-2 on the external alarm interface Door alarms, original state (when battery cabinet present)
c. d. The alarm wire Power Cabinet Door Switch Alarm is connected to J5-2 on the internal alarm interface board The alarm wire Battery Cabinet Door Alarm is connected to J2-1 on the external alarm interface
Original wiring situation Type of Document: Rework Instruction ISO Std: 4.2.3 Department: PS Engineering Page 34 of 56
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Update of connections: inside the Power Cabinet: wiring diagram

The ACU Alarm signals must be put in series, and the lights = Door alarms of both cabinets are paralleled. There fore the connections to and from the Power ACU alarm on the ACU The connections to the external alarm board must be changed The door alarm wire (light of battery cabinet) is connected to the door alarm of the ACU Power Cabinet The signaling is now the same as in the HEX cabinet.
ISO Std: 4.2.3
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ACU alarms, update a. When there is no ACU Battery cabinet present :

Disconnect the alarm wire Power Cabinet ACU Alarm in the Power Cabinet from J1-3. Connect the alarm wire Power Cabinet ACU Alarm in the Power Cabinet to J2-2
b. When there is an ACU Battery cabinet present:

Disconnect the alarm wire Power Cabinet ACU Alarm in the Power Cabinet from J1-3 (external alarm interface board) Disconnect the alarm wire BATT Cabinet ACU Alarm (green) in the Power Cabinet from J2-2 (external alarm interface board) Connect the alarm wire Power Cabinet ACU Alarm in the Power Cabinet to J2-2 Disconnect the red wire in the Power Cabinet from the COM alarm terminal (on the ACU) in the ACU Power cabinet. (insulate the end and mark as not used) Connect the alarm wire BATT Cabinet ACU Alarm (green) to the COM alarm terminal (on the ACU) in the ACU Power cabinet: extend the cable when necessary
Hint: use standard installations materials for the paralleling or extension of wires into the Power Cabinet, with crimped, soldered or screwed wire connections, insulated. We have supplied a pluggable connector to connect the extension battery cabinet. See the attached cable drawing. An installer has several options to go with.
Door alarms, update

c. d. The Power Cabinet Door Switch Alarm remains unchanged and connected to J5-2, prewired Remove the (yellow) ACU Batt Cabinet Door Alarm from J2-1 and connect it either to the Door Alarm relay NC terminal in the Power Cabinet, in parallel to the existing wire, or to the red wire 2pin terminal block for power cabinet light (item 7 in following drawing).
In the updated, new configuration up to four (4) Symmetry connections are available. The firmware and configuration files for both HEX system and ACU system are the same. a. The Symmetry 4 cable for Battery String no 4 can be connected to J2-1 in the Power Cabinet b. Battery String 5 can not have a symmetry cable installed Type of Document: Rework Instruction ISO Std: 4.2.3 Department: PS Engineering Page 36 of 56
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The green wire in the cable connection to the BATT cabinet is the alarm wire BATT Cabinet ACU Alarm The yellow wire in the cable connection to the BATT cabinet is the alarm wire BATT Cabinet Door Alarm
The yellow wire must be connected to the red wire in connector 7: verify this is the NC terminal on the Door Switch:
ISO Std: 4.2.3
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Ax.14
Commission the system

