2008 12 18 retrofit a procedure rev 05

7/30/2019 2008 12 18 Retrofit a Procedure Rev 05

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Proprietary Information of: Title: Document No. Rev.

Retrofit A Procedure 045781 05

Type of Document: Rework Instruction ISO Std: 4.2.3 Department: PS Engineering Page 1 of 56

RETROFIT AFOR ACU AND HEX CABINETS

INTENDED FORAlcatel-LucentDescription

Alcatel-Lucent P/N Power-One P/N Power-One Description

PSU cabinet PO16 1AF11757AAAA 1-148306 PODS 16.48-8000 HEX VENT

PSU cabinet POB16 1AF11757AAAB 1-148306G PODS 16.48-8000 HEX VENT

PSU cabinet POB16A 1AF11757ABAB 1-154483G PODS 16.48-8000 ACU VENT

ACU Batt cabinetBCAB2

1AF14355AAAB 1-154484G BATT CAB ACU VENT

HEX Cabinet Air Conditioned Cabinet


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CONTENTS

1. Purpose 3

2. Definitions 3

3. Sequence of Actions 3

4. List of Items and relation to referenced documents 4

5. Action Lists 5

6. Maintenance 8

7. Detailed Action Lists 9

Ax.1 Preparation: AC off, breakers off 9Ax.2 Disconnect the Battery terminals and isolate the lug ends 9Ax.3 Remove the (Narada) batteries and their venting Kits 10Ax.4 Replace the dummy panels with the Lateral Filter Panels. 12Ax.5 Install the Modification Kits. 15Ax.6 Refurbishment and AC-DC cabling inspection 19Ax.7 Install the battery terminal protection covers 24Ax.8 2 warning labels in position 25Ax.9 Install the Fiamm Batteries 26Ax.10 Prepare and Install the Battery Ventilation Kits from Fiamm 28Ax.11 Install the Battery Temperature sensor 32Ax.12 Install 1 to 3 pcs of the 2.6m symmetry cables in the system cabinet 33Ax.13 Air con system: rewire the door alarm and the air conditioning alarms 34Ax.14 Commission the system 38Ax.15 Update the controller firmware and the software configuration 40Ax.16 Fill in and sign the Checklists, Store documentation and 45Ax.17 Stick the retrofit A label 45

Supplement A Software Configuration 46

Supplement B Battery Discharge Currents 53

Supplement C Check Lists 54


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1. Purpose

This retrofit A instruction is for the specific purpose as a guideline in modifying the above listed outdoor powersystems, either equipped with a Heat Exchanger or an Air Conditioner, in order to install all elements for theRetrofit A program that includes lateral filter panels, an updated configuration and supports up to 3 x FIAMMFFT160 battery strings inside the system cabinet.

There is no difference between the software, just that an Air Condition failure causes an Air condition alarmand 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.


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4. List of Items and relation to referenced documents


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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 toavoid 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 PROCEDURERetrofit A procedure A0: for well trained and experienced installers only

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.

A1.1 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..

A1.2 Disconnect the battery terminals and isolate the battery cable lug endsA1.3 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.A1.4 Replace the blind panels (with the drilled holes) by the Lateral Filter Panels.A1.5 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.A1.6 Refurbish, i.e. clean and inspect the cabinet. Check electrical connections and cabling.A1.7 Install the battery terminal protection covers.A1.8 Check if 2 warning labels are in position, otherwise stick warning labels to their intended position.A1.9 Install the Fiamm BatteriesA1.10 Prepare and install the Battery Ventilation Kits from Fiamm. See recommended tube lengthsA1.11 Install the Battery Temp sensorA1.12 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 cabinetA1.13 Air conditioning system: rewire the door alarm and the air conditioning alarmsA1.14 Commission the system (during this procedure the battery breakers will be switched on)A1.15 Update the controller firmware and the software configurationA1.16 Fill in and sign the checklists and put the documentation in the document holder and

