Alcatel Lucent USA ONEBTS-11 UMTS-CDMA Transceiver System (850) User Manual 401703454i1
Alcatel-Lucent USA Inc. UMTS-CDMA Transceiver System (850) 401703454i1
Contents
users manual k
A- 63
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Seal both ends of the cable
conduit inside of the first
battery base module.
Perform the following steps to seal both ends of the cable conduit
inside of the first battery base module.
................................................................................................................................
............................................
1Check that all cables from the first battery base module, inside the
Modular Cell cabinet, have sufficient length to reach their connection
points. Refer to the figure on Page A - 66
................................................................................................................................
............................................
2Remove any excess slack in the cables inside the battery base module.
................................................................................................................................
............................................
3Insert the electrical duct seal into the chase nipple at both ends of the
cable conduit and pack it around the cables in such a way the conduit is
completely sealed. Refer to the figure below.
SEAL THE
CONDUIT HERE
SEALING RINGS
CONDUIT
FRONT VIEW
MODULAR CELL
CABINET FIRST BATTERY
BASE MODULE
SEAL THE
CONDUIT HERE
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How to identify, route and connect the
first EZBFo battery base module
cables in the Modular Cell 4.0B
cabinet
.............................................................................................................................................................................................................................................................
Overview
Purpose Important! The four DC cables will not be un taped or connected in
the Modular Cell cabinet at this time.
This section provides instructions for routing and connecting all first
EZBFo battery base module cables (except DC) in the Modular Cell
4.0B Modular Cell cabinet.
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.
All alarm cables and the AC cable will be routed and connected in the
Modular Cell cabinet.
How to identify cables and the HPDA in the Modular Cell 4.0B
cabinet
A - 65
How to route and connect the signal and AC cables in the
Modular Cell 4.0B cabinet
A - 68
A- 65
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How to identify cables and the HPDA in the Modular Cell 4.0B
.............................................................................................................................................................................................................................................................
cabinet
Overview The following illustrations and text are provided to enable the installer
to identify the cables from the EZBFo battery base unit inside of the
Modular Cell Cabinet, and to identify the HPDA to which some of the
cables will be connected.
The following instructions are provided.
Identify the individual cables on the Modular Cell cabinet side A - 66
Identify the HPDA in the 4.0B Modular Cell cabinet A - 67
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Identify the individual
cables on the Modular Cell
cabinet side
Identify the following cables/connectors that, except for the DC cables,
will be routed and connected inside of the Modular Cell cabinet. Refer
to the figure below for cable identification on the Modular Cell cabinet
side.
1. The DC cables (not to be connected at this time)
2. The fuse alarm cable (J309)
3. The first battery base module fan power/alarm cable (P2)
4. The intrusion alarm cable (SW1-COM and SW1-NC)
5. The thermal probe cable
6. The AC cable
FRONT VIEW
1. DC CABLE (1 of 8)
2. FUSE ALARM CABLE
3. FAN POWER/
ALARM CABLE
5. THERMAL PROBE
CABLE
(To ACPDA)
TO DC HPDA
MODULAR CELL
4.0B CABINET
4. INTRUSION
ALARM CABLE
(CONNECT TO
MODULAR CELL
CABINET FRONT
INTRUSION
ALARM SWITCH)
FIRST EZ
BFo
BATTERY
BASE MODULE
FOR
ALARM
DETAIL:
Refer to the
figure on
Page A - 4
4
6
. AC CABLE
(
3 Pin to AC PDA)
A- 67
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Identify the HPDA in the
4.0B Modular Cell cabinet When installing a first battery base module it is necessary to identify
the HPDA (high power distribution assembly) in the Modular Cell
cabinet.
................................................................................................................................
............................................
1Identify the HPDA in the 4.0B Modular Cell cabinet. Refer to the figure
below.
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How to route and connect the signal and AC cables in the Modular
.............................................................................................................................................................................................................................................................
Cell 4.0B cabinet
Overview The following illustrations and text are provided to enable the installer
to route and connect the signal and AC cables from the EZBFo battery
base unit inside of the Modular Cell Cabinet.
The following instructions are provided.
Signal and AC cable
routing Refer to the figure for signal and AC cable routing for an 4.0B primary
cabinet and a 4.0B dual band cabinet.
Route and connect the fuse alarm and fan power/alarm cables
in the Modular Cell 4.0B cabinet
A - 69
Route and connect the intrusion alarm cable in the Modular Cell
4.0B cabinet
A - 71
Route and connect the thermal probe cable in the Modular Cell
4.0B cabinet
A - 73
Connect the heater pad kit AC cable in the Modular Cell cabinet A - 74
MODOULA CELL
4.0B DUAL BAND
CABINET
AC AND
THERMAL
PROBE
CABLES
FRONT
VIEW
FIRST
BATTERY BASE
MODULE
DC *,
INTRUSION, AND
FUSE ALARM
CABLES
HPDA
ACPDA
MODULE
MODOULA CELL 4.0B
PRIMARY
CABINET
FRONT
VIEW
FIRST
BATTERY BASE
MODULE
HPDA
ACPDA
MODULE
AC AND
THERMAL
PROBE
CABLES
DC *,
INTRUSION, AND
FUSE ALARM
CABLES
DC *,
INTRUSION,
AND FUSE
ALARM
CABLES
* DC cables must not be connected at this time
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Route and connect the fuse
alarm and fan power/alarm
cables in the Modular Cell
4.0B cabinet
Perform the following steps to route and connect the fuse alarm and fan
power/alarm cables in the Modular Cell 4.0B cabinet. Refer to the
figure on Page A - 39 for cable identification.
................................................................................................................................
............................................
1Loosen the thumb screws and open the door of the HPDA (High Power
Distribution Assembly).
................................................................................................................................
............................................
2Connect the fan power/alarm cable connector (P2) to the connector on
the circuit board that is mounted on the inside of the HPDA door in the
Modular Cell 4.0B cabinet. Refer to the figure below for the connector
location in the HPDA.
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3Connect the fuse alarm cable connector (J309) to the fuse alarm cable
connector located to the right of the HPDA in the Modular Cell 4.0B
cabinet. Refer to the figure below for the connector location in the
HPDA.
................................................................................................................................
............................................
4Using wire ties, dress the excess cable down the interior right side of the
cabinet. Do this in such a way that they do not interfere with HPDA door
opening and closure, or installation/replacement of parts.
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Route and connect the
intrusion alarm cable in the
Modular Cell 4.0B cabinet
Refer to the figure below and perform the following steps to route and
connect the intrusion alarm cable in the Modular Cell 4.0B cabinet.
................................................................................................................................
............................................
1Disconnect the cable attached to the front intrusion alarm switch (two
wires with spade lugs, C (Common) and NC (Closed). Refer to the
figure below.
................................................................................................................................
............................................
2Attach double spade lugs on the end of the intrusion alarm cable to the
front intrusion alarm switch S1-NC to CLOSED and S1-COM to
COMMON lugs. Refer to the figure on Page A - 72, item 1.
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3Attach the spade lug connectors of the cable disconnected in Step 1, to
the intrusion alarm cable double spade lug CLOSED and COMMON
connections on the intrusion switch, where they were connected in the
previous step. Refer to the figure below, item 2.
................................................................................................................................
............................................
4Using the cable ties dress the excess cable down the interior right side
of the Modular Cell cabinet. Do this in such a way that they do not
interfere with HPDA door opening and closure, or installation/
replacement of parts.