Work only with insulated tools, professional equipment and according to the state of the art. Initial status: Passive procedure: ext Mains OFF, main switch OFF, rectifiers not in position, battery breakers OFF, load breakers OFF Live procedure: ext. Mains ON, main switch ON, rectifiers switched on, battery breaker OFF, loads connected and BTS in operation
1. Verify that the earth connection (FPE) to the system and in the surroundings or building is present and thoroughly connected (also going into the earth). 2. Verify the mains 3L+N and the connections into the system and their respective voltages. Measure the AC voltage on the AC terminal block, between phases and neutral. The correct value is approximately 230 V. If the value is different, check the AC connection. 3. Verify that nobody else is working in live voltage areas (AC line, DC power etc) in any part of the power system and/or telecom cabinets and systems, so that no accidents can occur when switching on the electrical power. Verify that no shorts can be made in any of the cabinets. Passive procedure only: Do not switch on in case of any risk of danger or threat. 4. Remove the covers and check that all connections are made according to the installation drawing. Verify that all connections are properly tightened with sufficient torque. 5. Passive Procedure only: Verify all load and battery MCB breakers are set to the OFF position 6. Verify the load and battery strings are connected properly. 7. Passive procedure only: Verify all rectifier modules are removed (disconnected from backplane). If not, remove each one in turn starting from the rightmost position. 8. Check the battery polarity and voltage with a calibrated, professional Multi meter (> 3 Digit, 01% dc). Place the positive lead of the meter to the positive bus bar, with the PE yellow green cable connected to, and the negative lead to the battery breaker. The meter must now show a positive voltage. If the voltage is negative, change over the connection of the blue and black battery cables to the batteries. 9. Verify that the battery ventilation kit is properly installed according to manufacturer requirements. Also ensure that the ventilation tubes are properly guided out of the cabinet for all batteries. The tubes should not be bent or compressed in any way that any hydrogen flow is obstructed in its attempt for leaving the cabinet. 10. The door switch can be brought into door closed position and can be fixed with tape during the commissioning to avoid the alarm. (or the installer accepts the alarm and uses the lamp) 11. Passive procedure only: Turn on the AC mains voltage in the external room level or floor level distribution.. 12. Passive procedure only: Turn on mains circuit breaker. 13. Passive procedure only: Plug in all rectifier modules, starting from the left most position. Make sure to fasten the rectifiers again. The rectifiers will turn on automatically. Type of Document: Rework Instruction ISO Std: 4.2.3 Department: PS Engineering Page 38 of 56
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14. Passive procedure only: Set load breakers into "1" (ON) position, including the light. 15. Passive procedure only: Green LED on controller should blink for approximately 20 sec. 16. Output voltage will increase to U1, i.e. 54.2V @ 25C for Fiamm UMTB or FFT battery strings. Calculate if value corresponds with temperature compensation value. 17. Turn battery breaker to "1" ("ON") position. (battery polarity must be OK) 18. Upload the new firmware and the new settings as described in Ax.14. 19. Check if the alarm cables are correctly connected according to the section Connecting Alarm Cables of instruction manual.. Generate various alarms and verify if these arrive in the BTS. For generation of / resetting alarms: see the instruction manual 043527 (1-153103). 20. For the ACU cabinet: check if each ACU generates the ACU/HEX alarms (switch on/off the AC breaker). 21. Check and confirm the settings of the battery symmetry, battery current limitation, battery test levels and amounts/year and temperature compensation factor. 22. Check if the displayed temperature on the PCC menu (Show data >Temperature: xx C) is in accordance with the current environment temperature. To test the temperature probe and temperature compensation, rub the probe element with the fingers to heat it up. Verify that the temperature measurement rises and that the DC output voltage drops slightly. To do this the sensor must be accessible. 23. Passive procedure: Switch off the main AC breaker and check if batteries take over the load power. Reconnect the main AC breaker and check that the rectifiers switch on and take the load power. Live Procedure: program the rectifiers down to 45.6V and check if the batteries take over the load power. Set the voltage of the rectifiers back to the original value. Now the test mains switch off test can be done. 24. Perform a battery test of 20-30 minutes with the settings as per the configuration. Use either the BTS load current, but preferably an external resistive load. 25. Verify that the installed battery capacity matches with the expected back up time: discharge currents matching with the required backup time can be taken from appendix B or the datasheets from the battery manufacturer, and compared to BTS load currents. 26. If any alarm occurs, it should be reset in accordance with Show alarms in product description controller of instruction manual. 27. At the end of the procedure the system should be without alarms. Disconnect the tape and the door switch will cause an alarm. 28. When closing the door, the door switch alarm must disappear and the light should be off. Verify this. 29. Open the door again and attach all system covers etc in their correct places. 30. Check that all changes to documentation and/or drawings, if any have, been registered and signed for: when a local project manager decides to make any changes like paralleling alarms, this must be well documented and signed for including name and date of the person in charge of this. Type of Document: Rework Instruction ISO Std: 4.2.3 Department: PS Engineering Page 39 of 56
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Ax.15
Update the controller firmware and the software configuration
A1.15.1 Update the controller firmware.

