Alcatel Lucent USA ONEBTS-11 UMTS-CDMA Transceiver System (850) User Manual 401703454i1

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Finishing the installation
............................................................................................................................................................................
Insert one end of the jumper cable through the applicable opening in the
antenna cable cover.
............................................................................................................................................................................
Connect the RF antenna jumper cable to the applicable connector on the
Modular Cell 4.0B primary or 4.0B dual band cabinet. Refer to the
figure below.
GPS
S3D1
S3D0
S2D1
S2D0
S1D1
S1D0
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Finishing the installation
............................................................................................................................................................................
Slide the boot towards the cabinet and install it into the opening on the
antenna cover. Refer to the figure below.
............................................................................................................................................................................
Turn the boot so that the split is at the bottom of the cable.
............................................................................................................................................................................
Ensure that the lip of the boot is fully seated in the antenna cable cover.
............................................................................................................................................................................
Tape the small end of the boot as shown in the figure below.
Cable Boot
RF Antenna Cable
Connector
Tape Here
SIDE VIEW
............................................................................................................................................................................
10
Repeat Steps 2 through 9 for all antenna jumper cables.
............................................................................................................................................................................
11
Torque the antenna jumper cable connections to 221 in.-lb. (25 Nm).
Refer to Step 11 on Page 7 - 11 for the correct method
............................................................................................................................................................................
12
Replace the top panel on the antenna cable cover. Torque the tamperproof screws to 15-20 in.-lb. (1.7 - 2.3 Nm).
END OF STEPS
.............................................................................................................................................................................
...........................................................................................................................................................................................................................................................
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Finishing the installation
Connect RF antenna
jumper cables to the
antenna cables
Use the following procedure to terminate and connect the RF antenna
jumper cables to the applicable antenna cables.
............................................................................................................................................................................
Route the RF antenna jumper cables from the Modular Cell 4.0B
primary or 4.0B dual band cabinet to the RF antenna connections.
............................................................................................................................................................................
Connect the RF antenna cable to the applicable RF antenna connection
at the surge suppressor.
DRIP LOOP
RF & GPS
SURGE PROTECTORS
ANTENNA JUMPER
CABLE SUPPORT STRUCTURE
ICE BRIDGE
(IF REQUIRED)
WATER PROOFING
(OPTIONAL)
RUBBER
BOOT (LUCENT
PROVIDED)
4-FOOT COAXIAL ANTENNA
JUMPER CABLES (1/2 - INCH)
(LUCENT SUPPLIED)
ANTENNA & GPS
CABLES
#6AWG STRANDED INSULATED
GROUND WIRE TO MAIN GROUND BUS
MODULAR CELL
CABINET
MAIN GROUND BUS
REAR HEAT
EXCHANGER
(If applicable)
THESE PARTS NOT PRESENT ON
DUAL BAND CABINETS
(2) #2 AWG BARE
SOLID TINNED COPPER
WIRE TO GROUND ELECTRODE
SYSTEM
CONCRETE PAD
FINISHED GRADE
Important! For a profile view of the sound muffler, refer to
Chapter 1, Modular Cell 4.0B cabinet side view 1 on Page 1 - 26. For
alternate cable routings refer to Chapter 1, Modular Cell 4.0B cabinet
side view 2 on Page 1 - 27.
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Finishing the installation
Important! When connecting/disconnecting a Lucent RF
coaxial jumper cable assembly to/from any 7-16 DIN female
receptacle connector at the antenna, it is highly recommended that
the cable assembly be connected/disconnected as shown in the
figure above. Please note that the mating receptacle connector
requires a wrench for support to hold it in place. Wrenches for
connecting/disconnecting the mating RF coaxial jumper cable's 716 DIN male plug, which is equipped with a rotating coupling nut,
are required.
............................................................................................................................................................................
Torque the antenna jumper cable connections at the antenna connection
to 221 in.-lb. (25 Nm) using the method shown in the figure below.
...........................................................................................................................................................................................................................................................
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Finishing the installation
............................................................................................................................................................................
Repeat Steps 1 through 3 for all RF antenna jumper cables.
MODULAR CELL
4.0B PRIMARY OR
4.0B DUAL BAND
CABINET
TERMINAL BLOCK NOT PRESENT
ON CABINETS WITH INTEGRATED
POWER. THREE OR SIX FEED
THROUGH CORD GRIP SEALS,
DEPENDING UPON THE CABINET
THESE PARTS NOT
PRESENT ON
DUAL BAND CABINETS
Important! Antenna jumper cables must be tested. Refer to
Lucent Technologies Installation Engineering Handbook, 238,
Indoor Installation Antenna Testing (Reference).
Important! Before system operation, the RF antenna cable
sections must be tested, and the power output of the amplifiers
must be adjusted. Those tasks are a part of system test and
integration.
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Finishing the installation
Replace / close all access
panels and doors
Use the following procedure to replace or close all access panels and
doors.
............................................................................................................................................................................
Verify that the EFIT and HPDA are closed and secured.
............................................................................................................................................................................
Inspect for and remove all tools, materials, and parts.
............................................................................................................................................................................
Check that the cabinet lifting eye bolts have been removed and that the
top solar shield has been installed.
Important!
If not, refer to Chapter 2 for specific instructions.
............................................................................................................................................................................
Verify that all power connections are installed and secure.
Important! Skip the next step if installing a primary cabinet
only.
............................................................................................................................................................................
Verify that all RF connections between the Modular Cell 4.0B primary
cabinet and the Modular Cell 4.0B dual band cabinet are installed and
secure.
Important! When performing the next step, the door must be
properly aligned. If not, refer to Chapter 2 to re-level the cabinet
and/or adjust the door.
............................................................................................................................................................................
Close and secure the cabinet door and panels.
Important! Do not replace any panels or close the door if
installing a battery cabinet at this time, since DC and AC cables
remain to be attached. Do not replace any panels if using external
power, since DC and AC cables remain to be attached.
............................................................................................................................................................................
Turn the appropriate main panel circuit breakers ON.
END OF STEPS
.............................................................................................................................................................................
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Finishing the installation
How to finish the installation of a first or second WNG24-BC battery
cabinet
.............................................................................................................................................................................................................................................................
Finish the installation of
the first or second WNG24BC battery cabinet
Following installation of a WNG24-BC battery cabinet, the system
should be tested before being put into operation. System test
procedures are not covered in this installation document. Information
concerning system test and integration is contained in Lucent
Technologies Installation Engineering Handbook, 238.
Use the following procedure to finish the installation.
............................................................................................................................................................................
Verify that the AC, DC, alarm and grounding connections in the primary
and battery cabinets are installed and secure.
............................................................................................................................................................................
Verify all battery hardware and connections are installed and secure.
............................................................................................................................................................................
Inspect for, and remove all tools, packing and installation materials, and
parts from the battery and primary cabinets.
............................................................................................................................................................................
Check that all unused battery cables, if applicable, are properly wrapped
and stored on an unpopulated shelf in the battery cabinet.
............................................................................................................................................................................
Check that the cabinet lifting eye bolts have been removed and replaced
with the supplied replacement bolts. If not, refer to Chapter 2 for
specific instructions.
............................................................................................................................................................................
Ensure that the circuit breaker "BATTERY HEATER" in the primary
cabinet, is in the ON position
Important! When performing the next step, the doors must be
properly aligned. If not, refer to Chapter 2 to re-level the cabinet
and/or adjust the doors.
............................................................................................................................................................................
Replace or close all access panels and doors of both cabinets.
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Finishing the installation
...........................................................................................................................................................................................................................................................
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Appendix A: EZBFo battery frame
installation with Modular Cell 4.0B
cabinets (with integrated power)
Overview
.............................................................................................................................................................................................................................................................
Purpose
This appendix provides instructions for installing the Lucent
Technologies EZBFo battery modules with an outdoor Modular Cell
4.0B cabinet that has integrated power.
The procedures provided in this Appendix are for right side EZBFo
installation with 4.0B primary cabinets. When EZBFo frames are being
installed with a 4.0B dual band cabinet, the frames are installed on the
left side of the cabinet. The procedures are all the same except for the
routing direction of the cables. Cable routing inside of the dual band
cabinet is provided.