OPEN
(NOT USED)
CLOSED
OPEN
CLOSED
COMMON
S1-
COM
S1-NC
PREVIOUSLY
DISCONNECTED
MODULAR CELL
CABINET CABLE
SW1-NC
SPADE
LUG
COMMON
SPADE
LUG
CABLE FROM
BATTERY
FRAME
TOP INTRUSION
ALARM SWITCH
IN THE MODULAR
CELL CABINET
DOUBLE SPADE
LUG (1 of 2)
1
1
2
2
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Route and connect the
thermal probe cable in the
Modular Cell 4.0B cabinet
Perform the following steps to route and connect the thermal probe
cable in the Modular Cell 4.0B cabinet.
................................................................................................................................
............................................
1Route the thermal probe cable to the AC PDA. Refer to the figure below.
................................................................................................................................
............................................
2Disconnect the existing cable from the pigtail connector P4. Refer to the
figure below. Secure it in a safe location where it will not interfere with
door closure or parts removal.
................................................................................................................................
............................................
3 Connect the thermal probe cable to the 3-pin connector P1 to P4 as
shown in the figure below.
................................................................................................................................
............................................
4Using wire ties, dress the excess thermal probe cable to the bottom of
the Modular Cell cabinet. Do this in such a way that it does not interfere
with door opening and closure, or installation/replacement of parts.
1 2
3 4
1 2
3 4
Primary
Rectifier
Shelf
Auxiliary
Rectifier
Shelf
CIRCUIT BREAKERS
ACPDA
IF A CABLE IS ALREADY CONNECTED HERE,
DISCONNECT IT. THEN CONNECT THE THERMA
L
PROBE CABLE CONNECTOR P1 HERE
Primary
Controllers
BATTERY
CONNECTOR
P4 (P1-BATT)
Auxiliary
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Connect the heater pad kit
AC cable in the Modular
Cell cabinet
Perform the following steps to connect the heater pad kit AC cable in
the Modular Cell 4.0B cabinet.
................................................................................................................................
............................................
1In the Modular Cell 4.0B cabinet, place the circuit breaker "BATTERY
HEATER" to the off position. Refer to the figure below.
................................................................................................................................
............................................
2Locate the three-pin connector (P6) at the bottom left of the power shelf.
Refer to the figure below.
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3Attach the three-pin AC cable connector to the connector shown in the
figure below.
................................................................................................................................
............................................
4Using wire ties, dress the excess AC cable at bottom of the Modular Cell
cabinet. Do this in such a way that it does not interfere with door
opening and closure, or installation/replacement of parts.
................................................................................................................................
............................................
5If additional battery modules remain to be installed, proceed to the next
page. If not, proceed to How to install the batteries in the EZBFo battery
modules on Page A - 124 to install the batteries.
AC CABLE
POWER SHELF IN MODULAR CELL CABINET (ACPDA)
AC CONNECTOR FOR
BATTERY HEATERS
3 21
P6
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How to install an EZBFo battery add-
on module on an existing EZBFo
battery module
.............................................................................................................................................................................................................................................................
Overview
Purpose Important! If additional battery modules remain to be installed,
proceed below. If not, proceed to How to install the batteries in the EZBFo
battery modules on Page A - 124 to install the batteries.
This section provides instructions for the installation of a two shelf
add-on battery module on the EZBFo battery base module.
Important! A second add-on module cannot be installed on a
EZBFo battery frame installed in Zone 4 unless a zone 4 field kit
is installed at the time of the installation of the second add-on
module. Refer to the instructions in the kit before starting the
installation of the second add-on module.
In this section the installer will perform the following procedures:
• Physically attach, prewire and ground an add-on module
• Route and connect the AC cable from the add-on module AC
block to the AC block in the lower battery module
• Route and connect the intrusion alarm cable and thermal probe
• Route and connect the module to module DC cables
Contents Step-by-step instructions are provided for the following tasks:
Description and wiring overview for adding additional battery modules to a
battery base module
A - 77
How to physically attach, prewire and ground an add-on module A - 79
How to route and connect the AC cable (for the heater kit) from the add-on
module AC block to the AC block in the lower battery module
A - 84
How to route and connect the intrusion alarm cable and thermal probe A - 86
How to route and connect the module to module DC cables A - 93
A- 77
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Description and wiring overview for adding additional battery
.............................................................................................................................................................................................................................................................
modules to a battery base module
Description Important! Before performing the wiring procedures, unplug
any battery disconnect connectors in the Modular Cell cabinet, as
well as the battery cables from the load and return buses on all
lower battery shelves. Do not reconnect them until instructed to do
so.
Also disconnect the 24V Return cables in the Modular Cell
cabinet. Refer to Connect (or reconnect) the 24V Return cables from
the first battery base module to the return bus in the Modular Cell 4.0B
cabinet on Page A - 146. which illustrates were they are
reconnected.
The battery base module provides two battery shelves. Two additional
battery modules may be stacked above the first battery base module,
each module providing two battery shelves each. Each battery shelf
holds:
• 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
• 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.
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Wiring overview This section provides instructions for the interconnections from an
added EZBFo battery module to the EZBFo battery base module, and a
Modular Cell 4.0B cabinet. This procedure also applies to a second
add-on module being installed above a first add-on module. Refer to
the figure below for a key to the following numbered list.
1. Battery +24V DC lo
a
d cables (2) between the added EZBFo
b
attery module and the EZBFo battery base module
2. Battery 24V Re
t
urn cables (2) between the added EZBFo battery
module and the EZBFo battery base module
3. Intrusion alarm cable to the added EZBFo battery module.
4.
I
nternal ground cable from the existing battery module to the
added EZBFo battery module.
5. Thermal probe and cable (moved from base module)
6. AC cable (for heater pad kit) to the added EZBFo battery
module.
FRONT VIEW
1
6
2
ADD-ON
BATTERY MODULE
4
FIRST BATTERY BASE
MODULE
5
GROUNDING
CABLE
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How to physically attach, prewire and ground an add-on module
Overview This procedure module provides instructions for physically attaching
an add-on module to the first EZBFo battery base module.and its
grounding.
Step-by-step instructions are provided for the following tasks:
Description of physically attaching and grounding an add-on module
An add-on module is physically attached on top of the previous module
with four bolts. The add-on module requires two ground cables: one
attached between the outer and inner frames and one attached between
the outer frames of the add-on module and the module below it.
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.
Attach an add-on module to an existing battery module and
attach the internal ground cable
A - 80
Install the heater pads and outer frame wiring (Reference) A - 81
Install the battery module outer frame over the inner frame and
attach the internal ground cables
A - 82
Attach the internal ground cable between the add-on module
and the module below it
A - 83
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Attach an add-on module to
an existing battery module
and attach the internal
ground cable
Perform the following steps to attach a two shelf add-on module to an
existing battery module. and attach the internal ground cable
................................................................................................................................
............................................
1Remove the top panel and filter panel from the battery module on which
the add-on module will be placed. Refer to Remove the top and filter
panels from the battery base module on Page A - 14.
Important! When performing the next steps care must be taken
since the fan power and alarm cable is attached to the front panel.
................................................................................................................................
............................................
2If applicable, remove the eight TR 25 Keytorx screws and remove the
front panel from the existing battery module. Place the front panel on the
left side of the battery module. Do not disconnect the lanyard cable.
Refer to the figure below.
................................................................................................................................
............................................
3If applicable, loosen the eight quarter-turn screws and open the front
door of the existing module. Refer to the figure below for screw
locations.
LOCATION OF
T
R
25 KEYTORX
SCREWS
(2 of 8)
MODULAR
CELL
CABINET
or
FIRST
BATTERY
BASE
MODULE
BATTERY
MODULE
FRONT VIEW
TOP PANEL AND FILTER PANEL
F
RONT PANEL
(
IF APPLICABLE)
LANYARD
CABLES
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............................................
4Install the four lifting eyebolts on the top of the add-on inner module.