Purpose:
The PCC firmware can be updated via the serial port of the controller. This document describes the procedure for doing this update on controllers that are mounted in systems at customer sites. This procedure can be performed while the system is in operation.
Equipment needed:
1. 1 PC with an RS232 port 2. PCS Burn program 3. Updated PCC software (.pcc file) 4. Update instructions (This document) 5. 1 Null-modem RS232 cable 6. USB to RS232 converter
Instructions:
The PCC firmware must be updated according to the Power-One Document: PCC Firmware update at customer site, document number: 041935. In the electronical version of the retrofit A procedure, this file is attached underneath:
PCSBurn1.09_setup. zip
PCC_114.zip (329 KB)
041935.pdf (276 KB)
Remark: In case of problems with the firmware upload a special reset must be made. This is however very seldom the case. Call your representative.
ISO Std: 4.2.3
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Ax.15.2
1
Update the software configuration.
Preparation 1.1 Ensure the PCG files from Appendix B are available on your computer so that they can be used to update the controller 1.2 Ensure the PowCom version 3.2 or higher is installed on your computer. If not, use the following procedure: a) Go to http://www.power-one.com/products/software_download.html ,
1-150197.zip
C-220041 1-154303 C-220041 1-154304 for 1-148306... for 1-148306...
b) c)
Select the Software Download link. Follow the instructions and use the login and password provided below to access the software for download. login: P1powcom password: 83w1ldcats Start PowCom Go to Communication|Properties in the menu. Click on the license tab in the Properties window. Copy and paste the following license number (1560-0C32-3CDC-23F5-0E8F) and click on the Activate License button. Powcom Password is: 1234 License level shall be 30 Exit the program and restart it again in order to fully activate the license.
d) e) f)
g) 2
Connecting to the controller. 2.1 2.2 2.3 Run PowCom. Connect to the controller via RS232 communication port by password 1234 (4321). Confirm license level must be 10 or up, please check via Communication - Properties menu as following. If not, reinstall the software according to step 1.
ISO Std: 4.2.3
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Upload file to the controller. 3.1 Click Update configuration from menu Utilities.
3.2
The following window will then be presented
ISO Std: 4.2.3
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3.3
Click Select update file to select PCG file, C-220041 for HEX and C-220044 for ACU click yes in the pop windows as following.
3.4
Click Transfer data to controller to update PCG to the controller as following.
3.5
A processing bar will appear after click Transfer data to controller, please waiting for updating completion.
3.6
Following window will appear after updating completion.
ISO Std: 4.2.3
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3.7
Click close to close this window; a pop window will appear.
3.8
Click ok to close this windows, update is successful.
ISO Std: 4.2.3
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Ax.16 Ax.17
Fill in and sign the Checklists, Store documentation and Stick the retrofit A label
Verification that all works have completed and what has been done
Bring documentation in a safe position where it can be found
Purpose:
Show that existing systems have been upgraded
Part List:
Label drawing
retrofit A completion label.pdf
Tools:
None
Procedure:
1. 2. 3. 4. 5. After successful commissioning Fill in and sign the checklists for installation and commissioning (see attachment B), Put the documentation in the document holder and Stick the retrofit A label on top of or near the system type label Clean the site Text : font:Arial , 10pt, bold, width factor: 1
80
retrofit A completed as per ECO S41264 1-148306G rev AI Or general applicable also for ACU systems: print locally and stick near type label:
ISO Std: 4.2.3
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Supplement A
Software Configuration
ISO Std: 4.2.3
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ISO Std: 4.2.3
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ISO Std: 4.2.3
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ISO Std: 4.2.3
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ISO Std: 4.2.3
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ISO Std: 4.2.3
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ISO Std: 4.2.3
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Supplement B
Battery Discharge Currents
ISO Std: 4.2.3
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Supplement C
Check Lists
SITE NAME SITE ADDRESS SYSTEM SERIAL NO
. . .
INSTALLATION: NAME: DATE: SIGNATURE: . . .
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
DESCRIPTION RACK POSITION OK; LEVELING OK ETC MAINS POWER SWITCHED OFF BATT CABLE ENDS ISOLATED / TAPED DC BREAKERS SWITCHED OFF REFURBISHMENT - CLEANING VERIFICATION OF AC / DC CONNECTIONS LATERAL FILTERS PANELS INSTALLED MODIFICATION KITS: 3 FIAMM BATT STRINGS POSSIBLE NO OF BATTERY STRINGS INSTALLED FIAMM INSTALLED BATTERY PROTECTION COVERS WARNING LABELS IN POSITION VENTILATION KITS INSTALLED BATT SYMMETRY CABLES INSTALLED BATT SYMMETRY WIRES IN CORRECT POSITION ONTO ALARM BOARD J1 BATT TEMPERATURE SENSOR INSTALLED ALARM CABLES CABLED INTO BTS DC LOAD CABLES L+L- CABLED INTO BTS
NO
OK
NOK
1 1 1 1 1 1
2 2 2 2 2 2 3 3
3 3 3 4 4
ISO Std: 4.2.3
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SITE NAME SITE ADDRESS SYSTEM SERIAL NO PCC SERIAL NO ELECTRICAL: NAME: DATE: SIGNATURE:
Rectifier amount: Rectifier amount: Battery type: Amount of strings: ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13
. . . .
. . .
FMP16.48 1 FFT105 1
2 other: 2 3 4 FFT130 FFT160 UMTB160 2 3 4

