BBS2000 Installation Instructions

46
Battery Backup System

Transcript of BBS2000 Installation Instructions

Page 1: BBS2000 Installation Instructions

Battery Backup System

Page 2: BBS2000 Installation Instructions

Copyright

© Copyright Ericsson AB 2005, 2007. All rights reserved.

Disclaimer

No part of this document may be reproduced in any form without the writtenpermission of the copyright owner.

The contents of this document are subject to revision without notice due tocontinued progress in methodology, design and manufacturing. Ericsson shallhave no liability for any error or damage of any kind resulting from the useof this document.

Abstract

This document describes the procedure for installation of the Battery BackupSystem, BBS 2000.

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Contents

Contents

1 Introduction 1

1.1 Target Group 1

1.2 Revision Information 1

2 Preconditions 1

2.1 General 1

2.2 Health and Safety Information 2

2.3 Tools and Equipment 2

2.4 Documentation 3

3 Installation Procedure 4

3.1 Unpacking and Preparing the BBS 4

3.2 Installing the Rack 4

3.3 Rack Layout 8

3.4 Mounting and Interconnecting the Batteries, 6 V Blocks 9

3.5 Mounting and Interconnecting the Batteries, 12 V Blocks 15

3.6 Connecting Cables 24

4 Start-Up Procedure 30

5 Extending the BBS 31

5.1 Battery Extension Without ICU 32

5.2 Battery Extension with ICU 34

6 Interconnection of BBS 2000 and BBS 2202 35

6.1 Principle of Interconnection 35

6.2 Materials 35

6.3 Preparating the Cabinets 36

6.4 Interconnecting the Cabinets 38

6.5 Starting Up the System 39

7 Concluding Routines 40

7.1 Updating the Site Installation Documentation 40

7.2 Performing Final Checks 42

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Preconditions

1 Introduction

This document describes the procedure for installation of the Battery BackupSystem, BBS 2000.

1.1 Target Group

The target group for these instructions is the installation personnel performingthe installation of BBS 2000.

1.1.1 Qualifications for Installation Personnel

Ericsson recommends that personnel performing the installation procedurepossess the following skills:

• Technical college or equivalent education with emphasis on electricalengineering

• Familiarity with the equipment used during the installation process

• An understanding of technical English

1.2 Revision Information

Other than editorial changes, this document has been revised as follows:

• Instructions concerning battery trays added

2 Preconditions

This section provides information on health and safety, tools, equipmentrequired and conditions to be met before starting this procedure.

2.1 General

The batteries to be installed must be in good condition, fully charged andwithout visible damages.

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2.2 Health and Safety Information

Personnel should exercise care when working on or around electricalequipment. In addition to this safety information, the specific safety instructionsfor all products involved in the installation procedure should be adhered to.

Caution!

Improper handling of batteries can result in the batteries short-circuiting, whichcan result in serious injury due to high energy levels. Exercise the necessarycare when working with batteries.

Caution!

Batteries can leak electrolyte if improperly handled. Electrolyte in contactwith skin or eyes can cause injury. In the event of electrolyte injuries, rinsethe affected area with water and seek medical attention immediately. Useprotective equipment when replacing batteries.

Before starting the installation, see Chapter Personal Health and Safety in theInstallation and Integration Manual for the specific RBS.

2.3 Tools and Equipment

The following tools and equipment are required:

• Tools used for RBS installation

• Crimping tool for cable lugs

• Insulated tools for the battery interconnections

• Screws and plugs suitable for the floor material

If the battery racks must be earthquake protected, then M12 screws andanchors must be used.

