Alcatel Lucent USA ONEBTS-11 UMTS-CDMA Transceiver System (850) User Manual 401703454i1
Alcatel-Lucent USA Inc. UMTS-CDMA Transceiver System (850) 401703454i1
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users manual k
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| Document ID | 635463 |
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| Document Description | users manual k |
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| Document Type | User Manual |
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| Filesize | 217.4kB (2717526 bits) |
| Date Submitted | 2006-03-10 00:00:00 |
| Date Available | 2006-03-09 00:00:00 |
| Creation Date | 2006-03-06 15:15:53 |
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| Document Lastmod | 2006-03-08 16:00:12 |
| Document Title | 401703454i1.book |
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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. ............................................................................................................................................................................ Check 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 ............................................................................................................................................................................ Remove any excess slack in the cables inside the battery base module. ............................................................................................................................................................................ Insert 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. MODULAR CELL CABINET FIRST BATTERY BASE MODULE SEALING RINGS SEAL THE CONDUIT HERE CONDUIT SEAL THE CONDUIT HERE FRONT VIEW ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 63 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 A - 65 cabinet How to route and connect the signal and AC cables in the A - 68 Modular Cell 4.0B cabinet ........................................................................................................................................................................................................................................................... A- 64 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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 Identify the HPDA in the 4.0B Modular Cell cabinet A - 66 A - 67 ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 65 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 FIRST EZBFo BATTERY BASE MODULE MODULAR CELL 4.0B CABINET 4. INTRUSION ALARM CABLE (CONNECT T O MODULAR CELL CABINET FRONT INTRUSION ALARM SWITCH) 1. DC CABLE (1 of 8) FOR ALARM DETAIL: Refer to the figure on Page A - 44 TO DC HPDA 2. FUSE ALARM CABLE 3. FAN POWER/ ALARM CABLE 6. AC CABLE (3 Pin to AC PDA) 5. THERMAL PROBE CABLE (To ACPDA) FRONT VIEW ........................................................................................................................................................................................................................................................... A- 66 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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. ............................................................................................................................................................................ Identify the HPDA in the 4.0B Modular Cell cabinet. Refer to the figure below. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 67 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. Route and connect the fuse alarm and fan power/alarm cables A - 69 in the Modular Cell 4.0B cabinet Route and connect the intrusion alarm cable in the Modular Cell A - 71 4.0B cabinet Route and connect the thermal probe cable in the Modular Cell A - 73 4.0B cabinet Connect the heater pad kit AC cable in the Modular Cell cabinet 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. MODOULA CELL 4.0B DUAL BAND CABINET MODOULA CELL 4.0B PRIMARY CABINET HPDA HPDA DC *, INTRUSION, AND FUSE ALARM CABLES FRONT VIEW FIRST BATTERY BASE MODULE DC *, INTRUSION, AND FUSE ALARM CABLES A - 74 FRONT VIEW ACPDA MODULE AC AND THERMAL PROBE CABLES ACPDA MODULE AC AND THERMAL PROBE CABLES FIRST BATTERY BASE MODULE DC *, INTRUSION, AND FUSE ALARM CABLES * DC cables must not be connected at this time ........................................................................................................................................................................................................................................................... A- 68 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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. ............................................................................................................................................................................ Loosen the thumb screws and open the door of the HPDA (High Power Distribution Assembly). ............................................................................................................................................................................ Connect 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 69 ............................................................................................................................................................................ Connect 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. ............................................................................................................................................................................ Using 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. ........................................................................................................................................................................................................................................................... A- 70 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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. ............................................................................................................................................................................ Disconnect the cable attached to the front intrusion alarm switch (two wires with spade lugs, C (Common) and NC (Closed). Refer to the figure below. ............................................................................................................................................................................ Attach 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 71 ............................................................................................................................................................................ Attach 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. ............................................................................................................................................................................ Using 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. PREVIOUSLY DISCONNECTED MODULAR CELL CABINET CABLE S1COM CABLE FROM BATTERY FRAME S1-NC COMMON SPADE LUG SW1-NC SPADE LUG DOUBLE SPADE LUG (1 of 2) CLOSED COMMON CLOSED OPEN TOP INTRUSION ALARM SWITCH IN THE MODULAR CELL CABINET OPEN (NOT USED) ........................................................................................................................................................................................................................................................... A- 72 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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. ............................................................................................................................................................................ Route the thermal probe cable to the AC PDA. Refer to the figure below. ............................................................................................................................................................................ Disconnect 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. ............................................................................................................................................................................ Connect