A1.17 Stick the retrofit A label on top of or near the system type label


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PASSIVE PROCEDURES

Retrofit A procedure A1, Replace Narada Battery Strings

A1.1 Switch off all AC Power. Open the system cabinet (and/or Battery cabinet). Switch off the breakers.A1.2 Disconnect the battery terminals and isolate the battery cable lug ends.A1.3 Remove the Narada batteries and their venting Kits.A1.4 Replace the blind panels (with the drilled holes) by the Lateral Filter Panels.A1.5 Install the Modification Kits when not installed yet but installation of 3 Fiamm batteries needed.A1.6 Refurbish. For example, clean and inspect the cabinet. Check electrical connections and cabling .A1.7 Install the battery terminal protection covers.A1.8 Check if 2 warning labels are in position, otherwise stick warning labels to their intended position.A1.9 Install the Fiamm Batteries

Remark: cover the battery terminals of a string before inserting a sheet metal above that string.A1.10 Prepare and install the Battery Ventilation Kits from Fiamm. See recommended tube lengthsA1.11 Install the Battery Temp sensor, preferably on the second row of batteries.A1.12 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 cabinetA1.13 Air conditioning system: rewire the door alarm and the air conditioning alarmsA1.14 Commission the systemA1.15 Update the controller firmware and the software configurationA1.16 Fill in and sign the checklists and put the documentation in the document holder andA1.17 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 Switch off all AC Power. Open the system cabinet (and/or. Battery cabinet). Switch off the breakers.A2.2 Disconnect the battery terminals and isolate the battery cable ends, except for the bottom rowA2.3 Remove the Fiamm batteries except for the bottom rowA2.4 Replace the blind panels with holes by the Lateral Filter Panels.A2.5A2.6 Check electrical connections and cabling.A2.7 Install the battery terminal protection covers.A2.8 Check if 2 warning labels are in position, otherwise stick warning labels to their intended position.A2.9 Re-install the Fiamm batteries

Remark: cover the battery terminals of a string before inserting a sheet metal above that string.A2.10 Install the Battery Ventilation Kits from Fiamm. See the recommended tube lengths

A2.11 Install the Battery Temp sensor, preferably on the second row of batteries.A2.12 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 cabinetA2.13 Air conditioning system: rewire the door alarm and the air conditioning alarmsA2.14 Commission the systemA2.15 Update the controller firmware and the software configurationA2.16 Fill in and sign the checklists and put the documentation in the document holder andA2.17 Stick the retrofit A label on top of or near the system type label


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Initial condition: Fiamm venting Kits are already installed: Symmetry measurement tbd

A2.1 Switch off all AC Power. Open the system cabinet (and/or Battery cabinet). Switch off the breakers.A2.2 Disconnect the battery terminals and isolate the battery cable ends except for the bottom row.A2.3 Remove the Fiamm batteries, except for the bottom row.A2.4 Replace the blind panels with holes by the Lateral Filter PanelsA2.5A2.6 Check electrical connections and cabling.A2.7 Install the battery terminal protection covers.A2.8 Check if 2 warning labels are in position, otherwise stick warning labels to their intended positionA2.9 Re-install the Fiamm batteries.

Remark: cover the battery terminals of a string before inserting a sheet metal above that string.A2.10 Replace the straight tube connections between blocks by 18cm connections

A2.11 Install the Battery Temp sensor, preferably on the second row of batteries.A2.12 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 cabinetA2.13 Air conditioning system: rewire the door alarm and the air conditioning alarmsA2.14 Commission the systemA2.15 Update the controller firmware and the software configurationA2.16 Fill in and sign the checklists and put the documentation in the document holder andA2.17 Stick the retrofit A label on top of or near the system type label

Retrofit A procedure A3, Warehouse upgrades

A3.1 Switch off all AC Power. Open the system cabinet (evt. Battery cabinet). Switch off the breakers.A3.2A3.3A3.4 Replace the blind panels with holes by the lateral filter panelsA3.5A3.6 Check electrical connections and cabling.A3.7 Install the battery terminal protection covers.A3.8 Check if 2 warning labels are in position, otherwise stick warning labels to their intended position.A3.9A3.10A3.11 Check if the Battery Temp sensor is present inside the cabinet.A3.12 Add 1 piece of the 2.6m symmetry cables into the system cabinetA3.13 Air conditioning system: rewire the door alarm and the air conditioning alarmsA3.14 Commission the system