Refer to the Step 3 figure on Page A - 29.
................................................................................................................................
............................................
5Place the add-on battery module inner frame on top of the existing
battery module inner frame and attach it with the four 1/2-inch bolts
provided. Torque according to the table in Chapter 1 and remove the
lifting eye bolts. Refer to the figure below.
................................................................................................................................
............................................
6Attach one end of the supplied 300 mm (11.8- inch) internal ground
cable (Step 1 figure on Page A - 28) to the inner frame using the bolts
and washers provided. Torque according to the table in Chapter 1. Refer
to the figure below.
Install the heater pads and
outer frame wiring
(Reference)
Important! Refer to How to install the battery heater pad kit in an
EZBFo battery module on Page A - 19 to continue the installation.
After installing the heater pad kit, 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.
TWO
BOLTS O
N EACH
SIDE (MAY BE
ACCESSED THROUGH
CUTOUTS IN THE
SIDES)
GROUND
LUG
INTERNAL
GROUND
CABLE
O
UTER FRAMES
O
F THE BATTERY
B
ASE MODULE
N
OT SHOWN FOR
C
LARITY
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Install the battery module
outer frame over the inner
frame and attach the
internal ground cables
Perform the following steps to install the battery module outer frame
over the inner frame and attach the internal ground cable.
1Detach the front panel from the add-on outer frame and place it on the
top of the frame. Do not disconnect the lanyard cable. Refer to the Step
5 figure on Page A - 11.
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.
................................................................................................................................
............................................
2Place the outer frame over the inner frame an attach it with the eight
bolts provided (shipped loose). Access to the rear bolts is through the
two openings in the rear of the inner fame. Torque according to the table
in Chapter 1. Refer to the figure below and the Step 6 figure on Page A
- 26.
................................................................................................................................
............................................
3Using the nuts and washers provided, attach the ground cable from the
inner frame to the threaded studs on the outer frame. Torque according
to the table in Chapter 1. Refer to Step 7 on Page A - 30.
................................................................................................................................
............................................
4Connect the heater pads to the AC connectors. Refer to Step 8 on Page
A - 31 and the associated figure.
BOLT LOCATIONS FOR
ATTACHING ADD-ON
M
ODULE OUTER FRAME
TO LOWER OUTER
FRAME
(2 of 8)
FRONT
OUTER FRAME
INNER FRAME
Minimum 1/4-Inch
clearance required
between the inner
frame and the 12v bus
TOP VIEW
12v bus
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Attach the internal ground
cable between the add-on
module and the module
below it
Perform the following steps to attach the internal ground cable between
the add-on module and the module below it.
................................................................................................................................
............................................
1Attach one end of the supplied 300 mm (11.8- inch) internal ground
cable (Step 1 figure on Page A - 28) to the outer frame using the nuts
and washers provided. Torque according to the table in Chapter 1. Refer
to the figure below.
................................................................................................................................
............................................
2Attach the other end of the supplied 300 mm (11.8- inch) internal ground
cable to the outer frame of the lower module using the nuts and washers
provided. Torque according to the table in Chapter 1. Refer to the figure
below.
TOP VIEW
GROUND
WIRE
ATTACH GROUND WIRE TO THE
A
DD-ON MODULE OUTER FRAME HERE
FRONT
FRONT VIEW
ATTACH GROUND WIRE TO
THE LOWER MODULE OUTER
FRAME HERE
GROUND
WIRE
FRONT VIEW
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How to route and connect the AC cable (for the heater kit) from the
.............................................................................................................................................................................................................................................................
add-on module AC block to the AC block in the lower battery module
Route and connect the AC
cable from the add-on
module to the next lower
module
Perform the following steps to route and connect the AC cable from the
add-on module to the next lower module.
................................................................................................................................
............................................
1Turn off and/or disconnect the AC source in the Modular Cell Cabinet.
Refer to Step 3 on Page A - 75.
................................................................................................................................
............................................
2Locate the AC 3-wire cable. Refer to the figure below.
................................................................................................................................
............................................
3Attach the wires to the bottom terminals of the AC terminal block in the
add-on module and tighten the screws. Torque screws to 1.5 to 1.8 Nm
(1.1 to 1.3 ft.- lb.). Refer to the figure on Page A - 85
................................................................................................................................
............................................
4Route the cable to the top of the AC terminal block in the lower module.
................................................................................................................................
............................................
5Attach the wires to the top front terminals of the AC terminal block in
the add-on module and tighten the screws. Refer to the figure below
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6Tighten the AC terminal block screws on the lower module block.
Torque screws to 1.5 to 1.8 Nm (1.1 to 1.3 ft.- lb.).
FRONT
VIEW
INP
UT
SIDE
SCREWS
SIDE
VIEW
L2
L1
OUTPUT
SIDE
SCREWS
L2
L1
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How to route and connect the intrusion alarm cable and thermal probe
Overview This procedure module provides instructions on how to route and
connect the intrusion alarm between the add-on module and the battery
module below it.
Also provided are instructions for moving the thermal probe from the
lower battery module to the add-on module.
Step-by-step instructions are provided for the following tasks:
Description of intrusion alarm cable and thermal probe installation
Important! Note that the procedure for attaching the module to
module intrusion alarm cable in the lower module differs if the
lower module is the battery base module, or the first add-on
module.
An intrusion alarm cable will be routed and connected between the
add-on module and the battery module below it. Also, the thermal
probe will be moved from the lower battery module to the add-on
module.
Route and connect the intrusion alarm cable from the existing
battery module and connect it in the add-on module being
installed
A - 87
Move the thermal probe from the existing battery module and
mount it in the add-on module being installed
A - 92
A- 87
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Route and connect the
intrusion alarm cable from
the existing battery module
and connect it in the add-
on module being installed
Perform the following steps to route and connect the intrusion alarm
cable from the existing battery module and connect it in the add-on
module being installed
................................................................................................................................
............................................
1Locate the module to module intrusion alarm cable. This cables has two
double spade lugs on each end. Select one end.
................................................................................................................................
............................................
2Refer to the figure below for module to module intrusion alarm cable
routing in add-on modules.
A
DD-ON INTRUSION
A
LARM CABLE (1 of 2
i
n figure)
INTRUSION ALARM
CABLE FROM
MODULAR CELL
CABINET
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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
................................................................................................................................
............................................
3 If installing:
• a second add-on module or
• a first add-on module on a second battery base module
Skip to Step 9.
If installing a first add-on module on a first battery base module
proceed to the next step.
................................................................................................................................
............................................
4If installing a first add-on module on a first battery base module, locate
the intrusion alarm cable from the Modular Cell cabinet and disconnect
the SW1-NC and SW1-COM wire single spade lugs from the intrusion
alarm switch in the first battery base module. Refer to the figure on Page
A - 89, items 1 and 2.
................................................................................................................................
............................................
5Attach the “ALM” double spade lug of the module to module cable to
the CLOSED lug on the intrusion alarm switch in the first battery base
module. Refer to the figure on Page A - 89, item 3.
................................................................................................................................
............................................
6Attach the “ALM RTN” double spade lug of the module to module cable
to the COMMON lug on the intrusion alarm switch in the first battery
base module. Refer to the figure on Page A - 89, item 4.
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................................................................................................................................
............................................
7Locate the wires disconnected in Step 4. Reattach the SW1-NC and
SW1-COM wire single spade lugs on the intrusion alarm cable from the
Modular Cell cabinet, to the intrusion alarm switch in the first battery
base module as follows. Refer to the figure below.
• SW1-NC to CLOSED (item 1)
• SW1-COM to COMMON (item 2).