Contents
This appendix contains the following sections.
Introduction
A-2
How to perform placement, anchor, and prewire procedures for installation of the first or
second EZBFo battery base modules
A-8
How to identify and route the cables from the Modular Cell cabinet to the first EZBFo
battery base module
A - 36
How to route and connect the cables in the first EZBFo battery base module
A - 47
How to identify, route and connect the first EZBFo battery base module cables in the
Modular Cell 4.0B cabinet
A - 64
How to install an EZBFo battery add-on module on an existing EZBFo battery module
A - 76
How to install a second EZBFo battery base module
A - 101
How to install the batteries in the EZBFo battery modules
A - 124
How to make final DC connections
A - 140
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A- 1
Introduction
Overview
.............................................................................................................................................................................................................................................................
Purpose
This module provides definitions and an overview description of the
EZBFo battery modules, as well as its inputs and outputs. Also
provided are general safety instructions
Contents
The following modules are provided in this section:
EZBFo Definitions
A-3
EZBFo battery frame description
A-4
EZBFo battery frame footprint with Modular Cell 4.0B primary
and dual band cabinets
A-5
EZBFo battery frame inputs and outputs
A-6
Safety instructions
A-7
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EZBFo
Definitions
.............................................................................................................................................................................................................................................................
Definitions
Refer to the figure on Page D -4.
Battery Module: The entire assembly consisting of the Battery
Module Inner Frame and the Battery Module Outer Frame.
Battery Module Inner Frame: The inside frame containing two
battery shelves
Battery Module Outer Frame: The outside frame including a front
panel (and a top panel if it is a Battery Base Module.
Battery Base Module: The initial (bottom) Battery Module installed.
Includes a top panel to be moved up as Battery Add-On Modules are
added above it. It provides all interface connections to the Modular Cell
Cabinet
Battery Add-On Module: The same as a Battery Module but shipped
without a top cover. Two may be added to a Battery Base Module for a
total of three Battery Modules depending upon seismic zone
Battery Shelf: A shelf on which the batteries are installed. The
Battery Base Module and the Add-On Battery Module both contain
two battery shelves. The batteries on these two shelves are configured
as follows:
•
With four L1-100Ah-12VDC batteries per shelf: Two 12VDC
batteries are connected in series to provide two 24VDC strings per
shelf, four strings per module, and up to twelve strings per frame.
Individual shelves may be populated
•
With three 12IR125 batteries per shelf: Each of the two shelves is
populated with three 12VDC batteries connected in parallel. to
provide two 12VDC shelves. The two shelves connected in series
to provide a 24VDC module. Both shelves must be populated.
Battery Frame: The assembly of the Battery Base Module and one
or two Add-On Battery Modules. There may be two battery frames,
referred to as the “First” or “Second” Battery Frames. The second
EZBFo battery frame provides all interface connections to the first
Battery Frame.
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EZBFo
battery frame description
.............................................................................................................................................................................................................................................................
Description
The EZBFo battery frame is designed to meet the power backup
requirements of the outdoor Modular Cell 4.0B cabinets that has
integrated power.
Each of the two possible battery frames has a battery base module and
up to two battery add-on modules. Each module has two battery
shelves. Module access is gained by removing the front panel of each
individual module. Each base module contains termination points for
load and return circuits (+24V DC load and 24V Return), as well as
various alarms, from the Modular Cell 4.0B cabinet. AC heater pads
are added to each battery shelf. Batteries are shipped separately and
will be installed later in this Appendix.
Important! Battery module growth may be vertical (with add-on
modules) or horizontal (with base modules). EZBFo frames are
installed on the left side of 4.0B Dual Band cabinets.
MODULAR CELL 4.0B
PRIMARY CABINET**
EZBFo BATTERY
FRAME #1
EZBFo BATTERY
FRAME #2
ADD-ON
BATTERY
MODULE #2*
(3rd Module)
ADD-ON
BATTERY
MODULE #2*
(6th Module)
ADD-ON
BATTERY
MODULE #1
(2nd Module)
ADD-ON
BATTERY
MODULE #1
(5th Module)
BATTERY
BASE
MODULE #1
(1st Module)
BATTERY
BASE
MODULE #2
(4th Module)
IMPORTANT:
* Only one add-on module may currently be installed in Seismic Zone 4
** For 4.0 Dual Band cabinets, the EZBFo frames are installed on the left side
of the cabinet
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EZBFo battery frame footprint with Modular Cell 4.0B primary and
dual
band cabinets
.............................................................................................................................................................................................................................................................
Description
The EZBFo battery frames on the right side (viewed from the front) of
the 4.0B primary cabinet support the primary cabinet only. WNG
battery cabinets (Chapter 4) may alternately be used to support the
primary cabinet. The EZBFo battery frames on the left side of the 4.0B
dual band cabinet support the 4.0B dual band cabinet only. WNG
battery cabinets are not available to support the 4.0B dual band cabinet.
2” conduit assembly
for AC power to
4.0B dual band
cabinet
Junction box
for AC power to
4.0B dual band
cabinet
2” conduit assembly for
AC power (TYP) in lower
position
2” conduit assembly for
T1/E1 and User Alarms
(TYP) in upperposition
914.4 (36.0) Min.
for service access
EZBFo
BATTERY
FRAME 2
EZBFo
BATTERY
FRAME 1
EZBFo
BATTERY
FRAME 1
EZBFo
BATTERY
FRAME 2
813
(32.0)
1016
(72.0)
FUTURE OFFERING
900.3 (35.44) Min.
for service access
EXAMPLE 1:
CABINET 1 = 850 Primary
CABINET 2 = PCS Dual Band
304.6 (11.99)
for concrete
pad
914.4 (36.0) for
rooftop
EXAMPLE 2:
CABINET 1 = PCS Primary
CABINET 2 = 850 Dual Band
304.6 (11.99)
for concrete
pad
914.4 (36.0) for
rooftop
CABINET
CABINET
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A- 5
EZBFo
battery frame inputs and outputs
.............................................................................................................................................................................................................................................................
Outputs
The EZBFo battery frame provides the following inputs from, and
outputs to, the Modular Cell 4.0B cabinet:
•
+24 VDC battery backup output to the Modular Cell cabinet
•
+24 VDC battery charge input to the first battery base module
•
Battery thermal probe signal output to the Modular Cell cabinet
•
Battery module fuse alarm signal output to the Modular Cell
cabinet
•
Fan power input to battery base module and fan alarm output to
the Modular Cell cabinet
Intrusion alarm input to the Modular Cell cabinet
•
AC heater input to the first battery base module
...........................................................................................................................................................................................................................................................
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Safety
instructions
.............................................................................................................................................................................................................................................................
Instructions
Review all safety precautions before beginning the installation of the
battery frames. Observe all caution symbols on the equipment and
individual safety precautions as they appear in the instruction text.
Safety precautions for power cabinet installation
DANGER
Electrical Shock Hazard
Failure to follow the order of the installation procedure (as
written) can result in an energized AC or DC circuit, which
creates an electrical shock hazard.
Follow these rules.
1.
Perform installation steps in the order provided. Do not
connect AC power until instructed to do so. Do not
make DC connections or interconnect batteries until
instructed to do so.
2.
Observe and strictly follow all safety precautions.
3.
When completing electrical connections, always use
tools that are properly insulated.
WARNING
Personnel injury or equipment damage
When moving the battery base module, use appropriate lifting
devices and a sufficient number of personnel. Two persons are
required.
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A- 7
How to perform placement, anchor, and prewire
procedures for installation of the first or second
EZBFo battery base modules
Overview
.............................................................................................................................................................................................................................................................
Purpose
Important! If installing a EZBFo battery add-on module only, proceed
to How to install an EZBFo battery add-on module on an existing EZBFo
battery module on Page A - 76 to continue the installation. If installing
an EZBFo battery base module, continue as instructed.
This section describes the procedures for placement, anchoring, and
prewiring of the first or second EZBFo battery base modules.