A3.15 Update the controller firmware and the software configurationA3.16 Fill in and sign the checklists and put the documentation in the document holder andA3.17 Stick the retrofit A label on top of or near the system type label

Internal Battery cable KitsA4.12 Add 1 piece of the 2.6m symmetry cables to the cable Kit

External Battery cable KitsA5.12 Add 1 piece of the 5 m symmetry cables in the external cable Kit


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6. MAINTENANCE

Documentation: Instruction manual 043527, Battery maintenance or supplier engineering manualInstruction 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 intemperature, water, dust, sand penetration, lightning protection devices etc. And if all screws still are tightened wellenough especially for installed cables. Recommended is do a first site / battery inspection after 2-3 months, then aftera 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.


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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 individualaction 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 someexperience.

Retrofit A procedure Ax.

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

1. Switch off all AC Power2. Open the system cabinet (evt. Battery Cabinet).3. Switch off all breakers, including battery breakers.

Warning!

IT IS STRONGLY RECOMMENDED TO TURN OFF THE AC MAINS AND BATTERYCIRCUIT BREAKERS TO THE POWER SYSTEM BEFORE PERFORMING THISINSTALLATION.

Live procedure (for trained and experienced installers only)L1 AC Power ON (external switch board),L2 Open the system cabinet (evt. Battery Cabinet).L3 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 Socket wrench set, insulated, various sizes;l Screwdriver set, cross, insulated.

Procedure:1. Disconnect the positive + cable to the positive pole of the battery string..2. Detach plastic pole protection caps to all battery poles.3. Disconnect the negative - cable to the negative pole of the battery string. Isolate the end e.g. with tape.4. Repeat steps 1 to 3 to disconnect battery cables for other battery branches in combination with the removal

of the battery (next section)


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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 ofeach battery respectively.

ii) Disconnect the ventilation assembly firmly to the ventilation tube from the cable entry.

iii) Uninstall these shorter ventilation tubes from each end of the three-way plug;iv) Uninstall the stopple to the left end of the leftmost three-way plug.


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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 circuitwith a live part (isolate live parts with tape or whatsoever).


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Ax.4 Replace the dummy panels (with/without drilled holes) with the LateralFilter Panels.

Part List:

l Plate;l Cover of air filterl Air filter box

Tools:

l Socket wrench set, insulated, various sizes;l Screwdriver set, cross, insulated.

Procedure:

1. Loosen and remove the nut and washer on the top of the lifting brackets to remove the lifting brackets fromthe bolt.

2. Unlock the cabinet top lid by turning the lock handle clockwise.

3. Lift the lid carefully and keep it in position using the lid support on the right side.4. 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 filterbox.


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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; twoM4 screws to another two screw holes to fix it.


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8. Follow the steps 5 to 7) to install another Lateral Filter Kit on the left side of the cabinet.


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Ax.5 Install the Modification Kits.

REWORK INSTRUCTION TO FIT 3 X FIAMMFFT160 BATTERY STRINGS

FOR

Alcatel-LucentDescription

Alcatel-LucentP/N

Power-OneP/N

Power-OneDescription

PPRD and Air GuideBattery ShelfSpacing

Kit required for3 x FFT160

PSU cabinetPO16

1AF11757AAAA 1-148306PODS 16.48-8000 HEX

Move PPRD to topposition and install airguide (HEX)

New Battery shelf tofit 3 x FFT160

1-155854-G

PSU cabinetPOB16

1AF11757AAAB 1-148306GPODS 16.48-8000 HEX

Move PPRD to topposition and install air

guide (HEX)


1-155854-G

PSU cabinetPO16A

1AF11757ABAA 1-151258GPODS 1364Alcatel ACU

PPRD in top position,no change (Never

Shipped)


1-155865-G

PSU cabinetPOB16A (with

Air con)

1AF11757ABAB 1-154483GPODS 16.48-8000 ACU

PPRD in top position,no change


1-155865-G

PSU cabinetPO16A cab

battery with air-con

1AF14355AAAB 1-154484GPODS 1364ACU Battery

N/A, no PPRD

No new shelfrequired, ensure

shelves are at 8Upitch

None

Purpose:

This rework instruction is for the specific purpose to modifying the above outdoor power systems in orderto be able to install 3 x FIAMM FFT160 battery strings. The use of this instruction requires an upgrade kit (Power-One part number 1-155854-G, and 1-155865-G) which includes the parts indicated below.