ALM RTN
(BLACK)
ALM
(RED)
INTRUSION ALARM
SWITCH IN THE
FIRST BATTERY
BASE MODULE
2
INTRUSION
ALARM CABLE
TO THE
FIRST ADD-ON
MODULE
INTRUSION
SWITCH
OPEN
(NOT USED)
CLOSED
OPEN
CLOSED
COMMON
PREVIOUSLY
DISCONNECTED
CABLE FROM-
MODULAR CELL
CABINET
SW1-COM
SPADE
LUG
DOUBLE SPADE
LUG (1 of 2)
SW1-NC
SPADE
LUG
3
4
1
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................................................................................................................................
............................................
8If installing a first add-on module, skip to Step 10.
................................................................................................................................
............................................
9If installing a second add-on module, or a first add-on module on a
second battery base module, attach the module to module cable as
follows: Refer to the figure below.
• Attach the "ALM" double spade lug (item 1) of the module to
module cable to the existing double spade lug on the CLOSED lug
of the intrusion alarm switch in the lower add-on module.
• Attach the "ALM RTN" double spade lug (item 2) of the module
to module cable to the existing double spade lug on the
COMMON lug of the intrusion alarm switch in the lower add-on
module.
OPEN
(NOT USED)
CLOSED
COMMON
OPEN
CLOSED
COMMON
ALM RTN
(BLACK)
ALM
(RED)
EXISTING INTRUSION
ALARM CABLE FROM
PREVIOUS MODULE
INTRUSION ALARM
SWITCH IN THE
LOWER BATTERY
MODULE
DOUBLE SPADE
LUG (1 of 2)
1
INTRUSION
ALARM
CABLE TO
THE
ADD-ON
MODULE
BEING
INSTALLED
2
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............................................
10 Route the intrusion alarm cable up to the intrusion alarm switch in the
add-on module.
................................................................................................................................
............................................
11 Attach the "ALM" double spade lug to the CLOSED spade lug at the
intrusion alarm switch in the add-on battery module. Refer to the figure
below, item 1.
................................................................................................................................
............................................
12 Attach the "ALM RTN" double spade lug to the COMMON spade lug
at the intrusion alarm switch in the add-on battery module.
................................................................................................................................
............................................
13 Route and dress the cable using the cable ties and self-stick anchors
provided.
INTRUSION
ALARM CABLE
FROM THE
LOWER BATTERY
MODULE
INTRUSION ALARM
SWITCH IN THE
ADD-ON BATTERY
MODULE
DOUBLE SPADE
LUG (1 of 2)
1
2
ALM RTN
(BLACK)
ALM
(RED)
OPEN
(NOT USED)
CLOSED
COMMON
OPEN
CLOSED
COMMON
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Move the thermal probe
from the existing battery
module and mount it in the
add-on module being
installed
Perform the following steps to move the thermal probe from the
existing battery module and mount it in the add-on module being
installed
Important! Note that the thermal probe cable is made long
enough for all applications. Therefore, excess cable should be
properly dressed.
................................................................................................................................
............................................
1Locate the thermal probe cable in the top inside location on the existing
lower battery module frame.
Important! If installing a second add-on module, or a first and
second add on modules in the same installation, move the thermal
probe to the top module when performing the next step.
................................................................................................................................
............................................
2Using the self-stick mounting bracket and cable ties, move the thermal
probe up to the same inside location on the add-on module as shown in
the figure below.
M
OVE THE THERMAL
P
ROBE, FROM INSIDE
T
HE FRAME ON THE
T
OP SHELF OF THE
L
OWER MODULE, TO A
P
OSITION INSIDE THE
F
RAME ON THE TOP
S
HELF OF THE NEWLY
A
DDED MODULE
THE OUTER FRAME IS
SHOWN REMOVED FOR
CLARITY
INNE
R
FRAM
E
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How to route and connect the module to module DC cables
Overview This procedure module provides instructions for the installation of four
2 AWG DC power cables (two +24V DC load and two 24V Return)
from an add-on battery module to the battery module below it.
Step-by-step instructions are provided for the following tasks:
Description of DC power cable routing and connection to an add-on
module
Four DC power cables [two +24V DC load cables (+) and two 24V
Return cables (-)] will be routed and connected between the add-on
module and the battery module below it.
Important! The two pre-terminated +24V DC load cables (and
two 24V Return cables) are supplied with the module.
Identify the module to module DC cables and wiring A - 94
Route and connect the two +24V DC load and two 24V Return
cables from the add-on module to the battery module below it
A - 96
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Identify the module to
module DC cables and
wiring
Perform the following steps to identify the module top module DC
cables and the wiring diagram for connecting the four 24V DC cables
from the add-on module to the battery module below it.
Important! Note that the cables are of different lengths. The
+24V DC load (positive) cables are longer than the 24V Return
(negative) cables.
................................................................................................................................
............................................
1Refer to the figure below for an illustration of one of the module to
module DC cables to be connected. Note that the load (positive) cables
have a red identification and the return (negative) cables have a black
identification.
Cable ID Heat
shrink #1
color
Termination
ID#1 Length
(mm)
+/-12mm
Termination
ID#2 Heat
shrink #2
color
RTN
Black
RTN BUS -
BASE/GWTH
450 RTN BUS -
GWTH Black
24V Red
24V BUS -
BASE/GWTH
550 24V BUS -
GWTH Red
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............................................
2Refer to the figure below for an illustration of the DC module to module
DC wiring.
BATTERY BASE
MODULE
ADD-ON BATTERY
MODULE (1)
ADD-ON BATTERY
MODULE (2)
SHELF 2
SHELF 3
SHELF 4
SHELF 5
LOAD BUS (+24VDC)
RETURN BUS (24VDC)
SHELF 1
SHELF 6
TWO DC LOAD
CABLES
TWO DC RETURN
CABLES
FRONT VIEW
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Route and connect the two
+24V DC load and two 24V
Return cables from the
add-on module to the
battery module below it
Perform the following steps to route and connect the two +24V DC
load and two 24V Return cables from the add-on module to the battery
module below it
Important! When performing this procedure, unplug any
battery disconnect connectors in the Modular Cell cabinet, as well
as the battery cables from the load and return buses on all lower
battery shelves. Do not reconnect them until instructed to do so.
Also disconnect the 24V Return cables in the Modular Cell
cabinet. Refer to Connect (or reconnect) the 24V Return cables from
the first battery base module to the return bus in the Modular Cell 4.0B
cabinet on Page A - 146. which illustrates were they are
reconnected.
................................................................................................................................
............................................
1Remove the plastic cover that shields the 12V and 24V bus bars in the
add-on module and the module below it. Refer to the Step 2 figure on
Page A - 58. Do not replace the cover until instructed later.
................................................................................................................................
............................................
2Locate and identify the +24V DC load (positive) cables identified red at
each end.
................................................................................................................................
............................................
3Locate the +24V DC load bus at the right-hand side of the add-on
module. Refer to the figure on Page A - 97.
................................................................................................................................
............................................
4Attach the two +24V DC load (red ends) cables to the threaded studs on
the add-on module load bus in the illustrated positions using the
supplied serrated nut/washers.
................................................................................................................................
............................................
5Route the two load cables down to the next lower battery module. Refer
to the figure on Page A - 97
................................................................................................................................
............................................
6Locate the +24V DC load bus at the right-hand side of the lower module.
Refer to the figure on Page A - 97.
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............................................
7Attach the two +24V DC load (red ends) cables to the threaded studs on
the lower module load bus in the illustrated positions using the supplied
nuts and washers. Torque to 28Nm (250 in.-lb.). Refer to the figure
below.
