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Installation Guide

351432.033
Information in this document is subject to change without notice and does not represent a
commitment on the part of Eltek Energy AS.
No part of this document may be reproduced or transmitted in any form or by any means —
electronic or mechanical, including photocopying and recording — for any purpose without
the explicit written permission of ELTEK Energy.

Copyright ©: Eltek Energy AS, Norway 2006


NS-EN ISO 9001:1994 Certifícate no: 900005Q
NS-EN ISO 14001:1996 Certifícate no: 900005E.
This product holds a CE mark and satisfies all requirements covering relevant standards and
directives.

EMC LVD
▫ EN61000-6-2 Industrial Environment ▫ LVD73/23/EEC Low Voltage Directive
▫ EN61000-6-3 Residential, Commercial and Light Industry ▫ EN60950 Safety of Technology Equipment
▫ ETS 300386 v1.3.1 Telecommunication Equipment ▫ UL60950,UL1801

Certificate no: 900005Q Certificate no: 900005E

POWER DISTRIBUTION
CENTER FOR
COMMUNICATIONS EQUIPMENT
9N73

Art. No. 351432.033 Issue 1, 2005 December


Published 2005-12-15
ESB.

MicroPower Outdoor Battery Cabinet has part no. 105418

2 Installation Guide MicroPower Outdoor Battery Cabinet, art 351432.033, v1-2005-10


TABLE OF CONTENTS

1 DESCRIPTION OF MICROPOWER OUTDOOR BATTERY CABINET 4


IMPORTANT NOTICES 4
OVERVIEW – GENERAL ARRANGEMENT 4
BLOCK DIAGRAM 5
DC DISTRIBUTION 5
TORQUE SETTINGS 6
ORDERING INFORMATION 6
SCOPE OF DELIVERY 7

2 INSTALLATION PROCEDURES 8
SAFETY PRECAUTIONS 8
RECOMMENDED TOOLS 8
MECHANICAL INSTALLATION 9
• Organize the installation site 9
• Lifting the cabinet 9
• Position and fasten the cabinet 10
• Wind resistance 10
• Preventing condensation 10
• Mount the batteries on the shelf. 11
• Fixing point for temperature sensor 11
ELECTRICAL INSTALLATION 12
• Cable access for MicroPower Cabinet 15
• Schematic Diagram 16
• Installation and maintenance instruction for filter mat in MicroPower Cabinet 17

3 ALARM RELAY OUTPUTS AND SIGNAL CONNECTIONS 19


ALARM RELAY SPECIFICATION 19
• About Fail-Safe Operation Mode 20
• Connections for Internal system wiring 20

3 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


1 Description of MicroPower Outdoor Battery Cabinet

This Installation Guide contains information about how to install the MicroPower Outdoor
Battery Cabinet.

Important notices

To be installed only in restricted access areas or the like, in


accordance with articles 110-16, 110-17, and 110-18 of the National
Electrical Code, ANSI/NFPA 70.
For supply connectors’ use wires suitable for at least 75˚C
Type: FEPW, RH, RHW, THHW, THW, THWN, ZHHW, USE, ZX or similar.
Use copper conductors only.
The over voltage protection kit contains a class C protection. This requires an external class B
protection on the system’s mains feed.

Overview – General Arrangement

The MicroPower Outdoor Battery Cabinet is a kit that provides an additional battery string
for the MicroPower Outdoor System. The cabinet is identical for both systems so the 3
different kits for mounting the cabinet are the same: Floor Mounting Kit, Pole Mounting Kit
and Wall Mounting Kit. The cabinet is designed for cable entry trough cable glands at the
cabinet base. The cabinet size is 590x427x775mm, (23.2 x 16.8 x 30.5”) (WxDxH). The
cabinet fulfils IP 55.
The MicroPower Outdoor Battery Cabinet can be expanded with a second battery string. See
the Battery Shelf Kit instruction manual for further details. It is also possible to mount the
Heater Kit in this cabinet. However the Heater kit requires the AC Kit for Battery Cabinet in
order to operate. See the installation manual for both kits for more information.

FAN

Analog
controller board

Battery Shelf
Battery breaker

Heater Kit
(option) 2-pol AC breaker
(option)

Figure 1 Flatpack Power Rack System General Arrangement

4 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


Block Diagram

MicroPower Outdoor MicroPower Outdoor


Cabinet Battery Cabinet

Temp.
FAN Heater*
sensor
+

+* T
+ +
Analog
controller
- Fb1 board

Fb2*

LVBD
-
F3*

Figure 2. Block diagram. All items marked with * are options.