To facilitate lifting the cabinets, the following RBS equipment may be used:

• Lifting eye, SAR 201 100/03

For further information on tools, see:

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Preconditions

Standard Tools and EquipmentCatalogue EN/LZT 720 0013

2.4 Documentation

The following documents are necessary for the installation:

• Floor plan of site

• Shipping specification

• Battery documents from the battery supplier

• Manuals:

Temperature Sensor, KET 103 03 1553–KET 103 03

Installation Kit for Battery ServiceDisconnectors, BMY 201 237/11 6/1531–BMY 201 237

Installation Kit for Interconnection Unit,BMG 701 030 8/1531–BMY 201 237

Documentation for Earthquake Protection

This section lists the documents needed if earthquake protection is to be usedat the site.

6 V block batteries:

Installation Kit for Seismic ShockProtection, BMY 201 2237/12 7/1531–BMY 201 237

12 V block batteries:

Earthquake Securing Kit,NTM 201 3262/2 1531–NTM 201 3262/2

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3 Installation Procedure

This section provides instructions for how to install the BBS 2000.

If an extension configuration is used, then it is recommended that the extensioncabinet is placed to the right of the main cabinet in order to facilitate cabling.

3.1 Unpacking and Preparing the BBS

This section provides instructions for unpacking the BBS and preparing it forlifting into place.

1. When the equipment arrives, make sure that all the boxes listed in theshipping specification are delivered and have the correct numbers.

2. If a lifting device will be used to lift the cabinets, then fit the lifting eyes tothe top of the cabinet, see figure below.

Figure 1 Fitting the Lifting Eyes

3.2 Installing the Rack

The racks must be fastened to the floor to prevent them from falling over.Screws and plugs used to fasten the rack must be suitable for the floor material.

1. Determine the location of the battery rack using the floor plan for the site.

2. Mark the location of the holes for securing the battery rack, see figure below.

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Figure 2 Marking Location of Holes

3. Drill the holes and mount the anchors, see figure below.

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Figure 3 Drilling Holes and Mounting Anchors

4. Install the rack over the prepared holes, using a level gage to ensure thatthe rack is level in all directions. See figure below.

5. Fasten the rack to the floor.

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Figure 4 Levelling and Fastening the Rack

Earthquake Kit

If an earthquake kit will be used for fixing batteries to the rack, then theinstructions for installing the seismic kits must be followed, see Page 3.

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3.3 Rack Layout

The location in the BBS of 6 V or 12 V batteries, BFU, DC/DC converter andthe ICU is shown in the figure below.

P013082A

BFU

DC/DC

ICU

Batteries

Figure 5 Location of Major Units in the BBS 2000

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3.4 Mounting and Interconnecting the Batteries, 6 V Blocks

This section describes how to install the 6 V block batteries in the rack.

Note: To avoid that a possible short circuit current exceeds the maximuminterrupt current of the system circuit-breakers, install only batterystrings with the following specifications:

Four 6 V monoblocks (2 V/cell) in series with a minimum internalresistance of 1.5 milliohms/block.

If earthquake protection is required, see the following:

Installation Kit for Seismic ShockProtection BMY 201 237/12 7/1531–BMY 201 237

1. Mount the battery support on the shelf so that the batteries cannot movebackwards, see figure below. The position of the support depends upon thetype of battery blocks used.

Figure 6 Placing 6 V Battery on Support

Caution!

Batteries can leak electrolyte if improperly handled. Electrolyte in contactwith skin or eyes can cause injury. In the event of electrolyte injuries, rinsethe affected area with water and seek medical attention immediately. Useprotective equipment when replacing batteries.

2. Beginning with the bottom row positions, place the battery block on theshelf in the rack, with the lid outside the shelf. Continue upwards as eachrow is completed.

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Batteries are mounted in the horizontal position.

3. Starting from the bottom row of batteries, connect all the inter-cellconnectors except for the top row. The inter-cell connectors marked in thefigure below will not be connected until the equipment is put into operation.

Figure 7 Mounting Inter-cell Connectors Between 6 V Batteries

4. Use a torque wrench to tighten the battery connectors to the torqueindicated in the battery’s installation instructions.