the thermal probe cable to the 3-pin connector P1 to P4 as shown in the figure below. Controllers Auxiliary Primary IF A CABLE IS ALREADY CONNECTED HERE, DISCONNECT IT. THEN CONNECT THE THERMAL PROBE CABLE CONNECTOR P1 HERE BATTERY 1 2 1 2 3 4 3 4 Auxiliary Rectifier Shelf CONNECTOR P4 (P1-BATT) Primary Rectifier Shelf CIRCUIT BREAKERS ACPDA ............................................................................................................................................................................ Using 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 73 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. ............................................................................................................................................................................ In the Modular Cell 4.0B cabinet, place the circuit breaker "BATTERY HEATER" to the off position. Refer to the figure below. ............................................................................................................................................................................ Locate the three-pin connector (P6) at the bottom left of the power shelf. Refer to the figure below. ........................................................................................................................................................................................................................................................... A- 74 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 ............................................................................................................................................................................ Attach the three-pin AC cable connector to the connector shown in the figure below. POWER SHELF IN MODULAR CELL CABINET (ACPDA) AC CONNECTOR FOR BATTERY HEATERS P6 3 2 1 AC CABLE ............................................................................................................................................................................ Using 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. ............................................................................................................................................................................ If 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 75 How to install an EZBFo battery addon 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: Contents • 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 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- 76 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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 on Page A - 146. which illustrates were they are reconnected. cabinet 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 77 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 load cables (2) between the added EZBFo battery module and the EZBFo battery base module 2. Battery 24V Return 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. Internal 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. ADD-ON BATTERY MODULE GROUNDING CABLE FIRST BATTERY BASE MODULE FRONT VIEW ........................................................................................................................................................................................................................................................... A- 78 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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: 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 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 79 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 ............................................................................................................................................................................ Remove 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. ............................................................................................................................................................................ If 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. ............................................................................................................................................................................ If applicable, loosen the eight quarter-turn screws and open the front door of the existing module. Refer to the figure below for screw locations. TOP PANEL AND FILTER PANEL LOCATION OF TR 25 KEYTORX SCREWS (2 of 8) FRONT PANEL (IF APPLICABLE) MODULAR CELL CABINET or FIRST BATTERY BASE MODULE BATTERY MODULE LANYARD CABLES FRONT VIEW ........................................................................................................................................................................................................................................................... A- 80 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 ............................................................................................................................................................................ Install the four lifting eyebolts on the top of the add-on inner module. Refer to the Step 3 figure on Page A - 29. ............................................................................................................................................................................ Place 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. ............................................................................................................................................................................ Attach 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. GROUND LUG INTERNAL GROUND CABLE OUTER FRAMES OF THE BATTERY BASE MODULE NOT SHOWN FOR CLARITY Install the heater pads and outer frame wiring (Reference) TWO BOLTS ON EACH SIDE (MAY BE ACCESSED THROUGH CUTOUTS IN THE SIDES) 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 81 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. Detach 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. ............................................................................................................................................................................ Place 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. BOLT LOCATIONS FOR ATTACHING ADD-ON MODULE OUTER FRAME TO LOWER OUTER FRAME (2 of 8) OUTER FRAME TOP VIEW INNER FRAME Minimum 1/4-Inch clearance required between the inner frame and the 12v bus 12v bus FRONT ............................................................................................................................................................................ Using 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. ............................................................................................................................................................................ Connect the heater pads to the AC connectors. Refer to Step 8 on Page A - 31 and the associated figure. ........................................................................................................................................................................................................................................................... A- 82 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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. ............................................................................................................................................................................ Attach 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. ............................................................................................................................................................................ Attach 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. ATTACH GROUND WIRE TO THE ADD-ON MODULE OUTER FRAME HERE TOP VIEW FRONT VIEW GROUND WIRE GROUND WIRE FRONT ATTACH GROUND WIRE TO THE LOWER MODULE OUTER FRAME HERE FRONT VIEW ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 83 