DC Distribution

Under the battery shelf is a DC distribution. This distribution is equipped with 1 battery
breaker (Fb1) and a terminal block (+) for DC connection to the battery bank.
In addition there are 2 terminal blocks (+ and -) for 48V DC supply to the Analog
Controller Board and a green/yellow terminal block (E) for earth connection to the
cabinet chassis.

CBI

60A
I

TRIP

0
CURVE U2

QY-1(13)-D
80V

+ -
10 kA

E +
Fb1

Figure 3 DC distribution.

5 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


Torque settings

• Screws in 16sqrmm terminal block: 3.0Nm


• Screws in 6sqrmm terminal block: 1.2Nm
• Screws in 2.5sqrmm terminal block: 0.6Nm
• Screws in CBI breaker: 3.0Nm
• Screws for battery shelf: 5.0Nm

Ordering information

Part number Description Net weight


105418 MicroPower Outdoor Battery Cabinet 29kg

6 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


Scope of delivery

The MicroPower Outdoor Battery Cabinet consists of the following components:


Part Note Quantity Unit
Basic Outdoor Battery Cabinet 1 1 pcs
Contb WDU 16 Screw terminal 2 2 pcs
End plate WAP 16/35 3 1 pcs
ContbCLmp=4SQ fuse/2p WAGO 4 2 pcs
Fuse cer5x20=T6A3 250V HBC IEC/UL 5 2 pcs
END plate:4SQ fuse/2 pol WAGO 6 2 pcs
Jumper 10-pol WDU 16mm2 7 0,4 pcs
Cable Gland M20 6-12 Black UL 8 5 pcs
Locknut M20 Black 9 5 pcs
Cable Gland M16 2-6 Black UL 10 4 pcs
Locknut M16 Black 11 4 pcs
Deka-fix ‘+’ 12 3 pcs
Deka-fix ‘-’ 13 2 pcs
Manual 14 1 pcs

8&9
10&11

4
7 3
1

Insta
6
llation
manua
l
Xxx xx
xxxxx

5
13
Xxx

12
Xxx xxxxxxx
xxxx
xxx

Eltek

14

7 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


2 Installation Procedures

This section describes how to install the MicroPower Outdoor Battery Cabinet. A step-by-
step procedure will guide you through the installation.
For installation of the kits for the MicroPower Outdoor Battery Cabinet refer to the
installation manual for each kit.

Safety Precautions

The equipment described in this manual must only be


installed by authorized personnel, and only operated by
persons who have attended a suitable Eltek Energy
training course.

The equipment represents an energy hazard and failure


to observe this could cause terminal injury and invalidate
our warranty.

Products into which our components are incorporated


have to comply with a number of requirements.
Installation is to be in accordance with the
recommendations herein.

Please read the manual carefully before using the


equipment.

Recommended tools

Always use insulated tools suitable for telecom installations.

TOOLS
recommended tools needed on the
installation of OEM systems
Phillips No.3 Battery shelf
Flat screwdriver 3mm All terminal clamps, screw or spring
clamps
Flat screwdriver 4,5mm
Flat screwdriver 6mm
Flat screwdriver < 3mm Spring connections to alarm/controller
board
Posidrive No2 (Flat screwdrivers also suited) MCBs
Socket wrench 10mm Common earth and battery poles

8 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


Mechanical Installation

Organize the installation site

Begin preparing the installation site, tools, AC supply cables and fuses, etc.
Check that clearances in front and over the cabinet are sufficient for cooling and to
facilitate operation and cable entry.
Check that all parts have been received — cabinet, batteries (if applicable),
documentation, etc. — and inspect them for physical or transit damages; contact
Eltek Energy otherwise. Protect all the parts.
To facilitate transport standard MicroPower deliveries consist of two strong packages on
pallets: one contains batteries, the other the cabinet.

Lifting the cabinet

Open the cabinet door and demount the 2 screws in the front. Take off the roof.

Unscrew these 2
screws and take
the roof off.

Fix straps to the eye-bolts. Close the door again so the door does not swing during
lifting. Lift the cabinet via the straps with lifting equipment to its intended position.
Balance the weight.

Eye-bolts.

Remove the straps and remount the roof once the cabinet has been moved and fixed to
its installation position.