5. Mount the temperature sensors on the upper shelf battery block as close tothe center as possible, see figure below. All temperature sensors should bemounted on the same block. For more information about the temperaturesensor, see:

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Temperature Sensor KET 103 03 1553–KET 103 03

Figure 8 Installing Temperature Sensor, 6 V Batteries

Note: If the battery block is secured by a belt, check that the temperaturesensor is not covered by the belt.

6. Connect the cable of each temperature sensor to a BFU, see figure below.

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Figure 9 Connecting Temperature Sensor Cables to BFU

7. Connect the positive and negative prefabricated battery cables to the barsunder the subrack, see figure below.

Note: The inter-cell connectors between the top two rows of batteriesare not to be connected until all other connections in the systemare made.

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Figure 10 Connecting Battery Cables, 6 V Batteries

8. Strap the battery cables to one side of the rack, see figure below.

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Figure 11 Strapping Battery Cables

Service Disconnectors

If service disconnectors are to be installed, follow the instructions in thedocument below:

Installation Kit for Battery ServiceDisconnectors BMY 201 237/11 6/1531–BMY 201 237

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3.5 Mounting and Interconnecting the Batteries, 12 VBlocks

This section provides instructions for mounting the 12 V battery blocks in therack.

In 12 V battery configurations, battery strings are vertical. Four batteriesmounted in a vertical line are coupled to work as one 12 V block. Strings areplaced from left to right in the rack. For each battery string, a plus and a minuscable will be connected to the cable bushing located on the back panel underthe BFU.

1. Remove the plate immediately under the BFU, ICU, and DC/DC converterby removing the screws at each side.

2. Locate the four holes with cable bushings at the front of the shelf under theBFU, ICU, and DC/DC converter, see figure below. These will be used forthe positive cables. Pull the plus cables through the cable bushings.

P013222A

(+) Connectors

Holes for( ) Connectors

( ) Connectors

Holes for(+) Connectors

Figure 12 Connecting Plus and Minus Cables, 12 V Batteries

3. Fasten the cables to the cable shoes on the copper bar B+ (left side) underthe BFU, see figure above.

The cables should not yet be connected to the batteries.

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4. Locate the four holes with cable bushings at the rear of the shelf under theBFU, ICU, and DC/DC converter, see Figure 12 on page 15. These will beused for minus cables. Pull the minus cables through the cable bushings.

5. Fasten the cables to the cable shoes on the copper bar B– (right side)under the BFU, see Figure 12 on page 15.

The cables should not yet be connected to the batteries.

6. If front terminals are not already mounted on the batteries, then mount oneto each of the four battery blocks using M8 bolts and washers, see figurebelow. Tighten to a torque of 8 Nm.

Figure 13 Mounting Front Terminals, 12 V Batteries

7. Attach the adhesive cushions to the right side of three batteries, see figurebelow. These batteries will be used on the first, third, and fourth rows ofbatteries.

Figure 14 Positioning Adhesive Cushions, 12 V Batteries

8. Attach the temperature sensor holder and an adhesive cushion to the rightside of a fourth battery, see figure below.

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Figure 15 Positioning Temperature Sensor Holder, 12 V Batteries

9. To avoid short circuit, put an insulating plastic battery tray under eachbattery before placing the battery on the shelf, see figure below.

P018854A

Figure 16 Battery Tray

10. Starting at the bottom and working upwards, place one battery at the far leftside of each shelf. The battery with a temperature sensor holder is placedon the second shelf from the top. The batteries on the top shelf and bottomtwo shelves will each have two adhesive cushions.

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Figure 17 Placing Battery String in Rack

11. Press the temperature sensor into the temperature sensor holder on thesecond battery from the top, see figure above. Connect the other end ofthe temperature sensor cable to the BFU, see Figure 18 on page 19 forBFU-21 and Figure 19 on page 20 for BFU-22.

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Figure 18 BFU-21 Front Panel

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Figure 19 BFU-22 Front Panel

12. Mount the inter-block connector A between the second and third batteries,see figure below. The plastic side faces outwards. Fasten at the upper leftand lower right corners with nuts and washers.