Parts List

1 -155854-G:

1 x new battery shelf1 x new air guide assembly8 x M6 screw8 x M5 screw

1 -155865-G:1 x new battery shelf8 x M6 screw


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Tool ListThe 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 batterystrings were taken out.

1. If the 4U power shelf is not installed in the upper most rack unit position, then move the shelf up 1U to thetop position. Check that all attached cables have enough slack in order to move the shelf. Remove themounting screws and carefully move the shelf to the top mounting position. Re-install the mounting screws.

2. 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 batteryshelf (the position can be confirmed as 2 screw holes will be visible immediately above the shelf instead of 1as seen on the bottom and middle shelf.Fasten the battery shelf with four M6 screws by torque 6Nm.


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4. Remove the cable tie bar on rear wall inside cabinet (See figure below).

Metal piece to be discarded for battery fitting

5. 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.

Battery Shelf

M6 Screw


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Air GuideSubassembly

M5 Screw


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Ax.6 Refurbishment and AC-DC cabling inspection

Purposel To clean the outdoor cabinets following the pacification and temporarily degraded IP rating of the

cabinet.l Inspection of cabling

Tools:l Vacuum cleanerl Cloth and detergent for cleaning metal surfacesl Power-One Lateral Ventilation Kit (Power-One part number 1-156613-G)l Standard set of screwdrivers

Safety Alerts!The use of Valve Regulated Lead Acid (VRLA) batteries means high energies inside thecabinet. Be aware and avoid any possible short circuit.

When doing the live procedure special attention must be made for the cleaning procedure

Procedure:

1. Have the cabinet door and top lid open for access.2. Remove any temporary ventilated panel(s) previously mounted according to procedure 3BK 17442 0004

RJZZA Revision 01a.3. Clean the area around the left and right panel openings.4. Inspect the cleanness of the Power-One lateral ventilation kit according to the installation procedure

delivered with the kit.

5. Clean distribution front panels using the cloth, then remove the front panels6. Use the vacuum cleaner to remove dust or other objects from the distribution.


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WARNING! Metal parts should not be entered into the distribution. Use a brush tip with plastic housing on thevacuum cleaner and proceed with care.WARNING!Avoid bodily contact with distribution bus bars and cabling.

7. Remove one rectifier and wait until it has shut down (fan will stop and LED will die out).8. 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: Vacuumcleaner around fans, thenuse cloth to thoroughly

clean the surface.

Clean all parts of the

distribution.


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9. Use the cloth to clean the rectifier backplane surfaces that are revealed when the rectifier is being removed.

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 aredundancy of 1 rectifier in the system. Verify how many rectifiers can be taken out maximally withoutendangering the BTS operation. Do not go beyond this amount. For the passive procedure it does notmatter.

Rectifier Rear: Gentle use of vacuum

cleaner to release dust from internal

components and connector. Use drycloth to clean rear, top and sides are

cleaned with a wet cloth.

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.


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WARNING! Metal parts should not be entered into the rectifier backplane. Use a brush tip with plastichousing on the vacuum cleaner and proceed with care.

WARNING!Avoid bodily contact with rectifier backplane.

12. Repeat steps 7 - 11 for each rectifier (one by one). Also perform the same operation for rectifier positionswith 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 thevacuum cleaner and then using the

cloth.

Rectifier backplane area behindrectifier to be cleaned.

Note: Shown here with three

rectifiers removed, rectifiers should

be removed one by one.