Instructions are given for right-hand (primary cabinet) installation.
Left hand installation (4.0B Dual Band cabinet) is the same except for
the routing of the cables into and through the 4.0B Dual Band cabinet.
This alternate routing is provided.
Anchor hole size requirements for the EZBFo battery base module
How to place and attach the EZBFo battery base module outer frame
A-8
A-9
and mark, drill, and set anchors
How to install the battery heater pad kit in an EZBFo battery module
How to install the inner battery frame and level, anchor, and ground the
A - 19
A - 27
first or second EZBFo battery base modules
Anchor
and hole size requirements
.............................................................................................................................................................................................................................................................
Anchor hole size
requirements for the
EZBFo battery base
module
The following table provides anchor type and hole size requirements
for the EZBF0 battery base module.
Seismic
Zone(s)
0, 1, and 2
3 and 4*
Anchor Quantity/Type
(4) 1/2" dia. drop in
(8) 1/2" dia. drop in
Hole Size / Depth
5/8" bit / 2" (50 mm) deep
5/8" bit / 2" (50 mm) deep
* A EZBFo battery frame installed in Zone 4 can be installed with only
one add-on module unless a zone 4 mounting kit is installed at the time
of the addition of the second add-on module.
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How to place and attach the EZBFo battery base module outer frame
and
mark, drill, and set anchors
.............................................................................................................................................................................................................................................................
Overview
In this module the installer will perform the following procedures:
•
Unstrap the front panel and place it on the top panel of the outer
frame, not detaching the lanyard cable
•
Attach the conduit to the battery base module outer frame
•
Place the battery base module outer frame into position with the
conduit into the Modular Cell cabinet and attach conduit
•
Remove the top and filter panels, not detaching the lanyard cable
•
If anchor holes have not been drilled:
•
•
Mark the anchor holes
•
Detach conduit at Modular Cell cabinet, move the battery
base module outer frame aside, and drill the anchor holes
•
Reposition the battery base module outer frame with the
conduit into the Modular Cell cabinet and attach the conduit
to Modular Cell cabinet
Set the 1/2 inch drop in anchors
This module contains the following procedures:
Place and attach a battery base module to the Modular Cell cabinet
A - 10
or the first battery base module using the applicable conduit
Before you begin
Remove the top and filter panels from the battery base module
A - 14
Mark and drill the anchor holes
A - 16
Set the 1/2-inch diameter drop-in anchor
A - 18
If installing a EZBFo battery add-on module only, proceed to How to
install an EZBFo battery add-on module on an existing EZBFo battery module
on Page A - 76 to continue the installation. If installing an EZBFo
battery base module, continue as instructed.
Important! If the Modular Cell cabinet is equipped with
internal batteries, disconnect the battery connector or connectors
inside of the cabinet before proceeding.
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A- 9
Place and attach a battery
base module to the
Modular Cell cabinet or the
first battery base module
using the applicable
conduit
Perform the following steps to place and attach the outer frame of a
battery base module to the Modular Cell cabinet or the first battery base
module using the applicable conduit. The outer frame may have a front
panel or a door. The front panel is shipped shrink-wrapped to the front
of the outer frame with the lanyard cable attached between them.
Important! Note that the base module may be mounted directly
on a concrete pad. Procedures for the preparation of other types of
mounting surfaces are the responsibility of the customer.
............................................................................................................................................................................
Skip the next step if the battery module is equipped with a front door
instead of a front panel.
............................................................................................................................................................................
Unwrap the front panel from the front of the outer frame and place it on
the top of the frame. Do not disconnect the lanyard cable between the
front panel and the outer frame. Refer to the figure on Page A - 11
............................................................................................................................................................................
If applicable, loosen the eight quarter-turn screws and open the front
door of the module. Refer to the figure below. Refer to the figure on
Page A - 11 for screw locations.
Note that the
front door may
be mounted with
the hinges on
the right side,
instead of on the
left as shown.
The Intrusion
Alarm switch is
always mounted
on the side
opposite the
hinges.
............................................................................................................................................................................
Check the bottom plate for the “F” front orientation marker. If it is not
in the correct location the bottom panel must be removed and
repositioned correctly. Refer to the figure on Page A - 16
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A- 10
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............................................................................................................................................................................
Move the outer frame of the battery base module into the approximate
position next to the Modular Cell cabinet or first battery base module.
Refer to the figure below.
FRONT PANEL
(IF APPLICABLE)
PLACED ON TOP
PANEL
(SHOWN WITH
CONNECTED
LANYARD CABLE)
MODULAR
CELL
PRIMARY
CABINET
or
FIRST
BATTERY
BASE
MODULE
BATTERY
BASE
MODULE
FRONT VIEW - RIGHT SIDE INSTALLIATION
............................................................................................................................................................................
Remove the cover plate shown in the figure below, from the left side of
the outer frame of the battery base module.
Front panel (if applicable)
placed on top panel with
lanyard cable attached
Battery Base Module
left side opening for
conduit connection to
Modular Cell cabinet or
first battery base module
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A- 11
............................................................................................................................................................................
Locate the conduit and associated parts used for routing of cables to the
first battery base module. Refer to the figure on Page A - 12.
............................................................................................................................................................................
Thread a lock nut completely onto one of the two supplied chase nipples.
Refer to the figure on Page A - 12.
............................................................................................................................................................................
From the inside of the battery base module insert a chase nipple with
locknut through the left side frame. Refer to the figure on Page A - 12.
............................................................................................................................................................................
10
From the outside of the battery base module place a sealing ring, “box
side” facing right, onto the protruding chase nipple. Refer to the figure
on Page A - 12.
............................................................................................................................................................................
11
Thread the conduit onto the chase nipple and hand tighten. Refer to the
figure on Page A - 12.
............................................................................................................................................................................
12
From the inside of the battery base module, tighten the locknut against
the side frame. Refer to the figure below.
SEALING RING
FIRST OR SECOND
BATTERY BASE
MODULE
CHASE
NIPPLE
CONDUIT
LOCKNUT
FRONT VIEW - RIGHT SIDE INSTALLIATION
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............................................................................................................................................................................
13
Place the outer frame with the conduit into position beside the Modular
Cell cabinet (or first battery base module) with the conduit against the
associated opening. Refer to the figure below.
............................................................................................................................................................................
14
Place a sealing ring, "box side" facing left, at the left end of the conduit.
Refer to the figure below
............................................................................................................................................................................
15
MODULAR CELL
CABINET OR FIRST
BATTERY BASE MODULE
From the inside of the Modular Cell cabinet or the first battery base
module, as applicable, remove the cover plate and insert a chase nipple
with locknut through the right side frame and the sealing ring and into
the conduit. Hand tighten the chase nipple and lock nut.
SEALING RINGS
FIRST OR SECOND
BATTERY BASE
MODULE
CHASE
NIPPLE
CHASE
NIPPLE
CONDUIT
LOCKNUT
LOCKNUT
FRONT VIEW - RIGHT SIDE INSTALLIATION
............................................................................................................................................................................................................................................................
401-703-454
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January, 2006
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A- 13
Remove the top and filter
panels from the battery
base module
Perform the following steps to remove the top and filter panels from the
battery base module
Important! When performing the next two steps do not
disconnect the lanyard cable between the front and top panels and
the outer frame.
............................................................................................................................................................................
If applicable, move the front panel off of the top panel and place it on
the left side of the outer frame. Refer to the figure below.
Important! When performing the next step, use the supplied TR
25 Keytorx bit and a driver.
............................................................................................................................................................................
Remove the two TR 25 Keytorx screws from the front of the top panel.
Refer to the figure below.
............................................................................................................................................................................
Slide the top panel slightly to the rear, lift the front of the panel up two
to three inches, and lift it off of the outer frame Place it beside the front
panel on the left side of the outer frame as shown in the figure below.
TOP PANEL
SCREW LOCATIONS
FRONT PANEL
(IF APPLICABLE)
MODULAR
CELL
CABINET
or
FIRST
BATTERY
BASE
MODULE
FILTER
PANEL
BATTERY
BASE
MODULE
LANYARD
CABLES
FRONT VIEW
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............................................................................................................................................................................