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. ............................................................................................................................................................................ Turn off and/or disconnect the AC source in the Modular Cell Cabinet. Refer to Step 3 on Page A - 75. ............................................................................................................................................................................ Locate the AC 3-wire cable. Refer to the figure below. ............................................................................................................................................................................ Attach 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 ............................................................................................................................................................................ Route the cable to the top of the AC terminal block in the lower module. ............................................................................................................................................................................ Attach 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 ........................................................................................................................................................................................................................................................... A- 84 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 ............................................................................................................................................................................ Tighten 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.). SIDE VIEW FRONT VIEW INPUT SIDE SCREWS L1 L2 OUTPUT SIDE SCREWS L1 L2 ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 85 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: 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 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. ........................................................................................................................................................................................................................................................... A- 86 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 Route and connect the intrusion alarm cable from the existing battery module and connect it in the addon 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 ............................................................................................................................................................................ Locate the module to module intrusion alarm cable. This cables has two double spade lugs on each end. Select one end. ............................................................................................................................................................................ Refer to the figure below for module to module intrusion alarm cable routing in add-on modules. ADD-ON INTRUSION ALARM CABLE (1 of 2 in figure) INTRUSION ALARM CABLE FROM MODULAR CELL CABINET ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 87 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 ............................................................................................................................................................................ 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. ............................................................................................................................................................................ If 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. ............................................................................................................................................................................ Attach 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. ............................................................................................................................................................................ Attach 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. ........................................................................................................................................................................................................................................................... A- 88 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 ............................................................................................................................................................................ Locate 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). INTRUSION ALARM SWITCH IN THE FIRST BATTERY BASE MODULE OPEN (NOT USED) OPEN DOUBLE SPADE LUG (1 of 2) CLOSED CLOSED COMMON SW1-COM SPADE LUG ALM (RED) SW1-NC SPADE LUG INTRUSION ALARM CABLE TO THE FIRST ADD-ON MODULE INTRUSION SWITCH PREVIOUSLY DISCONNECTED CABLE FROMMODULAR CELL CABINET ALM RTN (BLACK) ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 89 ............................................................................................................................................................................ If installing a first add-on module, skip to Step 10. ............................................................................................................................................................................ If 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. INTRUSION ALARM SWITCH IN THE LOWER BATTERY MODULE OPEN (NOT USED) OPEN CLOSED COMMON CLOSED COMMON DOUBLE SPADE LUG (1 of 2) ALM (RED) ALM RTN (BLACK) EXISTING INTRUSION ALARM CABLE FROM PREVIOUS MODULE INTRUSION ALARM CABLE TO THE ADD-ON MODULE BEING INSTALLED ........................................................................................................................................................................................................................................................... A- 90 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 ............................................................................................................................................................................ 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 SWITCH IN THE ADD-ON BATTERY MODULE OPEN (NOT USED) OPEN DOUBLE SPADE LUG (1 of 2) CLOSED COMMON CLOSED COMMON ALM (RED) ALM RTN (BLACK) INTRUSION ALARM CABLE FROM THE LOWER BATTERY MODULE ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 91 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. ............................................................................................................................................................................ Locate 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. ............................................................................................................................................................................ Using 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. INNER FRAME MOVE THE THERMAL PROBE, FROM INSIDE THE FRAME ON THE TOP SHELF OF THE LOWER MODULE, TO A POSITION INSIDE THE FRAME ON THE TOP SHELF OF THE NEWLY ADDED MODULE THE OUTER FRAME IS SHOWN REMOVED FOR CLARITY ........................................................................................................................................................................................................................................................... A- 92 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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: 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 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 93 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. ............................................................................................................................................................................ Refer 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 RTN Black 24V Red Termination ID#1 RTN BUS BASE/GWTH 24V BUS BASE/GWTH Length (mm) +/-12mm 450 550 Termination ID#2 RTN BUS GWTH 24V