CONNECT
TWO LOAD
CABLES
HERE FOR
FIRST
ADD-ON
MODULE
BATTERY
BASE MODULE
FIRST
ADD-ON
MODULE
CONNECT
TWO LOAD
CABLES
HERE FOR
SECOND
ADD-ON
MODULE
SECOND
ADD-ON
MODULE
LOAD BUS
BATTERY BASE MODULE TO FIRST
ADD-ON MODULE
AND
FIRST ADD-ON MODULE TO SECOND
ADD-ON MODULE
FRONT
RIGHT INSIDE VIEW
+24
V DC
+24
V DC
+24
V DC
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................................................................................................................................
............................................
8Locate and identify the 24V Return (negative) cables, identified with
black ends.
................................................................................................................................
............................................
9Locate the return bus (labeled RTN) at the left-hand side of the add-on
module. Refer to the figure on Page A - 99.
................................................................................................................................
............................................
10 Attach the two 24V Return (black ends) cables to the threaded studs on
the add-on module return bus in the illustrated positions using the
supplied nuts and washers.
................................................................................................................................
............................................
11 Torque to 28Nm (250 in.-lb.).
................................................................................................................................
............................................
12 Replace the plastic cover that shields the 12V and 24V bus bars in the
the module below the add-on module. Do not replace the cover in the
add-on module until instructed later. Refer to the Step 2 figure on Page
A - 58.
................................................................................................................................
............................................
13 Route the two return cables down to the next lower battery module.
Refer to the figure on Page A - 99
................................................................................................................................
............................................
14 Locate the return bus at the left-hand side of the lower module. Refer to
the figure on Page A - 99.
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............................................
15 Attach the two 24V Return (black) cables to the threaded studs on the
lower module return bus in the illustrated positions using the supplied
nuts and washers. Torque to 28Nm (250 in.-lb.). Refer to the figure
below.
BATTERY
BASE
MODULE
CONNECT TWO
RETURN CABLES
HERE FOR FIRST
ADD-ON MODULE
CONNECT TWO
RETURN CABLES
HERE FOR SEC-
OND ADD-ON
MODULE
SECOND
ADD-ON
MODULE
FIRST
ADD-ON
MODULE
RETURN BUS
BATTERY BASE MODULE
TO FIRST ADD-ON MODULE
OR
F
IRST ADD-ON MODULE TO
SECOND ADD-ON MODULE
EXAMPLE OF
THE
TWO PIGGY-
BACKED
TERMINAL LUG
S
BUS BAR
FRONT
VIEW
LEFT
RIGHT INSIDE
VIEW
F
RONT
CONNECT TWO
PIGGY-BACKED
*
RETURN CABLES
HERE FOR FIRST
ADD-ON MODULE
*
REQUIRED BECAUSE THE SECOND SET OF THREADED STUDS WILL BE USED LATER
RTN
RTN
RTN
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................................................................................................................................
............................................
16 Repeat Steps 1 through 15 if installing an additional battery add-on
battery module.
................................................................................................................................
............................................
17 Do not reconnect the battery disconnect connectors in the Modular Cell
cabinet or at the battery buses at this time.
................................................................................................................................
............................................
18 If not installing an additional battery base module at this time, skip to
How to install the batteries in the EZBFo battery modules on Page A - 124
to continue the installation.
If installing an additional battery base module at this time, proceed to
the next page to continue the installation
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How to install a second EZBFo battery
base module
.............................................................................................................................................................................................................................................................
Overview
Purpose This section contains the following procedures:
This section provides instructions for the installation of a second
EZBFo battery base module.
In this module the installer will perform the following procedures:
• Place, anchor and prewire the second battery base module
• Route and connect the signal cables from the first battery frame
and the second battery base module
• Route and connect the AC cable from the first battery frame and
the second battery base module
• Route and connect the DC cables from the first battery base
module and the second battery base module
Important! EZBFo frames are installed on the left side of 4.0B
Dual Band cabinets. Therefore, the following instructions should
performed on the left side of the first battery base module.
Contents Step-by-step instructions are provided for the following tasks:
Description and wiring diagram for adding a second battery
base module
A - 102
How to place, anchor and prewire the second battery base
module (Reference)
A - 104
How to route and connect the signal cables from the first to the
second battery base module
A - 105
How to route and connect the AC cable from first battery frame
to the second battery base module
A - 114
How to route and connect DC cables from the first to the
second battery base module
A - 117
How to add additional battery modules to the second battery
base module battery (reference)
A - 123
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Description and wiring diagram for adding a second battery base
.............................................................................................................................................................................................................................................................
module
Important! EZBFo frames are installed on the left side of 4.0B
Dual Band cabinets. Therefore, the following instructions should
performed on the left side of the first battery base module.
Important! Before performing the wiring procedures, unplug
any battery disconnect connectors in the Modular Cell cabinet, as
well as the battery cables from the 24V Return buses on all
existing battery modules. Do not reconnect them until instructed
to do so.
Also disconnect the 24V Return cables in the Modular Cell
cabinet. Refer to Connect (or reconnect) the 24V Return cables from
the first battery base module to the return bus in the Modular Cell 4.0B
cabinet on Page A - 146. which illustrates were they are
reconnected.
The battery base module provides two battery shelves. Two additional
battery modules may be stacked above the first battery base module,
each module providing two battery shelves each. Each battery shelf
holds:
• 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.
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Wiring overview This section provides instructions for the interconnections from the
first EZBFo battery base module to a second EZBFo battery base
module. Refer to the figure below for a key to the following numbered
list. The first battery base module was previously grounded to the
grounding system.
FRONT VIEW
ADD-ON
BATTERY
MODULE
SECOND BATTERY
BASE
MODULE
GROUNDING
CABLE (1 of 2)
FIRST BATTERY
BASE
MODULE
ADD-ON
BATTERY
MODULE
N
ote: EZBFo frames are installed on the left side of the 4.0B Dual Band cabinets. In this case th
e
second battery base module should installed on the left side of the first battery base module.
1. +24V DC load cables (2)
2. 24V Return cables (2)
3. Fan power and alarm cable
4. Intrusion alarm cable
5. AC cable ( 3 -wire)
6. Thermal probe cable.
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How to place, anchor and prewire the second battery base module
.............................................................................................................................................................................................................................................................
(Reference)
Place, anchor and prewire
the second battery base
module (Reference)
To place anchor and prewire the second battery base module refer to
How to perform placement, anchor, and prewire procedures for installation of
the first or second EZBFo battery base modules on Page A - 8.
Perform all of the indicated procedures from Page A - 8 to Page A - 34
before returning to this section.
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How to route and connect the signal cables from the first to the second
.............................................................................................................................................................................................................................................................
battery base module
Overview This procedure module provides instructions on how to route and
connect the signal and ground cables from the first to the second
battery base module.
Step-by-step instructions are provided for the following tasks:
Description of signal cable wiring installation in the battery base module
The fan power and alarm and intrusion alarm cables from the first
battery frame will be routed and connected. The thermal probe cable
will also be routed from the first battery frame and one of the thermal
probes moved to the second battery base module.
Route and connect the fan power and alarm cable between the
first battery frame and the second battery base module
A - 106
Route and connect the intrusion alarm cable between the first
battery frame and the second battery base module
A - 109
Relocate the thermal probe from the first battery frame to the
second battery base module
A - 112
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Route and connect the fan
power and alarm cable
between the first battery
frame and the second
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.
Perform the following steps to route and connect the fan power and
alarm cable between the first battery base module and the second
battery base module.
................................................................................................................................
............................................
1Remove the eight TR 25 Keytorx security screws front panel of the first
battery base module, and remove the front panel or open the front door
as applicable. Do not disconnect the lanyard cable.
................................................................................................................................
............................................