Disconnect the top panel lanyard cable from the outer frame. Refer to
the figure on Page A - 14. Ensure that the top panel in a secure location.
............................................................................................................................................................................
Remove the filter material from the filter panel. Refer to "A" in the
figure below.
............................................................................................................................................................................
Remove eight bolts from the filter panel and remove the panel. Refer to
"B" in the figure below.
............................................................................................................................................................................
Store the filter material and filter panel is a secure location.
TOP VIEW
FILTER MATERIAL
FILTER PANEL
BOLT LOCATIONS (2 of 8)
Important! If the anchor holes have been drilled during site
preparation, skip to Set the 1/2-inch diameter drop-in anchor on Page
A - 18 and follow the instructions to continue the installation from
that point. If the anchor holes have not been drilled during site
preparation, continue from this point.
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A- 15
Mark and drill the anchor
holes
If not already accomplished during site preparation, use the following
procedure to mark and drill the anchor holes in a concrete surface.
Consult Flexent Modular Cell 4.0/4.0B Outdoor Site Preparation
Guidelines, 401-703-413 for additional details.
............................................................................................................................................................................
Check the bottom plate for the "F" front orientation marker. If it is not
in the correct location the bottom panel must be removed and
repositioned correctly. Refer to the figure below.
Important! Note that the base module may be mounted directly
on a concrete pad. Procedures for the preparation of other types of
mounting surfaces are the responsibility of the customer.
............................................................................................................................................................................
Using the bottom plate as a marking template only, mark the four holes
identified as "A" for Zone 0, 1, and 2, installations. For Zones 3 and 4
installations, also mark the four holes identified as "B". Refer to the
figure below.
"F" FRONT
ORIENTATION
MARK ON
BASE PLATE
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............................................................................................................................................................................
From the inside and outside of the Modular Cell cabinet or the first
battery base module, as applicable, remove the chase nipple with
locknut and the sealing ring installed previously in Step 15 and Step 14
on Page A - 13. Refer to the figure on Page A - 13
............................................................................................................................................................................
Move the battery base module aside (exercise care since the front panel
remains placed on the top panel).
............................................................................................................................................................................
Drill the anchor holes (four or eight) to the proper size and depth as
specified in Anchor and hole size requirements on Page A - 8. Refer to the
figure below for the anchor hole drilling method.
............................................................................................................................................................................
Vacuum out the holes as shown in the figure below.
DEPTH
GAUGE
ANCHOR
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............................................................................................................................................................................
Replace the outer frame with the conduit into position beside the
Modular Cell cabinet (or first battery base module) with the conduit
against the associated opening. Refer to the figure on Page A - 13
............................................................................................................................................................................
Place a sealing ring, “box side” facing left, at the left end of the conduit.
Refer to the figure on Page A - 13
............................................................................................................................................................................
Set the 1/2-inch diameter
drop-in anchor
From the inside of the Modular Cell cabinet or the first battery base
module, as applicable, insert a chase nipple with locknut through the
right side frame and the sealing ring and into the conduit. Tighten the
chase nipple and lock nut. Refer to the figure on Page A - 13
Use the following procedure to install the 1/2-inch diameter drop-in
anchor.
............................................................................................................................................................................
Tap in the four or eight anchors.
............................................................................................................................................................................
Set the anchors using the setting tool. Refer to the figure below.
............................................................................................................................................................................
Do not install the anchor bolts at this time.
BASE PLATE
OF BATTERY
BASE MODULE
SETTING
TOOL
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How
to install the battery heater pad kit in an EZBFo battery module
.............................................................................................................................................................................................................................................................
Overview
In this module the installer will perform the following procedures:.
•
Remove the top and filter panels if they have not been removed
•
Remove the battery retaining brackets, separating the two parts, if
applicable
•
Install the internal AC wiring for heater pads on the battery
module outer frame
•
Install the heater pads on the shelves of the battery module inner
frame
This module contains the following procedures:
Remove the top and filter panels from the battery base module
A - 20
(Reference)
Remove the two piece battery retaining brackets, separating
A - 20
the two parts if applicable
Install the internal AC wiring for the heater pads
A - 21
Install the heater pads on each of the two battery shelves
A - 24
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A- 19
Remove the top and filter
panels from the battery
base module (Reference)
If the top panels have not been removed, refer to Remove the top and
filter panels from the battery base module on Page A - 14 to remove them.
Remove the two piece
battery retaining brackets,
separating the two parts if
applicable
Use the following procedure to remove the two piece battery retaining
brackets, separating them, if applicable.
Important! If L1 batteries will subsequently be installed, skip
the first step. The two piece battery retaining bracket should not be
separated for L1 batteries. Perform the first step only if 12IR125
batteries will be installed.
............................................................................................................................................................................
If 12IR125 batteries will be installed, remove the four bolts that attach
the top portion of the battery retaining bracket and remove the top
portion on both shelves. They will not be replaced but will be used as
battery spacers in a later procedure. Refer to the figure below.
............................................................................................................................................................................
Remove the battery retaining bracket from all shelves to be populated.
Refer to the figure below.
Remove this bolt
(1 of 4) and the
top portion of the
retaining bracket (for
12IR125 batteries only)
BATTERY RETAINING
BRACKET
(FRONT VIEW)
Remove these four
bolts and the battery
retaining bracket
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A- 20
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Install the internal AC
wiring for the heater pads
This procedure module provides instructions on how to install the AC
wiring for the heater pads the battery module.
Important! The following steps must be performed prior to the
placement of the inner frame into the outer frame (base module) or
outer frame over the inner frame (add-on module).
............................................................................................................................................................................
Locate the AC wire harness. Refer to the figure below.
HEAT PAD
CONNECTOR
(1 of 2)
L2/N
L1/L
............................................................................................................................................................................
Locate the AC terminal block assembly. Refer to the figure below.
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............................................................................................................................................................................
Attach the AC terminal block assembly to the bracket on the inside right
panel of the outer frame using the supplied nuts and washers. Refer to
the figures below for a front view and left side view.
HEATER PAD
AC CONNECTIONS
L1/L
L2/N
FRONT
VIEW
............................................................................................................................................................................
Route the wire harness to the rear and attach the temperature sensors to
the side panel threaded studs with the supplied nuts and washers.
Self Stick
anchors and
cable ties
AC
Terminal
Block
Temperature
Sensors
Heater Pad
Connectors
(to be
connected
later)
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............................................................................................................................................................................
Secure the wire harness to the side panel with the supplied plastic self
stick anchors and cable ties.
............................................................................................................................................................................
Loosen the indicated screws and insert the L1 and L2 two wire ferrules
into the top rear connections of the AC terminal block as shown in the
figure below. Tighten the indicated screws. Torque to 1.5 to 1.8 Nm (1.1
to 1.3 ft.- lb.).
HEATER PAD
AC CONNECTIONS
L1/L L2/N
HEATER PAD WIRES
(TOP REAR)
SCREWS
FRONT VIEW
LEFT SIDE VIEW
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A- 23
Install the heater pads on
each of the two battery
shelves
Perform the following steps install the heater pads on each of the two
battery shelves.
............................................................................................................................................................................
Slide the heater pad onto the battery shelf while routing the cable and the
rear end of the heater pad down through the slot in the shelf and through
the slot at the back of the module. Refer to the figures below.
BATTERY
SHELF
SLOT IN
MODULE
SLOT IN
SHELF
HEATER PAD
BATTERY
SHELF
SIDE VIEW
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Important! When performing the next step, ensure that the
heater pad is correctly positioned inside the cavity of the cover so
that no "pinching" of the heater pad occurs.
............................................................................................................................................................................
Place the metal cover over the heater pad and insert the two threaded
studs through the holes in the battery shelf. Refer to the figure below.
............................................................................................................................................................................
Under the battery shelf, attach the cover plate with the nuts and washers
provided. When performing this step on the lower battery shelf of a
battery base module it is necessary to raise the inner frame somewhat to
gain access to the threaded studs.