BUS GWTH Heat shrink #2 color Black Red ........................................................................................................................................................................................................................................................... A- 94 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 ............................................................................................................................................................................ Refer to the figure below for an illustration of the DC module to module DC wiring. RETURN BUS (24VDC) LOAD BUS (+24VDC) SHELF 6 ADD-ON BATTERY MODULE (2) SHELF 5 SHELF 4 ADD-ON BATTERY MODULE (1) SHELF 3 TWO DC LOAD CABLES TWO DC RETURN CABLES SHELF 2 BATTERY BASE MODULE SHELF 1 FRONT VIEW ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 95 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. ............................................................................................................................................................................ Remove 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. ............................................................................................................................................................................ Locate and identify the +24V DC load (positive) cables identified red at each end. ............................................................................................................................................................................ Locate the +24V DC load bus at the right-hand side of the add-on module. Refer to the figure on Page A - 97. ............................................................................................................................................................................ Attach 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. ............................................................................................................................................................................ Route the two load cables down to the next lower battery module. Refer to the figure on Page A - 97 ............................................................................................................................................................................ Locate the +24V DC load bus at the right-hand side of the lower module. Refer to the figure on Page A - 97. ........................................................................................................................................................................................................................................................... A- 96 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 ............................................................................................................................................................................ Attach 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. LOAD BUS BATTERY BASE MODULE TO FIRST ADD-ON MODULE AND FIRST ADD-ON MODULE TO SECOND ADD-ON MODULE SECOND ADD-ON MODULE +24 V DC CONNECT TWO LOAD CABLES HERE FOR SECOND ADD-ON MODULE FIRST ADD-ON MODULE +24 V DC FRONT RIGHT INSIDE VIEW CONNECT TWO LOAD CABLES HERE FOR FIRST ADD-ON MODULE BATTERY BASE MODULE +24 V DC ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 97 ............................................................................................................................................................................ Locate and identify the 24V Return (negative) cables, identified with black ends. ............................................................................................................................................................................ Locate 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. ........................................................................................................................................................................................................................................................... A- 98 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 ............................................................................................................................................................................ 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. RETURN BUS RTN BATTERY BASE MODULE TO FIRST ADD-ON MODULE OR FIRST ADD-ON MODULE TO SECOND ADD-ON MODULE SECOND ADD-ON MODULE CONNECT TWO RETURN CABLES HERE FOR SECOND ADD-ON MODULE FRONT RTN RIGHT INSIDE VIEW FIRST ADD-ON MODULE EXAMPLE OF THE TWO PIGGYBACKED TERMINAL LUGS CONNECT TWO RETURN CABLES HERE FOR FIRST ADD-ON MODULE CONNECT TWO PIGGY-BACKED * RETURN CABLES HERE FOR FIRST ADD-ON MODULE RTN LEFT BATTERY BASE MODULE BUS BAR FRONT VIEW *REQUIRED BECAUSE THE SECOND SET OF THREADED STUDS WILL BE USED LATER ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 99 ............................................................................................................................................................................ 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 ........................................................................................................................................................................................................................................................... A- 100 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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 ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 101 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. ........................................................................................................................................................................................................................................................... A- 102 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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 ADD-ON BATTERY MODULE 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. SECOND BATTERY BASE MODULE GROUNDING CABLE (1 of 2) Note: EZBFo frames are installed on the left side of the 4.0B Dual Band cabinets. In this case the second battery base module should installed on the left side of the first battery base module. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 103 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. ........................................................................................................................................................................................................................................................... A- 104 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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: Route and connect the fan power and alarm cable between the A - 106 first battery frame and the second battery base module Route and connect the intrusion alarm cable between the first A - 109 battery frame and the second battery base module Relocate the thermal probe from the first battery frame to the A - 112 second battery base module 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 105 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. ............................................................................................................................................................................ Remove 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. ............................................................................................................................................................................ In 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. The parts illustrated are mounted on the inside of the front panel IN FIRST BATTERY BASE MODULE UNPLUG FAN CABLE P9 FROM J9 HERE ........................................................................................................................................................................................................................................................... A- 106 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 ............................................................................................................................................................................ Identify the second battery base module fan power and alarm cable. Refer to the figure below. ............................................................................................................................................................................ Route 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 ............................................................................................................................................................................ In 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 ............................................................................................................................................................................ In 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 ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 107 ............................................................................................................................................................................ In 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. ............................................................................................................................................................................ 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 Cable from the Modular Cell cabinet Plug P9 of second battery base module fan power and alarm cable to J9 on cable from the Modular Cell cabinet Plug Fan 1 of second battery 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 ........................................................................................................................................................................................................................................................... A- 108 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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 Identify the second battery base module intrusion alarm cable. Refer to the figure below. 3250 ............................................................................................................................................................................ Refer to the figure below for the intrusion alarm routing in add-on modules. Intrusion alarm cable to/from second battery base module ............................................................................................................................................................................ Route the "Intrusion 2" end of the cable through the conduit into the second battery base module. Refer to the figure above. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 109 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 ............................................................................................................................................................................ In 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 ............................................................................................................................................................................ In 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. ............................................................................................................................................................................ In 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. INTRUSION ALARM SWITCH IN THE TOP INSTALLED BATTERY MODULE (FRAME 1) OPEN (NOT USED) OPEN CLOSED COMMON CLOSED COMMON DOUBLE SPADE LUG (1 of 2) ALM (RED) EXISTING INTRUSION ALARM CABLE FROM LOWER MODULE INTRUSION ALARM CABLE TO THE SECOND BATTERY BASE MODULE INTRUSION SWITCH ALM RTN (BLACK) ........................................................................................................................................................................................................................................................... A- 110 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 ............................................................................................................................................................................ In 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. ............................................................................................................................................................................ In 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. ............................................................................................................................................................................ Route and dress the cable using the cable ties and self-stick anchors provided. INTRUSION ALARM SWITCH IN THE SECOND BATTERY BASE MODULE OPEN (NOT USED) OPEN DOUBLE SPADE LUG (1 of 2) CLOSED COMMON CLOSED COMMON ALM ALM RTN INTRUSION ALARM CABLE FROM THE FIRST BATTERY FRAME ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 111 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 ............................................................................................................................................................................ Locate the thermal probe located in the highest position in the first battery frame assembly. Refer to the figure below ............................................................................................................................................................................ Disconnect the thermal probe from the thermal probe cable. Refer to the figure below ............................................................................................................................................................................ Attach the supplied extension cable to the connector from which the thermal probe was removed. ............................................................................................................................................................................ Route the extension cable to the second battery base module. Refer to the figure below 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 THE NEWLY ADDED BASE MODULE. THE OUTER FRAME IS SHOWN REMOVED FOR CLARITY ........................................................................................................................................................................................................................................................... A- 112 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 ............................................................................................................................................................................ Route the extension cable to the top shelf of the newly added base module. ............................................................................................................................................................................ Attach the thermal probe to the end of the extension cable. ............................................................................................................................................................................ Use the self-stick mounting bracket and wire tie to attach the thermal probe in the location inside the frame shown in the figure below. INNER FRAME Mount thermal probe from first battery base module in this location inside of the frame THE OUTER FRAME IS SHOWN REMOVED FOR CLARITY ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 113 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. ............................................................................................................................................................................ Disconnect the AC source in the Modular Cell Cabinet. Refer to Step 3 on Page A - 75. ............................................................................................................................................................................ Locate the AC 3-wire cable. Refer to the figure