2In the first battery base module, disconnect the fan cable P9 connector
from the J9 connector of the cable coming from the Modular Cell
cabinet. Refer to the figure below.
IN FIRST BATTERY BASE MODULE
UNPLUG FAN CABLE P9 FROM J9 HERE
T
he parts illustrat
ed
are mounted on th
e
inside of the front
panel
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................................................................................................................................
............................................
3Identify the second battery base module fan power and alarm cable.
Refer to the figure below.
................................................................................................................................
............................................
4Route the end of the cable that has only one connector (FAN 2) through
the conduit into the second battery base module. Refer to the figure on
Page A - 108
................................................................................................................................
............................................
5In the first battery base module connect the P9 connector to the J9
connector on the cable from the Modular Cell cabinet. Refer to the
figure on Page A - 108
................................................................................................................................
............................................
6In the first battery base module connect the FAN 1 connector to the P9
connector on the fan power and alarm cable. Refer to the figure on Page
A - 108
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................................................................................................................................
............................................
7In the second battery base module connect the FAN 2 connector to the
P9 connector on the fan power and alarm cable. Refer to the figure
below.
................................................................................................................................
............................................
8Route 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.
C
able from the
M
odular Cell cabinet
P
lug Fan 1 of second
b
attery base module fan
power and alarm cable
to P9 of fan power and
alarm cable
Plug Fan 2 of second
battery base module
fan power and alarm
cable to P9 of fan
power and alarm
cable
P
lug P9 of second battery base
module fan power and alarm
cable to J9 on cable from the
Modular Cell cabinet
T
he parts illustrated
are mounted on the
inside of the front
panel
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Route and connect the
intrusion alarm cable
between the first battery
frame and the second
battery base module
Perform the following steps to route and connect the intrusion alarm
cable between the first battery frame and the second battery base
module
1Identify the second battery base module intrusion alarm cable. Refer to
the figure below.
................................................................................................................................
............................................
2Refer to the figure below for the intrusion alarm routing in add-on
modules.
................................................................................................................................
............................................
3Route the "Intrusion 2" end of the cable through the conduit into the
second battery base module. Refer to the figure above.
3250
1
2
I
ntrusion alarm cable to/from
s
econd battery base module
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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
................................................................................................................................
............................................
4In the first battery base module route the “Intrusion 1" end of the cable
up through to the top installed battery module. Refer to the figure on
Page A - 108
................................................................................................................................
............................................
5In the top installed battery module connect the "ALM" double spade lug
to the double spade lug at the CLOSED lug on the intrusion alarm
switch. Refer to the figure below, 2.
................................................................................................................................
............................................
6In the top installed battery module connect the "ALM RTN" double
spade lug to the double spade lug at the COMMON lug on the intrusion
alarm switch. Refer to the figure below, 1.
OPEN
(NOT USED)
CLOSED
COMMON
OPEN
CLOSED
COMMON
ALM RTN
(BLACK)
ALM
(RED)
EXISTING INTRUSION
ALARM CABLE FROM
LOWER MODULE
INTRUSION ALARM
SWITCH IN THE
TOP INSTALLED
BATTERY MODULE
(FRAME 1)
DOUBLE SPADE
LUG (1 of 2)
1
2INTRUSION ALARM CABLE
TO THE SECOND BATTERY
BASE MODULE
INTRUSION SWITCH
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................................................................................................................................
............................................
7In the second battery base module connect the "ALM" double spade lug
to the CLOSED lug on the intrusion alarm switch. Refer to the figure
below, 2.
................................................................................................................................
............................................
8In the second battery base module connect the "ALM RTN" double
spade lug to the COMMON lug on the intrusion alarm switch. Refer to
the figure below, 1.
................................................................................................................................
............................................
9Route and dress the cable using the cable ties and self-stick anchors
provided.
ALM RTN
ALM INTRUSION
ALARM CABLE
FROM THE
FIRST BATTERY
FRAME
INTRUSION
ALARM SWITCH
IN THE SECOND
BATTERY BASE
MODULE
DOUBLE SPADE
LUG (1 of 2)
1
2
OPEN
(NOT USED)
CLOSED
COMMON
OPEN
CLOSED
COMMON
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Relocate the thermal probe
from the first battery frame
to the second battery base
module
Perform the following steps to relocate the thermal probe from the first
battery frame to the second battery base module
................................................................................................................................
............................................
1Locate the thermal probe located in the highest position in the first
battery frame assembly. Refer to the figure below
................................................................................................................................
............................................
2Disconnect the thermal probe from the thermal probe cable. Refer to the
figure below
................................................................................................................................
............................................
3Attach the supplied extension cable to the connector from which the
thermal probe was removed.
................................................................................................................................
............................................
4Route the extension cable to the second battery base module. Refer to
the figure below
THE OUTER FRAME IS SHOWN REMOVED FOR CLARITY
INNER
FRAME
DISCONNECT THE THERMAL PROBE
(LOCATED IN THE HIGHEST POSITION
IN FIRST MODULE) FROM THE
THERMAL PROBE CABLE. RELOCATE
THE THERMAL PROBE TO A POSITION
INSIDE THE FRAME ON THE TOP
SHELF OF THE NEWLY ADDED BASE
MODULE. INSTALL THE THERMAL
PROBE CABLE, SUPPLIED WITH THE
NEWLY ADDED BASE MODULE,
BETWEEN THE THERMAL PROBE
CABLE IN THE FIRST FRAME AND THE
RELOCATED THERMAL PROBE IN TH
E
NEWLY ADDED BASE MODULE.
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................................................................................................................................
............................................
5Route the extension cable to the top shelf of the newly added base
module.
................................................................................................................................
............................................
6Attach the thermal probe to the end of the extension cable.
................................................................................................................................
............................................
7Use the self-stick mounting bracket and wire tie to attach the thermal
probe in the location inside the frame shown in the figure below.
M
ount thermal
p
robe from first
b
attery base
m
odule in this
l
ocation inside
o
f the frame
THE OUTER FRAME IS SHOWN REMOVED FOR CLARITY
INNE
R
FRAM
E
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How to route and connect the AC cable from first battery frame to the
.............................................................................................................................................................................................................................................................
second battery base module
Route and connect the AC
cable from the first battery
frame to the second battery
base module
Perform the following steps to route and connect the AC cable from the
first battery frame to the second battery base module.
................................................................................................................................
............................................
1Disconnect the AC source in the Modular Cell Cabinet. Refer to Step 3
on Page A - 75.
................................................................................................................................
............................................
2Locate the AC 3-wire cable. Refer to the figure below.
................................................................................................................................
............................................
3Attach the wires to the top front terminals of the AC terminal block in
the top battery module in the first battery frame and tighten the screws.
Torque screws to 1.5 to 1.8 Nm (1.1 to 1.3 ft.- lb.). Refer to the figure on
Page A - 115
................................................................................................................................
............................................
4Tighten the AC terminal block screws on top module AC terminal block.
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................................................................................................................................
............................................
5Route the cable down to the bottom module, through the conduit, and
into the second battery base module.
FRONT
VIEW
OUTPUT
SIDE
SCREWS
SIDE
VIEW
L2/N
L1/L
F
IRST BATTERY
BASE MODULE
A
DD-ON BATTERY
MODULE
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................................................................................................................................
............................................
6Attach the wires to the bottom terminals of the AC terminal block in the
second battery base module and tighten the screws. Torque screws to 1.5
to 1.8 Nm (1.1 to 1.3 ft.- lb.). Refer to the figure below.
................................................................................................................................
............................................
7Route and dress the cable on the inside wall of the outer frame using the
supplied self-stick anchors and cable ties.
................................................................................................................................
............................................