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Figure 20 Mounting Inter-Block Connector A, 12 V Batteries

13. Mount an inter-block connector B between the first and second batteries,and another between the third and fourth batteries, see figure below.Fasten each inter-block connector with two nuts and washers.

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Figure 21 Mounting Inter-Block Connector B, 12 V Batteries

14. Using a torque of 6 Nm, connect the plus battery cable to the first (top)battery, see figure above. Fasten with a nut and washer.

15. Using a torque of 6 Nm, connect the minus battery cable to the fourth(bottom) battery, see figure above. Fasten with a nut and washer.

16. Put on the intact pole protection at the first (top) battery. It is secured byfour pins on the sides.

17. For the second, third, and fourth batteries, break off the front of the poleprotection so that the protection will fit over the poles behind the inter-blockconnectors, see figure below. Fit the front part over in front of the inter-blockconnectors so that it is held in place by the two pins in the centre. Fit therear part behind the inter-block connectors so that it is held in place bythe four pins on the sides.

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Figure 22 Attaching Pole Protections, 12 V Batteries

18. If more battery strings are needed, repeat steps 1 – 16 except step 7. Noadditional temperature sensors are needed for the other strings.

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3.6 Connecting Cables

This section describes how to connect cables to batteries, BFUs, and theprotective earth system. The top plate of the BBS 2000 can be removed foreasier access to some of the cable connections.

The types of cables to be connected are as follows:

• Optical communication cables between the BBS and the RBS, see Section3.6.1 on page 26

• Power distribution cables between the BBS and the transmission supply,see Section 3.6.1 on page 26

• ICU signalling cable (used with the ICU option)

• Power distribution cables between the BBS and the RBS, see Section3.6.2 on page 27

• Protective earth, see Section 3.6.3 on page 29

The location of the optical and ICU cables is shown in the figure below.

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Figure 23 Connecting Cables

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3.6.1 Connecting Optical and Transmission Power Supply Cables

This section provides instructions for connecting the optical cables betweenthe BBS and an RBS, and transmission power supply cables between theBBS and the transmission equipment.

Note: The maximum load allowed for each BFU provided must not exceed80% of the marked fuse rating for continuous loads exceeding 3 hours.

1. In the BBS 2000, connect the TD and RD optical cables to the BFU, seefigure below and Figure 18 on page 19 for BFU-21 or Figure 19 on page20 for BFU-22.

P008318B

TDRD TD

RD

+

+

Figure 24 Connecting Cables Between BBS and RBS (RBS 2206 shown)

2. Connect the other end of the optical cables to the FCU in the RBS, seeInstallation and Integration Manual for the specific location in each RBS.

3. Connect the transmission power supply cable to the front of the BFU in theBBS. Connect the other end to the transmission equipment.

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3.6.2 Power Distribution Cables

The cables which distribute power from the BBS 2000 to the RBS are locatedon the top of the BBS 2000.

The cross-sectional areas of the power distribution cables depends upon theRBS and cable length, see table below.

Table 1 Dimensions for Distribution Cables

RBS Distance Cable Dimension

<10 m 95 mm2RBS 2206

10 - 15 m 150 mm2

<11 m 50 mm2RBS 2202 andRBS 2207 11 - 15 m 70 mm2

1. Remove the top plate of the BBS 2000 for easier access to cableconnections.

2. Connect the distribution cables according to the figure below. Fasten thecables with a torque of 22.5 Nm. Connections are made in a similar manneron the positive side and the negative side.

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��������

����������������

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Figure 25 Connecting Distribution Cables to the Battery Cabinet, Viewedfrom Top of Cabinet

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3. Connect the other ends of the distribution cables to the DC filter in the RBS,following the instructions given in the Installation and Integration Manualfor the specific RBS. See Figure 24 on page 26.

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3.6.3 Protective Earth

This equipment must be connected directly to the DC earth collector bar (MainEarth Terminal), or to the point to which the earthing electrode of the DC supplysystem is connected.