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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 topare removed and replaced for degassing reason, opportunity shall be taken to check whether all the ACharness contacts are equally plugged on backplane. A mirror helping visual access may be needed. Nofurther 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 ascrewdriver.

17. It can be refrained from manual check of connector retention in backplane. However, when any damageoccur during AC/DC service life, e.g. backplane connector loosen by unplugging a rectifier (connector comesout with rectifier) entire shelf must be replaced

Pull out the controller to access therear. Gently use the vacuum cleaneron the internal components and

connector. Clean the cover using the

cloth.


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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 innersheet metals so both negative battery terminal and cable lug can not touch the cabinet thus avoid a short circuitof 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 thecabinet and verified with the dimension of the battery. The battery negative terminal lies at the middleof the Battery Terminal Protection Cover would be better.

2. Fix the Battery Terminal Protection Cover with two M6 screws.


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Ax.8 2 Warning labels in positionIf 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 theleft 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.


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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 ofthe system can be ordered according to your requirements.

The battery cables are connected to the systems battery circuit breakers at delivery. The + cable isconnected 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 wheneveravailable by the lifting handles.

Never apply force to, or drop anything on the terminal posts: doing so the threadsor the sealing of the terminal posts may be damaged.

WARNING: Improper handling of batteries can result in the batteries short-circuiting, which can result in serious injury due to high energy levels. Operationto the battery must be restricted to qualified personnel only.

WARNING: Ensure that the battery circuit breakers are off.

1. Measure the individual battery blocks: Well charged Fiamm FFT/UMTB blocks will show ca.12.75V DC2. Advice: access and installation of batteries is easiest when the shelves above the strings are removed

3. Place battery blocks on the battery shelf. The batteries should be handled and installed always according tothe battery manufacturers recommendations.

4. It is strongly advised to keep an equal distance between battery blocks of 5 mm -15 mm for properventilation.

5. Prepare and Install the battery ventilation Kit. See section Ax.106. 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 thepositive + cable to the positive pole of the battery string. Tighten the connection to 5 Nm -6 Nm. Attachplastic pole protection caps to all battery poles.

Warning: the battery cables do have 90degr lugs7. 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.119. 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 sectionAx.12


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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 turnthe special clamp of 90 to connect endcable on the longer side of the battery.


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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 beforeventilation kits are installed on all battery strings.

Part List:l 1 x single inlet plug with O-Ring seall 3 x double inlets plug with O-Ring seall 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 stringl 1.7 m for the middle battery string (if installed)l 2.1 m for the top battery string (if installed)

2. 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 Cut an appropriately sized hole in the nipple to accommodate the ventilation tube.

l Push the ventilation tube(s) through the hole in the rubber nipple from the inside to the outside. Leavesufficient length of tubing outside the cabinet to prevent the tube from sliding back into the cabinet.

l Assemble the rest of the nipples and ventilation tubes if needed.


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3. Install the nipples to the cable entry panel respectively.4. 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.5. 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, andl 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 (recommended18 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 bethe one with a blocked end in default.

CAUTION: Make sure the ventilation tubes are not obstructed, bent, blocked ordamaged during installation.


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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 theventilation 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 stringinto the cabinet and install the venting Kit as described before.


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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 thecontroller. The controller will adjust the float charge voltage according to the input temperature and thepreset 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 middleof the upper of the first two rows of battery strings on top of a battery block.


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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 MIDIbattery cabinet.

There are 4 inputs available for symmetry measurement. An example of the symmetry cable routing forthe first, lowest positioned, string is shown in the figure below. See for the connections the section forthe battery temperature sensor.

Follow the steps below to connect the symmetry cable with the battery.

1. Make sure the inter block connections between batteries are attached. See section Ax.9

2. Insert the separately supplied metal lug into the end of symmetry cable.3. 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 isnormally delivered with the battery cable kit option for additional battery strings. Connect the symmetrysignal (1 wire) to the controller interconnection board as per previous section. Route the cable to thebattery string using the pre-mounted symmetry cable as reference, and fasten the cable to the batteryblock as described above.