8Tighten the AC terminal block screws on the battery base module AC
terminal block Torque screws to 1.5 to 1.8 Nm (1.1 to 1.3 ft.- lb.).
FRONT
VIEW
L2/N
L1/L
AC INPUT (BOTTOM)
HEATER PAD
AC CONNECTIONS
FRONT VIEW
LEFT SIDE VIEW
INPUT
SIDE
(BOTTOM)AC INPUT
WIRE
SCREWS
INPUT
SIDE
SCREWS
RED BLACK GREEN
SECOND BATTERY BASE MODULE
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How to route and connect DC cables from the first to the second
.............................................................................................................................................................................................................................................................
battery base module
Overview This procedure module provides instructions for the installation of four
#2 -AWG DC power cables (two +24V DC load and two 24V Return)
from a second EZBFo battery base module to the first EZBFo battery
base module.
Step-by-step instructions are provided for the following tasks:
Description of DC power cable routing and connection
Important! Before performing the wiring procedures, unplug
any battery disconnect connectors in the Modular Cell cabinet, as
well as the battery cables from the +24V DC load and 24V Return
buses on all lower battery shelves. Do not reconnect them until
instructed to do so. Also disconnect the 24V Return cables in the
Modular Cell cabinet. Refer to Connect (or reconnect) the 24V
Return cables from the first battery base module to the return bus in the
Modular Cell 4.0B cabinet on Page A - 146. which illustrates were
they are reconnected.
The second EZBFo battery base module requires four DC power cables
from the first EZBFo battery base module: Two +24V DC load cables
(+) and two 24V Return cables (-).
Important! Two pre-terminated +24V DC load cables (and two
24V Return cables) are supplied in the cable and hardware kit for
the second Battery Base Module. Note that the load and return
cables are of different lengths: the longer are the return cables and
the shorter are the load cables.
Install the strap between the lower (RTN-1) and upper (RTN-2)
24V Return bus in the second battery base module
A - 118
Route and connect the four DC cables between the first and
second battery base modules
A - 119
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Install the strap between
the lower (RTN-1) and
upper (RTN-2) 24V Return
bus in the second battery
base module
Perform the following steps to install the strap between the lower and
upper return bus in the second battery base module
................................................................................................................................
............................................
1Mount the strap 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.
................................................................................................................................
............................................
2Attach the strap with the two sets of nuts and washers provided.
................................................................................................................................
............................................
3Torque the nuts to 28Nm (250 in.-lb.).
STRAP
RTN-1
RTN-2
SECOND BATTERY
BASE MODULE
F
RONT
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Route and connect the four
DC cables between the first
and second battery base
modules
Important! When performing the next step, unplug any battery
disconnect connectors in the Modular Cell cabinet, as well as the
battery disconnect connectors at all battery bases in the first
battery frame. Do not reconnect the cables until instructed.
Use the following procedure to connect the +24V DC load and 24V
Return cables to the applicable bus in the first EZBFo battery base
module, route them through the conduit to the second battery base
module, and connect them to the applicable bus. The cables are shipped
in a box separate from the battery base module.
................................................................................................................................
............................................
1 Refer to the figure below for an illustration of the DC cables.
................................................................................................................................
............................................
2Select the two load cables, the two shorter cables (1200 mm) of the four
supplied. These cables are coded red.
................................................................................................................................
............................................
3Remove the plastic cover that shields the 12V and 24V bus bars in the
the first and second battery base modules. Do not replace the covers
until instructed later. Refer to the Step 2 figure on Page A - 58.
Quantity Cable ID Heat
shrink #1
color
Termination
ID#1 Length
(mm)
+/-12mm
Termination
ID#2 Heat
shrink #2
color
2
RTN
Black
RTN BUS –
BASE#1 1600
RTN BUS
–
BASE#2 Black
2
24V
Red
24V BUS –
BASE#1 1200
24V BUS
–
BASE#2 Red
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................................................................................................................................
............................................
4Connect the two cables to the +24V DC load bus on the inside right
frame of the first battery base module, using antioxidant compound.
Refer to the figure on Page A - 120
................................................................................................................................
............................................
5Route these two load cables through the conduit to the second battery
base module.
................................................................................................................................
............................................
6Connect the two cables to the load bus on the inside right frame of the
second battery base module, using antioxidant compound. Refer to the
figure below. Torque the nuts to 28Nm (250 in.-lb.).
................................................................................................................................
............................................
7Replace the plastic cover that shields the 12V and 24V bus bars in the
the first base module. Do not replace the cover in the second base
module until instructed later. Refer to the Step 2 figure on Page A - 58.
CONNECT
TWO LOAD
CABLES
HERE
FIRST BATTERY
BASE MODULE
CONNECT
TWO LOAD
CABLES
HERE
LOAD BUS
FIRST BATTERY BASE MOD
ULE
LOAD BUS
SECOND BATTERY BASE MOD
ULE
SECOND BATTERY
BASE MODULE
EXAMPLE OF THE
TWO PIGGY-
BACKED
TERMINAL LUGS
BUS BAR
FRONT
VIEW
RIGHT
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................................................................................................................................
............................................
8Select the two return cables, the two longer cables (1600 mm) of the four
supplied. These cables are coded black.
................................................................................................................................
............................................
9Remove the nuts and washers that are attaching the two existing cables
to the top of the return bus bar located on the inside left frame of the first
battery base module and place the terminal lugs of the two 24V Return
cables onto the same threaded studs. Refer to the figure on Page A - 122
................................................................................................................................
............................................
10 Attach the two cables to the return bus, using the removed nuts and
washers and antioxidant compound. Refer to the figure below.
................................................................................................................................
............................................
11 Route these two return cables through the conduit to the second battery
base module.
................................................................................................................................
............................................
12 Connect the two cables to the return bus on the inside left frame of the
second battery base module, using antioxidant compound. Refer to the
figure below.
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................................................................................................................................
............................................
13 Torque the nuts to 28Nm (250 in.-lb.).
F
IRST
B
ATTERY
B
ASE
M
ODULE
C
ONNECT
T
WO
R
ETURN
C
ABLES
H
ERE
CONNECT
TWO
RETURN
CABLES
HERE
SECOND
BATTERY
BASE
MODULE
RETURN BUS
FIRST BATTERY BASE MODULE
RETURN BUS
SECOND BATTERY BASE MODULE
EXAMPLE OF THE
TWO PIGGY-
BACKED
TERMINAL LUGS
BUS BAR
FRONT
VIEW
LEFT
SOME DC RETURN
CONNECTIONS IN THE
FIRST BATTERY BASE
MODULE OMITTED FOR
CLARITY
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How to add additional battery modules to the second battery base
.............................................................................................................................................................................................................................................................
module battery (reference)
Refer to How to install an EZBFo battery add-on module on an existing
EZBFo battery module on Page A - 76 to add battery modules to the
second battery base module.
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How to install the batteries in the
EZBFo battery modules
.............................................................................................................................................................................................................................................................
Overview
Purpose Step-by-step instructions are provided for the following tasks:
Approved batteries
You will need the following recommended materials or equivalent.
Battery Safety A - 125
How to install L1 batteries in the EZBFo battery modules A - 127
How to install 12IR25 batteries in the EZBFo battery modules A - 134
Quantity: Name
As required per
site
specification
Power CSL-12100 L1-type batteries (four
minimum) with interconnection bus bars
Marathon GNB M12V100FT L1-type
batteries (four minimum) with interconnecting
bus bars and spacers (One per battery)
12IR125 (six minimum)
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.............................................................................................................................................................................................................................................................
Battery Safety
Battery safety and
precautions Your understanding of the following information is important to ensure
a proper and safe installation of the batteries.