There must not be any switching or disconnection devices in this connection.

DC equipment located in the same immediate area (such as adjacent cabinets)must be earthed to the same earthing point.

1. Connect an insulated 35 mm2 cable between the earth clamp on the top ofeach rack and the earth cable connected to the MET (Main Earth Terminal),see figure below.

Figure 26 Earth Clamp on Top of Rack

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4 Start-Up Procedure

1. Ensure that the Battery Disconnect switch in all BFUs are in the Disconnect(down) position.

2. Start the RBS by switching on mains power and wait until the LEDs on thereplaceable units (RUs) in the BBS show a steady green light. The BFUswill also indicate ‘‘Battery Disconnected’’ with a yellow LED. If the red LEDis illuminated on any RU in the BBS, remove the RU.

3. Connect the batteries to the BBS.

For systems with 6 V blocks, this is done by connecting the last inter-cellconnection in the battery strings.

For systems with 12 V blocks, this is done by connecting the minus cablesto the battery blocks.

4. Change the Battery Disconnect switch in all BFUs to the Connect (up)position. If the battery voltage and the PSU voltage are within set limits, thecontactors in the BFUs will connect the RBS to the batteries.

5. Ensure that all circuit breakers are in the On position. To avoid alarms, alsocheck that circuit breakers which are not in use are in the On position.

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Extending the BBS

5 Extending the BBS

The BBS 2000 may be extended by using an additional battery rack. If the twobattery racks are immediately adjacent to one another, they are electricallyconnected using special cables and no ICU, see Section 5.1 on page 32. If theracks are not next to each other, then the ICU is used to connect them, seeSection 5.2 on page 34.

Figure 27 BBS Rack Extension

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5.1 Battery Extension Without ICU

When the battery is extended with another battery rack adjacent to the existingone, the electrical interconnection should be made with cables and cablelugs protected by conduits (included in set of parts BMY 201 237/14), seefigure below.

Figure 28 Connector RPM 626 011/x

1. Check that there is no voltage between the battery bars of the extensioncabinet.

If there is voltage, a block connector of the battery must be opened.

2. Check with an ohm-meter that there is no connection between the batterybars of the extension cabinet or between the positive bar and the cabinetchassis.

3. Use connector RPM 626 011/2 to connect the minus cable from the B ‘‘–’’terminal of the extension cabinet to the B ‘‘–’’ terminal of the first cabinet,see figure below.

Figure 29 Connecting Cables Between Battery Racks Without ICU

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Extending the BBS

4. Use connector RPM 626 011/1 to connect the plus cable from the B ‘‘+’’terminal of the extension cabinet to the B ‘‘+’’ terminal of the first cabinet,see figure above.

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5.2 Battery Extension with ICU

The ICU is required when the racks are separated (not installed close to eachother). The ICU forms a connection between the battery positive bars in the BBSracks to be joined. The materials are included in set of parts BMY 201 237/13.

1. Connect the other rack to the ICU according to Figure 30 on page 34 andthe following instructions:

Installation Kit for InterconnectionUnit BMG 701 030 8/1531–BMY 201 237

Use double-insulated 95 mm2 cables (included in BMY 201 237/9) if thedistance between cabinets is 10 m or less, and 150 mm2 cables (includedin BMY 201 237/10) for distances of 10 – 15 m.

Figure 30 Rack Extension with ICU

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Interconnection of BBS 2000 and BBS 2202

6 Interconnection of BBS 2000 and BBS 2202

This section describes how to connect a BBS 2000 together with a BBS 2202.

Note: The distance between the BBS cabinets must not exceed 10 m.

6.1 Principle of Interconnection

Interconnection is made with cables with minimum cross–sectional area of95 mm2. The positive cable is connected to one of the DFUs in the BBS 2202and to an ICU in the BBS 2000. The negative cable interconnects the negativebusbars of the systems. See figure below.