BATTERY
SHELF
HEATER
PAD
HEATER
PAD COVER
THREADED STUD
(1 of 2)
ATTACH COVER WITH NUTS
ON THE THREADED STUDS
FROM UNDERNEATH
............................................................................................................................................................................
Repeat steps 1 through 3 for the second battery shelf
............................................................................................................................................................................
At the rear of the inner battery frame, slide the heater pads rearward and
forward to ensure they are not pinched by the previously installed metal
heater pad cover. The heater pads must be all the way forward after
testing.
Important! When performing the next step, do not make sharp
bends in the heater pad.
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............................................................................................................................................................................
At the rear of the inner battery frame, curve the rear of the heater pads
as shown in the figure below, and. tape them to the rear of the module
with electrical tape:
•
A: For a battery base module curve both heater pads upwards and
tape
•
B: For an add-on battery module curve the bottom heater pad
downward into the module below and tape.
•
C: For an add-on battery module curve the top heater pad upward
and tape.
The bottom heater pad of an add-on
module must be curved downward (B).
Since access to the bolts for attaching
the add-on module outer frame to the
base module outer frame is through the
rear of the add-on module, curving the
pad upwards would block the access
opening
............................................................................................................................................................................
If installing a first or second battery base module continue the
installation on the next page.
If installing an add-on module with heater pads, skip to Install the battery
module outer frame over the inner frame and attach the internal ground cables
on Page A - 82 to continue the installation.
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How to install the inner battery frame and level, anchor, and ground
the
first or second EZBFo battery base modules
.............................................................................................................................................................................................................................................................
Overview
In this module the installer will perform the following procedures:.
•
Attach the internal ground cable and install the inner battery frame
into the outer battery frame
•
Attach the internal ground cable to the outer battery frame and
level and anchor the completed battery base module
•
Attach the site grounding cable to the outer frame of the battery
base module.
This module contains the following procedures:
Remove the two piece battery retaining brackets, separating
A - 27
the two parts if applicable (Reference)
Prepare the battery module inner frame and place it inside the
A - 28
outer frame and attach the internal ground cable
Remove the two piece
battery retaining brackets,
separating the two parts if
applicable (Reference)
Level and anchor the battery base module
A - 32
Connect the battery base module grounding cables
A - 34
If the battery retaining brackets have not been previously removed
from the battery shelves, refer to Remove the two piece battery retaining
brackets, separating the two parts if applicable on Page A - 20 for
instructions, and remove the retaining brackets at this time.
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A- 27
Prepare the battery module
inner frame and place it
inside the outer frame and
attach the internal ground
cable
Use the following procedure to prepare and place the battery module
inner frame into the outer frame and attach the internal ground cable.
.............................................................................................................................................................................
WARNING
Personnel injury or equipment damage
When moving the battery module, use appropriate lifting
devices and a sufficient number of personnel.
Important! The internal ground cable must be attached to the
inner frame prior to installing it inside of the outer frame.
............................................................................................................................................................................
Locate the supplied 300 mm (11.8- inch) internal ground cable. Refer to
the figures below.
INTERNAL GROUND CABLE
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............................................................................................................................................................................
Attach one end of the supplied 300 mm (11.8- inch) internal ground
cable to the inner frame using the bolts and washers provided. Refer to
the figures below. Torque according to the table in Chapter 1.
INNER
FRAME
ATTACH INTERNAL
GROUND CABLE
HERE WITH TWO
BOLTS
Important! Four lifting eyebolts are provided with the inner
frame for use as lifting aids. They may be temporarily screwed
into the top of the inner frame in the locations shown in the figure
below.
............................................................................................................................................................................
Install the lifting eyebolts in the locations shown in the figure below.
LOCATIONS
FOR LIFTING
EYE BOLTS
(2 of 4)
INNER
FRAME
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A- 29
Important! When performing the next step, take great care not
to damage the heater pads at the rear of the inner frame as it is
lowered into the outer frame.
............................................................................................................................................................................
Place the battery base module inner frame into position inside the outer
frame and over the anchor holes. Observe the 1/4- inch clearance note.
Refer to the figure below.
OUTER FRAME
TOP VIEW
INNER FRAME
Minimum 1/4-Inch
clearance required
between the inner
frame and the
12v bus bar
12v bus
FRONT
............................................................................................................................................................................
Remove the lifting eye bolts.
............................................................................................................................................................................
Place the terminal lug of the internal ground cable from the inner frame
on the two threaded studs on the inside right side frame of the battery
module outer frame. Refer to the figure on Page A - 31.
............................................................................................................................................................................
Using the nuts and washers provided, attach the ground cable to the
threaded studs. Torque according to the table in Chapter 1. Refer to the
figure on Page A - 31.
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............................................................................................................................................................................
Connect the heater pads to the AC connectors shown in the figure below.
Attach the
internal
ground cable
from the inner
frame here
AC
Terminal
Block
Connect heater
pads here
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A- 31
Level and anchor the
battery base module
Important! If installing an add-on module, return to Attach the
internal ground cable between the add-on module and the module below
it
on Page A - 83 to continue the installation.
Use the following procedure to level and anchor the battery base
module and attach the internal ground cable.
Align the battery base module inner frame and outer frame mounting
holes with the anchor holes or anchors, as applicable.
•
Seismic Zones 0, 1, and 2: Over the four installed anchors
•
Seismic Zones 3 and 4: Over the eight installed anchors.
Important! When performing the next step, do not tighten the
anchor bolts until the battery base module has been leveled in the
following step.
............................................................................................................................................................................
Insert the four or eight anchor bolts, as applicable, with two washers
each but leave loose. Refer to the figure below.
THE OUTER
BATTERY FRAME
IS NOT SHOWN
FOR CLARITY
ANCHOR BOLT
LOCATION "A"
(2 each side)
INNER
FRAME
ANCHOR BOLT
LOCATION "B"
(2 each side)
BOTTOM PLATE
OF OUTER FRAME
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...............................................................................................................................................................................
FRONT PANEL
(IF APPLICABLE)
Level the battery module using shims under the bottom plate. Refer to the
figure below.
TOP PANEL AND FILTER PANEL
MODULAR
CELL
CABINET
or
FIRST
BATTERY
BASE
MODULE
BATTERY
BASE
MODULE
PLACE SHIMS
AROUND
ANCHOR BOLTS
UNDER BOTTOM
PLATE
FRONT VIEW
...............................................................................................................................................................................
Observe the minimum 1/4-inch clearance between the inner battery
frame and the 12v bus. Refer to the figure on Page A - 30.
...............................................................................................................................................................................
Tighten the anchor bolts to 18 ft.-lb (24 Nm).
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A- 33
Connect the battery base
module grounding cables
This procedure provides instructions for the installation of two # 2
AWG / 35-mm2 battery base module grounding cables. The battery
base module requires two grounding cables that connect the base
module to the grounding system. The grounding cables are supplied as
part of site preparation. The crimp lugs, with installation hardware, are
supplied with the base module. Refer to the figure on Page A - 35.
Perform the following steps to connect the battery base module
grounding cables.
Important! This section describes the procedures for grounding
of the first and second EZBFo battery base modules. Instructions
for the subsequent internal grounding of stackable add-on battery
modules on top of the battery base module are provided later in
this appendix as part of the installation instructions. Batteries are
also installed later in this appendix.
............................................................................................................................................................................
Prepare the grounding cables with sufficient length to reach from the
grounding system to the rear of the battery base module. Leave
approximately six inches of slack. Refer to the figure on Page A - 35.
............................................................................................................................................................................
Strip the battery base module end of both cables.
............................................................................................................................................................................
Remove the two double-hole terminal lugs from the shipping location
on the bottom rear of the battery base module. Refer to the figure on
Page A - 35.
............................................................................................................................................................................
Crimp a double-hole terminal lug onto the battery base module end of
both cables.
............................................................................................................................................................................
Verify that the battery base module grounding lug locations are free of
paint and polish if necessary.
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............................................................................................................................................................................