9 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


Position and fasten the cabinet

Flatpack PSB 3kW, 48VDC, Outdoor Power Cabinet has different mounting possibilities; Pole
mounting, Wall mounting and Floor mounting options are available. Please refer to the
Installation guides for the respective mounting kit.
Pole
Pole mounting kit makes it possible to mount the Micropower Outdoor Cabinet
to a pole with minimum diameter 60mm and maximum diameter 115mm.
Floor
The floor mounting kit is intended for mounting the Micropower Outdoor
Cabinet to a pad/floor.
Wall
The Micropower Outdoor cabinet can be mounted to a wall with the wall
mounting kit.

Wind resistance

Cabinets are tested according to GR 487.


Depending upon the geographic location of a cabinet, exposure to high wind speed wind
gusts is often a threat. Unbalanced forces may be applied to pole or wall mounted cabinets
resulting in a turning moment. Pole or wall mounted cabinets are capable of resisting the
turning moment resulting from a 67m/s wind gust acting on half of the front or rear of the
cabinet surface, without damage to the mounting hardware.
Plinth mounted cabinets are capable of resisting the overturning moment resulting from a
wind gust of 67m/s perpendicular to the largest vertical surface.

Preventing condensation

Condensation might be a problem in case the cabinet is left unpacked overnight without
powering it up. In order to avoid condensation put drying agent next to the system and pull
a plastic bag over the cabinet. It is important to cover the roof (air outlet) and the air inlet
gills on the door.
The system is packed in a plastic bag at delivery. This bag can be wrapped around the
system. Only fresh drying agent should be put inside. Use tape and/or rubber bands to
tighten the plastic bag to the cabinet.

Adhesive tape

Drying agent

Figure 4 Cabinet wrapping.


10 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10
Mount the batteries on the shelf.

Lift and position the batteries on the shelf. Fit the inter-links between the batteries.
Do not terminate the battery cables yet.
Use lifting straps for heavy batteries; Refer to
the battery supplier’s manual for installation
instructions.

WARNING: The batteries represent a major energy hazard. To avoid short-


circuit of battery poles always remove metallic objects like un-insulated
Electric tools, rings, watches, etc. — from the vicinity of the batteries.
shock

Fixing point for temperature sensor

It is recommended to place the temperature sensor in the middle of the battery bank. Fix
the sensor with a cable tie to the inter-link between battery number 2 and 3.

Temperature
sensor

Figure 5. The temperature sensor fixed with a cable tie to the inter-link between
battery no. 2 and 3.

11 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


Electrical Installation

Installation Comments OK
To ease access to the DIN rail, located at the bottom of the MicroPower
1. PREPARATION
Outdoor Battery Cabinet, it is necessary to remove the factory
mounted battery shelf.
• Remove four PAN screws minding the nuts for square hole in rack.
• Pull the battery shelf out.
• Turn OFF the MicroPower system.
• Turn OFF the battery breaker. Note! This will disconnect 48V feed
to the load.

Cable entry is from bottom of cabinet. Remove the appropriate size


2. CABLE ENTRY
knock-outs to accommodate the supplied cable glands. Refer to
the section ‘Cable access for MicroPower Cabinet’ for an
overview of all knock-outs in the cabinet base.
• Put a flat screw driver between the 2 tags that support
the disc. Give the top of the screw driver a knock with a
hammer.
• Put the screw driver to the other side between the tags
and knock again. Start knocking cautiously and gradually
increase the force.
• Repeat the knocking until the tags are so fatigued that
the disc drops out.

12 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


Mount cable glands in the opened knock-outs.
3. CABLE GLANDS
• Pull the cables through the glands. All cables should be pulled
at least 10mm too far inside the cabinet and then be pulled the
same distance back again. This will lock the cable in the gland
and ensure full IP protection.

First prepare the connections in the MicroPower system.