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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. The alarm wire Power Cabinet Door Switch Alarm is connected to J5-2 on the internal alarm interface boardd. The alarm wire Battery Cabinet Door Alarm is connected to J2-1 on the external alarm interface

Original wiring situation


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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.


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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. (insulatethe 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 installerhas several options to go with.

Door alarms, updatec. The Power Cabinet Door Switch Alarm remains unchanged and connected to J5-2, prewiredd. 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 followingdrawing).

In the updated, new configuration up to four (4) Symmetry connections are available. The firmware and configuration filesfor 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 Cabinetb. Battery String 5 can not have a symmetry cable installed


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The green wire in the cable connection to the BATT cabinet is the alarm wire BATT Cabinet ACU AlarmThe 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:


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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 ACvoltage on the AC terminal block, between phases and neutral. The correct value is approximately 230 V. Ifthe 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 powersystem and/or telecom cabinets and systems, so that no accidents can occur when switching on the electricalpower. Verify that no shorts can be made in any of the cabinets. Passive procedure only: Do not switch onin 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 thatall 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). Placethe positive lead of the meter to the positive bus bar, with the PE yellow green cable connected to, and thenegative 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 ensurethat the ventilation tubes are properly guided out of the cabinet for all batteries. The tubes should not be bentor 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 thecommissioning 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 fastenthe rectifiers again. The rectifiers will turn on automatically.


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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 ifvalue 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 ofinstruction 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 andamounts/year and temperature compensation factor.

22. Check if the displayed temperature on the PCC menu (Show data >Temperature: xx C) is in accordance withthe current environment temperature. To test the temperature probe and temperature compensation, rub theprobe element with the fingers to heat it up. Verify that the temperature measurement rises and that the DCoutput 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 loadcurrent, 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 thedatasheets from the battery manufacturer,

and compared to BTS load currents.

26. If any alarm occurs, it should be reset in accordance with Show alarmsin product description controller ofinstruction manual.

27. At the end of the procedure the system should be without alarms. Disconnect the tape and the door switch willcause 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: whena local project manager decides to make any changes like paralleling alarms, this must be well documentedand signed for including name and date of the person in charge of this.


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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 fordoing 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 customersite, document number: 041935. In the electronical version of the retrofit A procedure, this file is attachedunderneath:

PCSBurn1.09_setup.zip

PCC_114.zip (329KB)

041935.pdf (276KB)

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.


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Ax.15.2 Update the software configuration.

1 Preparation1.1 Ensure the PCG files from Appendix B are available on your computer so that they can be used to

update the controller1.2 Ensure the PowCom version 3.2 or higher is installed on your computer. If not, use the following

procedure:

a) Go to h t tp : / / www.power -one.com/ produc ts/ so f tware_down load .htm l ,

1-150197.zipC-220041 1-154303

for 1-148306...C-220041 1-154304

for 1-148306...

b) Select the Soft ware Download l ink.

c) Fol low t he instruct io ns and use t he login and p assword provided below to access the sof twarefor download.login: P1powcompassword: 83w1ldcats

d) Start PowCom

e) Go to Comm unicat ion| Propert ies in the me nu.

f ) Click on th e l icense t ab in t he Propert ies window. Copy and paste the f ol low ing l icense number

(1560-0C32-3CDC-23F5-0E8F) and cli ck on t he Act ivat e License but to n.Powcom Password is: 1234License level shall be 30

g) Exit the program and restart i t again in order t o ful ly act ivat e the l icense.

2 Connecting to the controller.

2.1 Run PowCom.2.2 Connect to the controller via RS232 communication port by password 1234 (4321).2.3 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.
http://www.power-one.com/products/software_download.htmlhttp://www.power-one.com/products/software_download.html


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3 Upload file to the controller.3.1 Click Update configuration from menu Utilities.

3.2 The following window will then be presented


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3.3 Click Select update fileto select PCG file, C-220041 for HEX and C-220044 for ACU click yesin thepop windows as following.

3.4 Click Transfer data to controllerto update PCG to the controller as following.

3.5 A processing bar will appear after click Transfer data to controller, please waiting for updatingcompletion.

3.6 Following window will appear after updating completion.


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3.7 Click closeto close this window; a pop window will appear.