Connect the grounding lugs to the battery base module using the
provided hardware (antioxidant compound required). Refer to the figure
below.
............................................................................................................................................................................
Torque according to the table in Chapter 1.
............................................................................................................................................................................
If installing a second battery base module skip to How to route and
connect the signal cables from the first to the second battery base module
on
Page A - 105.
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A- 35
How to identify and route the cables
from the Modular Cell cabinet to the
first EZBFo battery base module
Overview
.............................................................................................................................................................................................................................................................
Purpose
This section identifies and routes the cables necessary to interface the
first EZBFo battery base module to the Modular Cell 4.0B cabinet.The
installer will identify the correct ends of each cable to route, and route
all cables from the from Modular Cell 4.0B cabinet to the EZBFo
battery base module. A wiring overview is provided.
Instructions are given for right-hand (primary cabinet) installation. Left
hand installation (4.0B Dual Band cabinet) is the same except for the
routing of the cables into and through the 4.0B Dual Band cabinet. This
alternate routing is provided.
Contents
Step-by-step instructions are provided for the following tasks:
Wiring overview
A - 37
How to identify the Modular Cell to first EZBFo battery base
module cables
A - 39
How to identify the connectors and route the cables from the
Modular Cell 4.0B cabinet to the first EZBFo battery base
module
A - 42
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Wiring
overview
.............................................................................................................................................................................................................................................................
Overview
This module provides a overview of the DC wiring from the Modular
Cell 4.0B cabinet to the first EZBFo battery base module, as well as the
thermal probe, fuse, fan / power and intrusion alarm cables. Refer to the
figure below (right side installation) or the figure on the next page (left
side installation).
HPDA
MODOULA CELL
4.0/4.0B
PRIMARY
CABINET
DC
FRONT
VIEW
ALARM
CABLE
ACPDA MODULE
FIRST
BATTERY BASE
MODULE
GROUNDING
CABLE
THERMAL
PROBE
CABLE
AC
CABLE
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A- 37
LEFT SIDE INSTALLATION
(FOR 4.0B DUAL BAND CABINETS)
MODOULA CELL
4.0B DUAL BAND
CABINET
HPDA
FRONT
VIEW
ALARM
CABLE
ACPDA
MODULE
FIRST
BATTERY BASE
MODULE
GROUNDING
CABLE
DC
THERMAL
PROBE
CABLE
AC CABLE
...........................................................................................................................................................................................................................................................
A- 38
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How to identify the Modular Cell to first EZBFo battery base module
cables
.............................................................................................................................................................................................................................................................
Identify the first EZBFo
battery base module AC
heater cable
The first EZBFo battery base module AC heater cable is shown in the
figure below:
3048 (120.0)
FIRST
BATTERY
BASE
MODULE
END
MODULAR
CELL
CABINET
END
Identify the first EZBFo
battery base module alarm
and fan power cable
harness
The first EZBFo battery base module alarm and fan power cable
harness consists if the following cables combined in one harness. Refer
to the figure below:
1.
The fan power and alarm cable
2.
The intrusion alarm cable
3.
The fuse alarm cable
MODULAR CELL
CABINET END
FIRST BATTERY
BASE MODULE END
4826 (190.0)
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A- 39
Identify the first EZBFo
battery base module
thermal probe cable(s) and
thermal probe(s)
The first EZBFo battery base module thermal probe cables for use with
4.0B cabinets are shown in the figure below:
MODULAR CELL
CABINET END
FIRST BATTERY
BASE MODULE END
4500 (177.0)
THERMAL PROBE CABLE FROM
MODULAR CELL 4.0B
The thermal probe is shown in the figure below:
THERMAL PROBE CABLE IN EZBFo
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Identify the first EZBFo
battery base module 2
AWG DC cables
The first EZBFo battery base module 2 AWG DC cables are shown in
the figure below. Lengths are given for use with both primary cabinets
(right side installation) and dual band cabinets (left side installation,
which are longer). Note that the four +24V DC load cables (marked
red) are the longer of the eight cables.right side cables, but are the
shorter of the eight left side cables.:
FIRST BATTERY
BASE MODULE END
MODULAR CELL
CABINET END
+24V DC LOAD CABLE FROM MODULAR CELL CABINET (2 AWG) 1 of 4
2784 (110.0)
2937 (115.6)
3556 (140.0)
24V RETURN (RTN) DC CABLE FROM MODULAR CELL CABINET (2 AWG) 1 of 4
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A- 41
How to identify the connectors and route the cables from the Modular
Cell
4.0B cabinet to the first EZBFo battery base module
.............................................................................................................................................................................................................................................................
Overview
This module provides instructions for routing the first EZBFo battery
base module cables from the Modular Cell 4.0B cabinet. The parts
required are shipped separate from the EZBFo battery base module.
Instructions are given for right-hand (primary cabinet) installation. Left
hand installation (4.0B Dual Band cabinet) is the same except for the
routing of the cables into and through the 4.0B Dual Band cabinet.
Refer to the figure on Page A - 5. This alternate routing is provided.
Important! DC cables must be routed last. They will be routed and
individually taped at the Modular Cell cabinet end but will not be
connected in the Modular Cell cabinet at this time
Identify the individual cable connectors and their terminations
A - 43
on each end
Route the cables through the conduit into the first battery base
A - 45
module
...........................................................................................................................................................................................................................................................
A- 42
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Identify the individual cable
connectors and their
terminations on each end
Identify the individual cable connectors on the Modular Cell cabinet
end. Refer to the numbered list below and the figure on Page A - 44 for
cable and connector identification.
1.
The fuse alarm cable (J309)
2.
The battery module fan power/alarm cable (P2)
3.
The intrusion alarm cable (SW1-COM and SW1-NC)
4.
4.0B Thermal probe cable
5.
The AC heater cable 3-Pin
6.
The DC cables (four +24V load / four 24V Return, without
terminal lugs) 2 AWG
Identify the individual cables/connectors on the first EZBFo battery
base module end. Refer to the numbered list below and the figure on
Page A - 44 for cable and connector identification.
7.
The fuse alarm cable: Connectors SW2-1 and SW2-4
8.
The intrusion alarm cable: Connectors "SW1-COM" and
"SW1- NC"
9.
The fan power/alarm cable: Connector "J9" (the fan power/alarm
connector)
10. 4.0B Thermal probe cable with thermal probe
11. The AC heater cable (3 wire)
12. The DC cables (four +24V load / four 24V Return, with 2 hole
terminal lugs) 2 AWG
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A- 43
MODULAR CELL TO EZBFo CABLES
FIRST EZBFo BATTERY
BASE MODULE END
MODULAR CELL 4.0B
CABINET END
4 LOAD / 4 RETURN - 2 AWG
DC CABLES
12
DOOR NC
SW1- NC
INTRUSION ALARM
COMMON
SW1-COM
SW2-1
ALARM CABLE
HARNESS
FUSE ALARM
J309
DC CABLES
ALARM CABLE
HARNESS
SW2-4
4.0B THERMAL
PROBE CABLE
J9
P2
4.0B: P1
4.0B: 1 Probe
10
3 Pin
AC CABLE
FAN POWER/ ALARM
L1
L2
4.0B THERMAL
PROBE CABLE
AND PROBE
11
...........................................................................................................................................................................................................................................................
A- 44
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Route the cables through
the conduit into the first
battery base module
Important! Routing of the alarm and thermal probe cables, as
well as the AC cable, through the conduit from the Modular Cell
4.0B cabinet to the first battery base module must be
accomplished prior to routing of the DC cables through the
conduit. DC cables must be routed last and individually taped in
the Modular Cell cabinet. No cables will be connected in the
Modular Cell cabinet at this time
Perform the following steps to route the cables through the conduit into
the first battery base module.
............................................................................................................................................................................
Route the correct end of the alarm cable harness through the conduit
from the Modular Cell 4.0B cabinet to the first battery base module.
Refer to the figure on Page A - 46 for the first battery base module end
of the cables.
............................................................................................................................................................................
Route the correct end of the thermal probe cable through the conduit
from the Modular Cell 4.0B cabinet to the battery base module.