4. CONNECTIONS IN
THE MICROPOWER
• Remove the End stop at the right hand side of the battery
OUTDOOR CABINET breaker (Fb1). Mount 1 of the 16sqrmm terminal blocks and
the End plate on the DIN bar. Lock the terminal block and End
plate in place with the End stop. The free cable labelled ‘Ext
Bat’ must have insulation removed and terminated into the top
of the terminal block. The 4th terminal block is only required is
optional BTS 2 load circuit breaker is fitted. Torque: 3.0Nm.
• Remove the End stop at the right hand side of the positive
terminal blocks. Also remove the End plate. Mount the
16sqrmm terminal block and the End plate on the DIN bar.
Connect the 4 position inter-link in the middle of the terminal
blocks. Cut off one position of the inter-link if there are only 3
terminal blocks present.
• Put the ceramic fuses into the 2.5sqrmm terminal blocks. Also
put the End plates on both 2.5sqrmm terminal blocks before
they are mounted on the DIN bar. Connect the 2 cables
prepared for these two terminal blocks. These cables are
labelled ‘Fext1 +Ve’ and ‘Fext2 –Ve’. Lock the new terminal
blocks with the End stop removed earlier.
t.
Ex

Lo
da

13 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


Connect cables to the battery cabinet.
5. CABLE
CONNECTIONS NOTE! These cables are not delivered with the system because the
length of these cables will vary from site to site.
Turn OFF the battery breaker(s) in the battery cabinet.
• Connect the ground cable to the green/yellow terminal block
(E) in the battery cabinet. Maximum earth cable cross sectional
area is 6sqrmm. Torque: 1.2Nm.
• Connect the battery cables from the terminal blocks in the
MicroPower system to the terminal block/battery fuse in the
battery cabinet. Maximum length is 10m. Maximum size is
16sqrmm. Torque: 3.0Nm at the terminal blocks and battery
fuse.
• Connect the DC supply cables from the MicroPower fused
terminals to the battery cabinet terminal blocks. Maximum
cable cross sectional area is 2.5sqrmm. Torque: 0.5Nm.

Batt.
t.
Ex

Lo
ad
CBI CBI CBI

60A 16A 60A


I I I

TRIP TRIP TRIP

0
+ -
0 0
CURVE U2 CURVE U2 CURVE U2

QY-1(13)-D QY-2(13)-D QY-1(13)-D

80V 80V 80V

- + + + + -
10 kA

E +
10 kA 10 kA

Fb1 F1 Fb1

Commissioning is performed from the MicroPower Outdoor


6. COMMISIONING
Cabinet. See the installation manual for this system.
When the MicroPower system has been powered up turn on the
battery breaker in the MicroPower Outdoor Battery Cabinet.
Verify that the batteries are being charged.

Carefully vacuum clean or remove any accumulation of dust or


7. MAINTENANCE
dirt. Especially notice to clean the grill in front of the filter mat.
See ‘Installation and maintenance instruction for filter mat in
MicroPower Cabinet’.

14 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


Cable access for MicroPower Cabinet

In the cabinet base there are several knock-outs for cables to the MicroPower Outdoor
Battery Cabinet. Below is an overview of all knock-outs and how to use them.

Cabinet rear

Cabinet front

Figure 6 View on inside of cabinet base

APPLICATION POWER CABINET BATTERY CABINET


AC input KNOCK-OUT E1, CABLE DIA 13.0 TO 20.0mm KNOCK-OUT J1, CABLE DIA 9.0 TO 16.0mm
FOR 3X4.0mmSQ OR 3X6.0mmSQ FOR 3X2.5mmSQ

BTS1 KNOCK-OUTS F4 & F5, CABLE DIA 6.0 TO ---


12.0mm

BTS2 KNOCK-OUTS F6 & F7, CABLE DIA 6.0 TO ---


12.0mm

BATTERY KNOCK-OUTS F2 & F3, CABLE DIA 6.0 TO KNOCK-OUTS F2 & F3, CABLE DIA 6.0 TO
12.0mm 12.0mm

ALARM KNOCK-OUT F8, CABLE DIA 6.0 TO 12.0mm ---

GROUND KNOCK-OUT F1, CABLE DIA 6.0 TO 12.0mm KNOCK-OUT F1, CABLE DIA 6.0 TO 12.0mm

DC CONTROL KNOCK-OUTS G1 & G2, CABLE DIA 2.0 TO KNOCK-OUTS G1 & G2, CABLE DIA 2.0 TO
6.0mm 6.0mm

SPARE KNOCK-OUTS E2 & E3, CABLE DIA 13.0 TO KNOCK-OUTS E2 & E3, CABLE DIA 13.0 TO
20.0mm 20.0mm

15 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


Schematic Diagram

+FAN

-FAN
Con 1

Con 4
Con 6

Figure 7. Schematic diagram of MicroPower Outdoor Battery Cabinet with all options
installed.