3.8 Click ok to close this windows, update is successful.


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Ax.16 Fill in and sign the Checklists, Store documentation and

Ax.17 Stick the retrofit A label

Purpose:Verification that all works have completed and what has been doneBring documentation in a safe position where it can be found

Show that existing systems have been upgraded

Part List:

Label drawing

retrof it A completionlabel.pdf

Tools:

None

Procedure:

1. After successful commissioning

2. Fill in and sign the checklists for installation and commissioning (see attachment B),3. Put the documentation in the document holder and4. Stick the retrofit A label on top of or near the system type label5. Clean the site

retrofit A completed as per ECO S41264 1-148306G rev AI

Text : font:Arial , 10pt, bold, width factor: 1

80

Or general applicable also for ACU systems: print locally and stick near type label:


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Supplement A Software Configuration


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Supplement B Battery Discharge Currents


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Supplement C Check Lists

SITE NAME .SITE ADDRESS .SYSTEM SERIAL NO .

INSTALLATION:

NAME: .DATE: .SIGNATURE: .

ITEM DESCRIPTION NO OK NOK

1 RACK POSITION OK; LEVELING OK ETC

2 MAINS POWER SWITCHED OFF3 BATT CABLE ENDS ISOLATED / TAPED

4 DC BREAKERS SWITCHED OFF

5 REFURBISHMENT - CLEANING6 VERIFICATION OF AC / DC CONNECTIONS

7 LATERAL FILTERS PANELS INSTALLED

8 MODIFICATION KITS: 3 FIAMM BATTSTRINGS POSSIBLE

9 NO OF BATTERY STRINGS INSTALLED 1 2 3

10 FIAMM INSTALLED11 BATTERY PROTECTION COVERS 1 2 3

12 WARNING LABELS IN POSITION 1 2

13 VENTILATION KITS INSTALLED 1 2 314 BATT SYMMETRY CABLES INSTALLED 1 2 3 4

15 BATT SYMMETRY WIRES IN CORRECTPOSITION ONTO ALARM BOARD J1

1 2 3 4

16 BATT TEMPERATURE SENSOR INSTALLED17 ALARM CABLES CABLED INTO BTS 1 2 3 4

18 DC LOAD CABLES L+L- CABLED INTO BTS


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SITE NAME .SITE ADDRESS .SYSTEM SERIAL NO .PCC SERIAL NO .

ELECTRICAL:

NAME: .DATE: .SIGNATURE: .

Rectifier amount:

FMP16.48

2 other: Rectifier amount: 1 2 3 4 5

Battery type: FFT105 FFT130 FFT160 UMTB160

Amount of strings: 1 2 3 4

ITEM DESCRIPTION STATEVALUES

OK NOK

1 PE FPE CONNECTED:2 BREAKERS OFF

3 MAINS VOLTAGE LEVEL: V

4 SWITCH ON MAIN BREAKER5 RECTIFIERS 1 2 3 4 5

6 BATTERY POLARITY7 BATTERY STRING VOLTAGES: V8 BATTERY BREAKER ON

9 LVD10 FIRMWARE UPLOAD

11 PARAMETER, CONFIGURATION UPLOAD

12 FLOAT VOLTAGE LEVEL U1 V13 VERIFY SETTINGS

BATT CURRENT LIMIT VALUETEMP COMPENSATION FACTORSYMMETRY LEVEL

AV/10K

V14 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 ..Min19 BATTERY DISCHARGE END VOLTAGE V

20 BATTERY MINIMUM VOLTAGE DURING TEST V

21 ALARMS TESTED22 ALARMS ARRIVAL TO BTS TESTED 1 2 3 4

23 DC LOADS POWERED UP and WORKING

24 PULL OUT CONTROLLER: FLOAT VOLTAGE V25 RE-INSERT CONTROLLER: FLOAT VOLTAGE V

26 DC LOAD CURRENT OF BTS A

27 RETROFIT A LABEL


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2008 12 18 retrofit a procedure rev 05

Documents