............................................................................................................................................................................
Route the correct end of the AC cable through the conduit from the
Modular Cell 4.0B cabinet to the first battery base module.
Important! When performing the next step leave sufficient
length in the Modular Cell cabinet to reach the HPDA at the top
right of the cabinet
............................................................................................................................................................................
Route the correct ends of the eight DC cables through the conduit from
the Modular Cell 4.0B cabinet to the first battery base module.
Important! The next step is absolutely necessary to prevent
electrical shock and damage to equipment.
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A- 45
............................................................................................................................................................................
Individually tape the unterminated ends all eight of the DC cables inside
the Modular Cell 4.0B cabinet
KEY
1.
The fuse alarm cable: Connectors SW2-1 and SW2-4
2.
3.
4.
5.
The intrusion alarm cable: Connectors "SW1-COM" and "SW1-NC"
The fan power/alarm cable: Connector "J9" (the fan power/alarm connector)
The thermal probe cable
a.
Thermal probe cable
–
One for first battery base module, when installed , to be moved to the second
battery base module, when installed
b. Thermal probe ; the thermal probe is shipped unconnected
–
One for each connector on the thermal probe cable
The AC heater cable ( 3 wire)
6.
The DC cables ( four +24V DC load/ four 24V Return / with terminal lugs)
MODULAR CELL
4.0B
CABINET
FIRST EZBFo
BATTER Y BASE
MODULE
SW2-1 / SW2-4:
FUSE ALARM
"SW1-NC" AND
"SW1-COM":
INTRUSION ALARM
FOR
DETAIL:
Refer to the
figure on
Page A - 44
"J9": FAN
POWER/ALARM
CABLE CONDUIT
a. THERMAL PROBE CONNECTION
b. THERMAL
PROBE
...........................................................................................................................................................................................................................................................
A- 46
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How to route and connect the cables in
the first EZBFo battery base module
Overview
.............................................................................................................................................................................................................................................................
Purpose
In this module the installer will perform the following procedures to
route and connect the cables from the Modular Cell cabinet in the first
EZBFo battery base module.
•
Route and connect the signal cables in the first battery base
module
•
Route and connect the DC cables in the first battery base module
•
Install and connect heater pads and AC wiring in the battery
module
Instructions are given for right-hand (primary cabinet) installation. Left
hand installation (4.0B Dual Band cabinet) is the same except for the
routing of the cables into and through the 4.0B Dual Band cabinet. This
alternate routing is provided.
Instructions for the subsequent installation of one or two stackable addon battery modules on top of each battery base module are provided
later in this appendix.
This section contains the following procedures:
Contents
Step-by-step instructions are provided for the following tasks:
How to connect the AC cable from the Modular Cell cabinet
A - 48
How to route and connect the signal cables in the first battery
base module
A - 51
How to route and connect the DC cables in the first battery
base module
A - 57
How to seal the cable conduit
A - 62
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A- 47
How
to connect the AC cable from the Modular Cell cabinet
.............................................................................................................................................................................................................................................................
Overview
Route and connect the AC cable from the Modular Cell cabinet
A - 48
to the AC block in the battery base module
Description of the AC wiring installation for the heater pads in the
battery base module
The AC cable from the Modular Cell cabinet will be routed across the
bottom front of the battery base module and connected to the AC
terminal block that was previously installed as part of the AC heater kit.
Route and connect the AC
cable from the Modular Cell
cabinet to the AC block in
the battery base module
Perform the following steps to route and connect the AC cable in the
battery base module.
............................................................................................................................................................................
Route the AC cable from the conduit on the left side of the battery base
module, across the bottom front of the module to the right side. Refer to
the figure below.
AC CABLE
............................................................................................................................................................................
Position the cable against the inside front edge of the outer frame.
............................................................................................................................................................................
Dress the AC cable, and secure it to the inside front edge of the outer
frame with wire ties, in such a way that:
•
It does not come into contact with DC cables
•
It does not interfere with the subsequent installation of batteries
...........................................................................................................................................................................................................................................................
A- 48
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•
It does not interfere with the reinstallation of the front panel
............................................................................................................................................................................
Route the AC cable up to the top of the AC terminal block mounting
bracket and then down from the top as shown in the figure below.
............................................................................................................................................................................
Wire tie the cable to the mounting bracket in the two locations shown in
the figure below.
AC Terminal Block
Wire tie AC
Cable to the
terminal
block
bracket at
these two
points
AC Cable from
the Modular
Cell Cabinet
............................................................................................................................................................................
Route the AC cable to the bottom of the AC block and cut it to the
correct length, while leaving adequate slack. Refer to the figure on Page
A - 49
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A- 49
............................................................................................................................................................................
Strip the individual wires to expose 5/8-inch.
............................................................................................................................................................................
Fully loosen the applicable input screws. and connect the AC input
wires to the terminal block. Refer to the figure below for connection
references.
............................................................................................................................................................................
Torque the screws to 1.5 to 1.8 Nm (1.1 to 1.3 ft.- lb.).
HEATER PAD
AC CONNECTIONS
FRONT VIEW
OUTPUT
SIDE
(TOP)
AC
OUTPUT
WIRE
SCREWS
INPUT
SIDE
SCREWS
FRONT
VIEW
INPUT
SIDE
(BOTTOM)
L1/L
L2/N
RED
BLACK GREEN
AC INPUT (BOTTOM)
AC INPUT
WIRE
LEFT SIDE VIEW
...........................................................................................................................................................................................................................................................
A- 50
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How to route and connect the signal cables in the first battery base
module
.............................................................................................................................................................................................................................................................
Overview
This procedure module provides instructions on how to route and
connect the signal cables in the first battery base module.
Instructions are given for right-hand (primary cabinet) installation. Left
hand installation (4.0B Dual Band cabinet) is the same except for the
routing of the cables into and through the 4.0B Dual Band cabinet. This
alternate routing is provided.
Step-by-step instructions are provided for the following tasks:
Install the fuse, the fuse alarm actuator and the fuse alarm
A - 52
switch in the first battery base module
Route and attach the fuse alarm cable to the fuse alarm switch
A - 53
in the battery base module
Route and attach the fan power and alarm cable in the battery
A - 54
base module
Route and attach the intrusion alarm cable in the battery base
A - 55
module
Route the thermal probe cable and mount the thermal probe in
A - 56
the battery base module
Description of heater pad and AC wiring installation in the battery base
module
The fuse, fuse alarm actuator and switch will be installed on the return
bus. The fuse alarm, fan power and alarm, intrusion alarm cables from
the Modular Cell cabinet will be routed and connected. The thermal
probe cable will be routed and the thermal probe placed.
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A- 51
Install the fuse, the fuse
alarm actuator and the fuse
alarm switch in the first
battery base module
Perform the following steps to install the fuse, fuse alarm actuator and
fuse alarm switch in the first battery base module. Use the hardware
supplied on the bus bars.
............................................................................................................................................................................
Attach the fuse between the upper and lower return bus bars which are
mounted on the inside front left side of the outer frame. Refer to the
figure below. The fuse rating will vary depending upon the application.
............................................................................................................................................................................
Attach the fuse alarm actuator between the upper and lower return bus
bars next to the fuse.
............................................................................................................................................................................
Mount the fuse alarm switch on the top of the actuator with the spade
lugs pointing down.
RTN2
FUSE ALARM
ACTUATOR
FUSE ALARM
SWITCH
(SPADE LUGS
DOWN)
FRONT
FUSE ALARM
ACTUATOR AND
SWITCH
RTN1
FUSE
SIDE VIEW
FRONT VIEW
............................................................................................................................................................................
Torque all connections to 28Nm (250 in.-lb.).
...........................................................................................................................................................................................................................................................
A- 52
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Route and attach the fuse
alarm cable to the fuse
alarm switch in the battery
base module
Refer to the figure below, and perform the following steps to route and
attach the fuse alarm cable to the fuse alarm switch in the battery base
module.
............................................................................................................................................................................
Refer to the figure below for an illustration of the connectors to be
attached.
............................................................................................................................................................................