STATE VALUES OK
DESCRIPTION
NOK
PE FPE CONNECTED: BREAKERS OFF MAINS VOLTAGE LEVEL: V SWITCH ON MAIN BREAKER RECTIFIERS 1 2 3 4 5 BATTERY POLARITY BATTERY STRING VOLTAGES: V BATTERY BREAKER ON LVD FIRMWARE UPLOAD PARAMETER, CONFIGURATION UPLOAD FLOAT VOLTAGE LEVEL U1 V VERIFY SETTINGS A BATT CURRENT LIMIT VALUE V/10K TEMP COMPENSATION FACTOR V SYMMETRY LEVEL 14 BATT TEMP SENSOR TESTED 1 2 3 15 BATT TEMP SENSOR VALUE C 16 REFERENCE AMBIENT TEMPERATURE . C 17 BATT SYMMETRY MID VOLTAGES V 18 BATTERY TEST DURATION ..Min 19 BATTERY DISCHARGE END VOLTAGE V 20 BATTERY MINIMUM VOLTAGE DURING TEST V 21 ALARMS TESTED 22 ALARMS ARRIVAL TO BTS TESTED 1 2 3 4 23 DC LOADS POWERED UP and WORKING 24 PULL OUT CONTROLLER: FLOAT VOLTAGE V 25 RE-INSERT CONTROLLER: FLOAT VOLTAGE V 26 DC LOAD CURRENT OF BTS A 27 RETROFIT A LABEL Type of Document: Rework Instruction ISO Std: 4.2.3 Department: PS Engineering
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ISO Std: 4.2.3
Page 56 of 56

2008 12 18 Retrofit A Procedure Rev 05

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PODS 16.48-8000 HEX VENT

PSU cabinet POB16

PODS 16.48-8000 HEX VENT

PSU cabinet POB16A ACU Batt cabinet BCAB2

PODS 16.48-8000 ACU VENT

BATT CAB ACU VENT

HEX Cabinet Type of Document: Rework Instruction ISO Std: 4.2.3

Air Conditioned Cabinet Department: PS Engineering Page 1 of 56

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Supplement A Supplement B Supplement C

Software Configuration Battery Discharge Currents Check Lists

Type of Document: Rework Instruction

ISO Std: 4.2.3

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ISO Std: 4.2.3

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4. List of Items and relation to referenced documents

Type of Document: Rework Instruction

ISO Std: 4.2.3

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Type of Document: Rework Instruction

ISO Std: 4.2.3

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PASSIVE PROCEDURES Retrofit A procedure A1, Replace Narada Battery Strings

Retrofit A procedure A2, Retrofit a sealed cabinet with Fiamm Batteries

Type of Document: Rework Instruction

ISO Std: 4.2.3

Proprietary Information of:

Retrofit A procedure A3, Warehouse upgrades

Internal Battery cable Kits

External Battery cable Kits

Type of Document: Rework Instruction

ISO Std: 4.2.3

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Type of Document: Rework Instruction

ISO Std: 4.2.3

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7. Detailed Action Lists

Ax.1 Preparation: AC off, breakers off Passive procedure (standard)

Live procedure (for trained and experienced installers only)

Type of Document: Rework Instruction

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Ax.3 Remove the (Narada) batteries and their venting Kits.

Type of Document: Rework Instruction

ISO Std: 4.2.3

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Type of Document: Rework Instruction

ISO Std: 4.2.3

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Type of Document: Rework Instruction

ISO Std: 4.2.3

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Type of Document: Rework Instruction

ISO Std: 4.2.3

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Type of Document: Rework Instruction

ISO Std: 4.2.3

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PODS 1364 ACU Battery

Type of Document: Rework Instruction