below. ............................................................................................................................................................................ Attach 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 ............................................................................................................................................................................ Tighten the AC terminal block screws on top module AC terminal block. ........................................................................................................................................................................................................................................................... A- 114 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 ............................................................................................................................................................................ Route the cable down to the bottom module, through the conduit, and into the second battery base module. FRONT VIEW SIDE VIEW L1/L L2/N OUTPUT SIDE SCREWS ADD-ON BATTERY MODULE FIRST BATTERY BASE MODULE ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 115 ............................................................................................................................................................................ Attach 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. HEATER PAD AC CONNECTIONS FRONT VIEW SCREWS INPUT SIDE SCREWS FRONT VIEW INPUT SIDE (BOTTOM) L1/L RED L2/N AC INPUT WIRE BLACK GREEN AC INPUT (BOTTOM) LEFT SIDE VIEW SECOND BATTERY BASE MODULE ............................................................................................................................................................................ Route and dress the cable on the inside wall of the outer frame using the supplied self-stick anchors and cable ties. ............................................................................................................................................................................ Tighten 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.). ........................................................................................................................................................................................................................................................... A- 116 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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: 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 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 117 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 ............................................................................................................................................................................ Mount 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. ............................................................................................................................................................................ Attach the strap with the two sets of nuts and washers provided. ............................................................................................................................................................................ Torque the nuts to 28Nm (250 in.-lb.). RTN-2 STRAP FRONT RTN-1 SECOND BATTERY BASE MODULE ........................................................................................................................................................................................................................................................... A- 118 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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. ............................................................................................................................................................................ Refer to the figure below for an illustration of the DC cables. Quantity Cable ID Heat shrink #1 color RTN Black 24V Red Termination ID#1 Length (mm) +/-12mm RTN BUS – BASE#1 24V BUS – BASE#1 1600 1200 Termination ID#2 RTN BUS – BASE#2 24V BUS – BASE#2 Heat shrink #2 color Black Red ............................................................................................................................................................................ Select the two load cables, the two shorter cables (1200 mm) of the four supplied. These cables are coded red. ............................................................................................................................................................................ Remove 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 119 ............................................................................................................................................................................ Connect 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 ............................................................................................................................................................................ Route these two load cables through the conduit to the second battery base module. ............................................................................................................................................................................ Connect 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.). LOAD BUS LOAD BUS FIRST BATTERY BASE MOD ULE SECOND BATTERY BASE MOD ULE BUS BAR CONNECT TWO LOAD CABLES HERE CONNECT TWO LOAD CABLES HERE RIGHT EXAMPLE OF THE TWO PIGGYBACKED TERMINAL LUGS FRONT VIEW FIRST BATTERY BASE MODULE SECOND BATTERY BASE MODULE ............................................................................................................................................................................ Replace 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. ........................................................................................................................................................................................................................................................... A- 120 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 ............................................................................................................................................................................ Select the two return cables, the two longer cables (1600 mm) of the four supplied. These cables are coded black. ............................................................................................................................................................................ Remove 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 121 ............................................................................................................................................................................ 13 Torque the nuts to 28Nm (250 in.-lb.). RETURN BUS RETURN BUS FIRST BATTERY BASE MODULE SECOND BATTERY BASE MODULE CONNECT TWO RETURN CABLES HERE SECOND BATTERY BASE MODULE FIRST BATTERY BASE MODULE CONNECT TWO RETURN CABLES HERE EXAMPLE OF THE TWO PIGGYBACKED TERMINAL LUGS LEFT FRONT VIEW SOME DC RETURN CONNECTIONS IN THE FIRST BATTERY BASE MODULE OMITTED FOR CLARITY BUS BAR ........................................................................................................................................................................................................................................................... A- 122 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 123 How to install the batteries in the EZBFo battery modules Overview ............................................................................................................................................................................................................................................................. Purpose Step-by-step instructions are provided for the following tasks: Battery Safety How to install L1 batteries in the EZBFo battery modules How to install 12IR25 batteries in the EZBFo battery modules A - 125 A - 127 A - 134 Approved batteries You will need the following recommended materials or equivalent. 