Connect the cable spade lugs to the fuse alarm switch as shown in the
figure below: SW2-1 to lug 1 (COMMON) and SW2-4 to lug 4. (NO).
............................................................................................................................................................................
Route and dress the cable using the cable ties and self-stick anchors
provided.
FUSE ALARM
ACTUATOR
RTN-2
FUSE ALARM
SWITCH
FUSE ALARM
ACTUATOR AND
SWITCH
2 (NOT
USED)
RTN-1
FRONT VIEW
INSIDE LEFT
VIEW
SW2-1
SW2-4
FUSE ALARM
CABLE FROM
THE MODULAR
CELL CABINET
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A- 53
Route and attach the fan
power and alarm cable in
the battery base module
Important! The fan, temperature sensor, and cable are located
on the front panel of the battery module. Therefore the front panel
must be connected to the outer frame via the lanyard cable when
connecting the fan power and alarm cable.
Refer to the figure below, and perform the following steps to route and
attach the fan power and alarm cable in the battery base module.
............................................................................................................................................................................
Locate the fan power and alarm cable harness from the Modular Cell
cabinet. Refer to the figure below
............................................................................................................................................................................
Connect J9 on the fan power and alarm cable harness to connector P9 at
the fan unit on the front panel of the battery base module. Refer to the
figure below.
............................................................................................................................................................................
Route and dress the cable using the cable ties and self-stick anchors
provided. The slack allowed in the cable must be at least as long as the
lanyard cable.
The parts illustrated
are mounted on the
inside of the front
panel
ATTACH FAN
CABLE J9 TO P9
HERE
...........................................................................................................................................................................................................................................................
A- 54
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Route and attach the
intrusion alarm cable in the
battery base module
Refer to the figure below, and perform the following steps to route and
attach the intrusion alarm cable in the battery base module.
Important! On battery modules that have a front door instead of
a panel, the intrusion alarm switch is located at the bottom front,
on the opposite side from the door hinge, either the left or right
side, as applicable. Refer to the Step 3 figure on page A - 10
............................................................................................................................................................................
Locate the alarm cable harness from the Modular Cell cabinet and the
double spade lugs marked SW1- NC and SW1-Com. Connect the SW1COM spade lug to the COMMON connector on the intrusion alarm
switch as shown in the figure below, item 1.
............................................................................................................................................................................
Connect the SW1- NC spade lug to the CLOSED connector on the
intrusion alarm switch as shown in the figure below, item 2.
............................................................................................................................................................................
Route and dress the cable using the cable ties and self-stick anchors
provided.
OPEN
(NOT USED)
INTRUSION
ALARM SWITCH
IN THE BATTERY
MODULE
OPEN
CLOSED
COMMON
CLOSED
COMMON
SPADE LUG (1 of 2)
SW1-NC
SW1-COM
INTRUSION ALARM CABLE
FROM THE
MODULAR CELL
CABINET
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A- 55
Route the thermal probe
cable and mount the
thermal probe in the
battery base module
Perform the following steps to route the thermal probe cable and mount
the thermal probe in the battery base module.
............................................................................................................................................................................
Locate the thermal probe cable from the Modular Cell cabinet. This
cable has a connector for connection of an internal thermal probe.
Attach the internal thermal probe to the connectors.
Important! Note that the internal thermal probe cable is made
long enough for other applications. Therefore, excess cable should
be properly dressed.
............................................................................................................................................................................
Route the thermal probe cable from the outer frame into the inner frame
on the left side. Using the self-stick mounting bracket and wire tie,
attach the thermal probe in the location inside the frame shown in the
figure below.
Mount the
thermal probe
in this location
on the inside of
the frame
INNER
FRAME
THE OUTER FRAME IS
SHOWN REMOVED FOR
CLARITY
Important!The thermal probe will be moved up to the top add-on
module as subsequently installed.
...........................................................................................................................................................................................................................................................
A- 56
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How to route and connect the DC cables in the first battery base
module
.............................................................................................................................................................................................................................................................
Overview
Important! DC cables must be individually taped in the Modular Cell
cabinet at this time
This procedure module provides instructions for the routing and
connection of the eight 2 AWG DC power cables (four +24V DC load
and four 24V Return) from the Modular Cell cabinet, in the first
EZBFo battery base module.
Step-by-step instructions are provided for the following tasks
Route and connect the four +24V DC load cables in the battery
A - 58
base module
Route and connect the four 24V Return cables in the battery
A - 60
base module
Description of DC power cable routing and connection
The first battery base module requires eight 2 AWG DC power cables
from the Modular Cell cabinet: Four +24V DC load cables (+) and four
24V Return cables (-). These cables are terminated with two hole
terminal lugs on the first battery base module end and unterminated on
the Modular Cell end.
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A- 57
Route and connect the four
+24V DC load cables in the
battery base module
Perform the following steps to route and connect the four +24V DC
load cables in the battery base module.
Important! Before performing the following step be sure that
the unterminated ends (Modular Cell ends) are individually taped.
............................................................................................................................................................................
Lay out the four +24V DC load cables across the bottom front of the
battery base module to reach the load bus (Marked “24V”) located
inside the outer frame on the right side. Refer to the figure on Page A 59.
............................................................................................................................................................................
Remove the plastic cover that shields the 12V and 24V bus bars. Refer
to the figure below. Do not replace the cover until instructed later.
............................................................................................................................................................................
Remove the nuts from the specific load bus bar locations. Refer to the
figure on Page A - 59.
...........................................................................................................................................................................................................................................................
A- 58
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............................................................................................................................................................................
Using antioxidant compound, place the terminal lugs of the four load
cables on the threaded studs in the locations shown, two piggy-backed
on both sets of studs. Refer to the figure below.
............................................................................................................................................................................
Replace the nuts and torque all connections to 28Nm (250 in.-lb.).
RIGHT
INSIDE
OUTER
FRAME
BUS BAR
FRONT
LEAVE THIS
SET OF
LUGS
UNUSED
RIGHT
CONNECT
ONE LOAD
CABLE
HERE
CONNECT
TWO LOAD
CABLES IN
BOTH
LOCATIONS
SIDE VIEW
EXAMPLE OF THE
PIGGY-BACKED
TERMINAL LUGS
FRONT VIEW
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See notice on first page
A- 59
Route and connect the four
24V Return cables in the
battery base module
Perform the following steps to route and connect the four 24V Return
cables in the battery base module.
Important! Before performing the following step be sure that
the unterminated ends (Modular Cell ends) are individually taped.
............................................................................................................................................................................
Lay out the four 24V Return cables in the battery base module to reach
the 24V Return bus (Marked “RTN-1) located inside the outer frame on
the left side. Refer to the figure on Page A - 61.
............................................................................................................................................................................
Remove the nuts from the specific RTN bus bar locations. Refer to the
figure on Page A - 61.
............................................................................................................................................................................
Using antioxidant compound, place the four load cables on the threaded
studs in the locations shown, two piggy-backed on both sets of studs.
Refer to the figure on Page A - 61
...........................................................................................................................................................................................................................................................
A- 60
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............................................................................................................................................................................
Replace the nuts and torque all connections 28Nm (250 in.-lb.).
RTN-2
LEFT
SIDE
BUS BAR
OUTER
FRAME
FRONT
LEFT
RTN-1
EXAMPLE OF TWO
ATTACHED
TERMINAL LUGS
CONNECT TWO
RETURN CABLES IN
BOTH LOCATIONS
FRONT VIEW
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A- 61
How
to seal the cable conduit
.............................................................................................................................................................................................................................................................
Overview
This procedure module provides instructions for the sealing of the
cable conduit at the first EZBFo battery base module and the Modular
Cell 4.0B cabinet ends.
Step-by-step instructions are provided for the following task
Seal both ends of the cable conduit inside of the first battery
A - 63
base module.
Description of cable conduit sealing
Both ends of the cable conduit must be sealed with electrical duct seal
to prevent air from passing between the Modular Cell cabinet and the
EZBFo battery base module.
...........................................................................................................................................................................................................................................................
A- 62
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---

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