CAUTION
To batteries in this product can present a risk of high
short circuit and fire. The following precautions
should be observed when working on batteries:
•Remove watches, rings, or other metal objects
•Use insulated tools
•Wear rubber gloves and boots
•Disconnect charging source prior to connecting or
disconnecting battery terminals
DANGER
Injury to Personnel - Chemical Burns
The batteries contain electrolyte (sulfuric acid and water),
which can generate hydrogen gas, even under open circuit
conditions. Extreme caution must be taken when handling
batteries. Carefully follow all applicable procedures.
WARNING
Injury to Personnel
Lifting of the batteries by one person can result in a serious
injury. Always use two people (or use a lifting device) to
handle the batteries.
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WARNING
High Energy hazard
The following procedures are the safest method to install and
connect the batteries. If these procedures are not followed in
the exact sequence listed, a serious electrical shock hazard
will result. Ensure that loose cables cannot cause a short
circuit. Since the batteries are charged, do not touch battery
terminals or cross terminals with metal objects. Do not
remove the insulated cover from the battery terminals until
you are preparing to complete each connection.
CAUTION
To reduce the risk of fire or injury to persons, read
and follow these instructions:
•Use only batteries approved for use with this product.
Refer to Approved batteries on Page A - 124 for the list of
approved batteries
•Do not dispose of the batteries in a fire. The cell may
explode. Check with local codes for possible disposal
instructions
•Do not open or mutilate the batteries. Released
electrolyte is corrosive and may cause damage to the eye
and skin. It may be toxic if swallowed
•Exercise care in handling batteries in order not to short
the battery with conductive materials such as rings,
bracelets, and keys. The battery or conductor may
overheat and cause burns
•Do not mix old and new batteries in this product.
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.............................................................................................................................................................................................................................................................
How to install L1 batteries in the EZBFo battery modules
Overview This procedure module provides instructions for the installation of L1
batteries.
Important! The batteries will be installed on the shelves and the
battery cables will be connected to the batteries in this section. The
battery cables must not be connected to the bus bars until later. Refer to
How to make final DC connections on Page A - 140.
Step-by-step instructions are provided for the following tasks:
Description of L1 batteries
The L1-type battery terminals are located on the front end of the
battery. Positive and negative terminals are clearly labeled "+" and "-".
Dual strap handles are permanently attached to the battery along its top.
An example Power CLS-12100 L1 battery is shown in the figure below.
Important! An insulated cover is factory-installed over the
terminals on the batteries to prevent an inadvertent electrical short
during battery installation. Do not remove this cover until you are
preparing to complete the battery connection.
Place batteries on a shelf A - 128
Connect the battery cables to all batteries A - 130
Attach interconnecting bus bars to all battery strings A - 132
BATTERY
STRAP
NUT or BOLT
FOR
BATTERY
CABLE
ATTACHMENT
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...........................................................................................................................................................................................................................................................
Place batteries on a shelf Use the following procedure to place batteries on a shelf, starting with
Shelf 1 (bottom).
................................................................................................................................
............................................
1Check and record battery initial voltages and record all battery date
codes.
Important! The next step is not required if the top panel has
been removed from the module, since the batteries may be
installed on the top shelf through the top
................................................................................................................................
............................................
2Remove the two nuts and remove the top flange from the front of the
battery module. Refer to the figure below.
................................................................................................................................
............................................
3If it has not been previously removed, remove the four bolts and the
battery retaining bracket from the shelf to be populated with batteries.
Start with the lowest battery shelf. Do not disassemble the two part
battery retaining bracket.
BATTERY BASE MODULE
R
EMOVE NUT
I
NSIDE LEFT
F
LANGE
TOP FLANGE
REMOVE NU
T
INSIDE RIGH
T
FLANGE
Remove these four
bolts and the battery
retaining bracket
BATTERY RETAINING
BRACKET
(FRONT VIEW)
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................................................................................................................................
............................................
4Lift and place each of the four batteries on the bottom battery shelf, with
the battery terminals facing the front of the battery shelf.
................................................................................................................................
............................................
5Replace the battery retaining bracket.
................................................................................................................................
............................................
6Torque the bolts according to the table in Chapter 1.
................................................................................................................................
............................................
7Repeat Steps 1 through 6 for all battery shelves to be populated.
................................................................................................................................
............................................
8Replace the top flange removed in Step Important!
BATTERY RETAINING
BRACKETS
SHELF 1
SHELF 2
1234
1234
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Connect the battery cables
to all batteries Perform the following steps to connect the battery cables to all
batteries. Route all cables downward from their battery connections.
Important! Do not attach the battery cables to the bus bars at
this time.
................................................................................................................................
............................................
1Refer to the figure below for an illustration of the battery cable to be
attached to the batteries and a table showing the four different cables
required per shelf.
Important! A battery wiring diagram is shipped with the cables
................................................................................................................................
............................................
2Remove the attaching hardware from the positive (+) terminals of
batteries 2 and 4, and the negative (-) terminals of batteries 1 and 3.
Cable # Cable ID Heat
shrink #1
color
Termination
ID#1 Length
(mm)
+/-12mm
Termination
ID#2
Heat shrink
#2 color
1 RTN
Black
RTN BUS
425 BAT1( -) Black
2 24V
Red
24V BUS
425
BAT2(+)
Red
3 RTN
Black
RTN BUS
575 BAT3( -) Black
4 24V
Red
24V BUS
575
BAT4(+)
Red
Termination ID#1
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............................................................................................................................................................................................................................................................
Important! If installing Marathon GNB M12V100FT L1-type
batteries install the supplied spacer before making the battery
cable connections (using the extra long bolt) in the next two steps.
Place the spacers on the terminals identified with an * in the figure
below. This applies to all battery shelves.
................................................................................................................................
............................................
3Using the previously removed attaching hardware (and antioxidant
compound), connect the one-hole lug end of each battery cable to the
batteries in the following order. Refer to the figure below and the table
on Page A - 130.
• Cable #2 marked BAT2(+) to positive (+) terminal of battery 2
• Cable #4 marked BAT4(+) to positive (+) terminal of battery 4
• Cable #1 marked BAT1(-) to negative (-) terminal of battery 1
• Cable #3 marked BAT3(-) to negative (-) terminal of battery 3
................................................................................................................................
............................................
4Double check that the BAT 1 to 4 cables are each attached to the correct
battery, and that the black marked cable is attached to the negative
terminal and the red marked terminal is attached to the positive terminal.
................................................................................................................................
............................................
5Repeat steps 2 through 4 for all remaining populated battery shelves.
................................................................................................................................
............................................
6Torque the battery connections to the value shown on the batteries.
122
1
1
1234
1234
2
3
4
UPPER
SHELF
LOWER
SHELF
**
*
*
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Attach interconnecting bus
bars to all battery strings
CAUTION
High Energy hazard
Do not connect the battery cables to the bus bars until told to
do so.
Perform the following steps to connect the interconnecting bus bars to
all battery strings.
................................................................................................................................
............................................
1Starting with batteries 1 and 2 on the left side of Shelf 1, remove the
attaching hardware from the positive (+) terminal of Battery 1 and the
negative (-) terminal of Battery 2. Refer to the figure on Page A - 133.
................................................................................................................................
............................................
2Remove the interconnecting bus bar from the kit that is provided with
each pair of batteries and polish the bus bar.
................................................................................................................................
............................................
3Apply antioxidant compound to the interconnecting bus bar.
................................................................................................................................
............................................
4Apply antioxidant compound to the positive (+) terminal of Battery 1
and the negative (-) terminal of Battery 2.
................................................................................................................................
............................................
5Place the interconnecting bus bar between the positive terminal of the
left-hand battery (#1) and the negative terminal of the right-hand battery
(#2).