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) ........................................................................................................................................................................................................................................................... A- 124 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 125 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. ........................................................................................................................................................................................................................................................... A- 126 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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: Place batteries on a shelf A - 128 Connect the battery cables to all batteries A - 130 A - 132 Attach interconnecting bus bars to all battery strings 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. NUT or BOLT FOR BATTERY CABLE ATTACHMENT BATTERY STRAP 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. ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 127 Place batteries on a shelf Use the following procedure to place batteries on a shelf, starting with Shelf 1 (bottom). ............................................................................................................................................................................ Check 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 ............................................................................................................................................................................ Remove the two nuts and remove the top flange from the front of the battery module. Refer to the figure below. TOP FLANGE REMOVE NUT INSIDE RIGHT FLANGE REMOVE NUT INSIDE LEFT FLANGE BATTERY BASE MODULE ............................................................................................................................................................................ If 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 RETAINING BRACKET (FRONT VIEW) Remove these four bolts and the battery retaining bracket ........................................................................................................................................................................................................................................................... A- 128 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 ............................................................................................................................................................................ Lift and place each of the four batteries on the bottom battery shelf, with the battery terminals facing the front of the battery shelf. ............................................................................................................................................................................ Replace the battery retaining bracket. BATTERY RETAINING BRACKETS SHELF 2 SHELF 1 ............................................................................................................................................................................ Torque the bolts according to the table in Chapter 1. ............................................................................................................................................................................ Repeat Steps 1 through 6 for all battery shelves to be populated. ............................................................................................................................................................................ Replace the top flange removed in Step Important! ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 129 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. ............................................................................................................................................................................ Refer 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. Termination ID#1 Cable # Cable ID Heat shrink #1 color Termination ID#1 Length (mm) +/-12mm Termination ID#2 Heat shrink #2 color RTN 24V RTN 24V Black Red Black Red RTN BUS 24V BUS RTN BUS 24V BUS 425 425 575 575 BAT1( -) BAT2(+) BAT3( -) BAT4(+) Black Red Black Red Important! A battery wiring diagram is shipped with the cables ............................................................................................................................................................................ Remove the attaching hardware from the positive (+) terminals of batteries 2 and 4, and the negative (-) terminals of batteries 1 and 3. ........................................................................................................................................................................................................................................................... A- 130 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006 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. ............................................................................................................................................................................ Using 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 ............................................................................................................................................................................ Double 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. ............................................................................................................................................................................ Repeat steps 2 through 4 for all remaining populated battery shelves. ............................................................................................................................................................................ Torque the battery connections to the value shown on the batteries. UPPER SHELF LOWER SHELF ............................................................................................................................................................................................................................................................ 401-703-454 FOA Draft Issue 1 January, 2006 Lucent Technologies – Proprietary See notice on first page A- 131 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. ............................................................................................................................................................................ Starting 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. ............................................................................................................................................................................ Remove the interconnecting bus bar from the kit that is provided with each pair of batteries and polish the bus bar. ............................................................................................................................................................................ Apply antioxidant compound to the interconnecting bus bar. ............................................................................................................................................................................ Apply antioxidant compound to the positive (+) terminal of Battery 1 and the negative (-) terminal of Battery 2. ............................................................................................................................................................................ Place the interconnecting bus bar between the positive terminal of the left-hand battery (#1) and the negative terminal of the right-hand battery (#2). ........................................................................................................................................................................................................................................................... A- 132 Lucent Technologies – Proprietary See notice on first page 401-703-454 FOA Draft Issue 1 January, 2006
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