16 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


Installation and maintenance instruction for filter mat in MicroPower Cabinet

1. Open the front door of the cabinet by operating the swing handle.

Figure 8. Door with filter


2. Pull the filter mat out of the rectangular aperture at the inside of the front door.

Figure 9. Pull out the filter

3. Fit the filter mat into the aperture in the opposite way of item 2.

Figure 10. Fit the new filter

Please consider the right direction of the filter. The side with the higher density
(harder surface) is to fit towards the door side and is not visible to the user.

Wrinkled surface towards


the door.

Smooth surface visible


from inside of door.

Figure 11. Direction of filter.

17 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


Make sure that the grill in front of the filter is free from damage, carefully vacuum
clean or remove any accumulation of dust and dirt.

The filter should be replaced by a new one with same density and material quality (EU5
grade acc. to EN 779, Eltek part nr. 200892).
Under normal operational conditions (normal industrial pollution) we recommend to
change the filter on a yearly period.
Under ambient conditions with high pollution and near the coast we recommend to change
the filter twice a year or shorter.
The pollution of the filter can be detected by an increase of the internal cabinet
temperature without any failure of the fan or/and the change of the colour of the mat from
white to grey.

18 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


3 Alarm Relay Outputs and Signal Connections

The analog alarm interface board inside the MicroPower Outdoor Battery Cabinet is the
same as in the MicroPower system. However these 2 boards are separate alarm boards
monitoring and controlling each cabinet. The alarms in the battery cabinet are not the same
as in the system cabinet.
The alarm relays are operated in fail-safe, i.e. the relays are energized when there is no
alarm. If several external devices are going to the same digital input, they must be
connected in series.

The description below describes the pin out in normal state, i.e. the NO output is open in
normal operation and shorts to the COM output in the alarm-state.

Alarm relay specification

Nominal switching capacity 2A/30V DC


Maximum switching power 60W (resistive load)
Maximum switching voltage 220V DC
Maximum switching current 2A DC

1-15 alarm relays CON 4 16-19 Control relays

Figure 12. Alarm relay outputs


CON 4 Pin Assignments For Analog Controller board- Micro Power
Pin Signal Function Pin Signal Function
1 NO Relay 1: 10 NO Relay 4:
2 Com Low Voltage Alarm 11 Com Low Temp Alarm
3 NC 42±0,5Vdc 12 NC Below -5°C ±1-2°C
4 NO Relay 2: 13 NO Relay 5:
5 Com Not operating 14 Com Mains abnormal alarm (Only operating
when the ‘AC kit for Battery Cabinet
6 NC (Module Fail Alarm) 15 NC
Heater’ is installed)
Below 85Vac or above 300Vac
7 NO Relay 3: 16 NO Relay 6:
8 Com High Temp Alarm 17 Com Not operating (LVBD Control
9 NC Over 40°C ±1-2°C Disconnect at 39±0,5Vdc)
18 NO Relay 7:
19 Com Fan Control
Fan ON: +25°C ±1-2°C
Fan OFF: +18°C±1-2°C

19 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


About Fail-Safe Operation Mode

All Flatpack PSS alarm outputs use the Fail-Safe Operation Mode (relay coils energized
in the system’s normal operation mode). In order to implement fail-safe digital inputs
circuits, the external relay coil must be energized and the contact closed in the
system’s normal mode of operation.

Normal
Relay X NC +
(Energized coil) COM -
NO

Alarm
Relay X NC +
(De-energized coil) COM -
NO

Correct Use of Alarm Outputs (example)

Figure 13

Connections for Internal system wiring

Figure 14

CON 1 Pin Assignments CON 6 Pin Assignments


For Analog Controller board- MicroPower For Analog Controller board- MicroPower
Pin Signal Function Pin Signal Function
1 L AC Mains input Temperature Probe
2 N 1 + Red
2 - Blue
3 N Heater Control System Voltage input
4 L Heater ON: +5°C 3 + Red
Heater OFF: +15°C 4 - Blue

20 Installation Guide MicroPower Outdoor Battery Cabinet, Art 351432.033, v1-2005-10


Main Office:

Eltek Energy AS
P.O. Box 2340 Strømsø
N-3003 DRAMMEN
Norway
Phone: 47 32 20 32 00
Fax: 47 32 20 32 10
E-Mail: mailto:eltek@eltek.no
eltek@eltekenergy.com
Internet: www.eltekenergy.com