Figure 31 Schematic Diagram for Interconnecting BBSs

6.2 Materials

The following materials are needed for interconnecting a BBS 2000 with aBBS 2202.

Table 2 Materials for Interconnection

Product Number Description Quantity orAmount

BMY 201 237/13 Installation kit ICU 1

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Product Number Description Quantity orAmount

TFL 103 108/08 Cable, 95 mm2 (included inBMY 201 237/9)

20 m

SNG 809 63 Cable lug 2

6.3 Preparating the Cabinets

The batteries to be interconnected in the systems must be in good condition,fully charged and without visible damages. Check them according toestablished procedures.

1. Switch off the CBs of the BBS cabinets to disconnect the RBSes.

2. Using insulated tools, disconnect all the batteries in both the BBS 2202 andthe BBS 2000, as follows:

6 V blocks Disconnect the battery by removing one of its inter-cellconnectors, see Figure 7 on page 10.

12 V blocks Disconnect the battery by removing the minus cablefrom the battey block, see Figure 21 on page 22.Insulate the cable lug with tape.

3. In the BBS 2202, move the battery “+” cable from DFU input B3+ to DFUinput B2+. Place the cable lug on top of the existing cable lug at B2+. Seefigure below.

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Figure 32 Moving Positive Cables on RBS 2202 DFU Inputs

4. Install an ICU in the BBS 2000 cabinet according to the followinginstructions:

Installation Kit for InterconnectionUnit BMG 701 030 8/1531–BMY 201 237

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6.4 Interconnecting the Cabinets

1. Connect the plus (+) cable from the ICU ‘‘+’’ terminal in BBS 2000 to B3+ inthe BBS 2202.

2. Connect the minus (–) cable from the ICU ‘‘–’’ terminal in BBS 2000 toB3– in the BBS 2202.

Figure 33 Interconnecting BBS 2000 and RBS 2202

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6.5 Starting Up the System

1. Using insulated tools, reconnect the batteries in both the BBS 2202 andthe BBS 2000, as follows:

6 V blocks Connect the batteries to the BBS by connecting the lastinter-cell connections in the battery strings.

12 V blocks Connect the batteries to the BBS by connecting theminus cables to the battery blocks.

2. Set the circuit breakers of the BBS cabinets to the On positions to connectthe RBSes.

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7 Concluding Routines

Before leaving the site, ensure the following:

If any battery in the cabinet is missing a battery tray, place one under thatbattery.

If acid has leaked out on a tray or if a tray is otherwise damaged, replace thattray.

Note: Ericsson strongly advises that when cleaning up after installing theRBS cabinet, the personnel performing the installation pay particularattention to the environment. Primarily, recycle all waste materials thatcan be recycled and sort waste so that it can be disposed of accordingto local regulations.

Table 3 Objects to be Recycled or Disposed of after Cabinet Installation

Item Sort or recycle?

Cable insulation fromcrimping, brazing orwelding

Packing chips

Foam

Polystyrene

Bubble plastic

Cable tie clippings

Sorted with plastics

Paper and wood Paper recycling

Waste metal from cableladders

Pieces of cable

Nuts, bolts, washers andscrews

Recycled or sorted as metals

Note: All packing material should be recycled, and shock absorbers disposedof, in accordance with local recycling regulations.

7.1 Updating the Site Installation Documentation

1. Check the Site Installation Documentation for deviations from the actualinstallation.

2. Update the documents with the changes that apply.

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Concluding Routines

3. Send the documents to the person responsible for Site InstallationEngineering.

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7.2 Performing Final Checks

Before leaving the site, ensure that the following tasks have been completed:

Table 4 Checklist

Check the following: OK

1 All cables are properly routed and connected. Whereapplicable, cables are strapped to the plate on the top of thecabinet, or to the sides of the cabinet.

2 The site is clear of waste materials.

3 The Site Installation Documentation is updated.

4 The modified Site Installation Documentation has been handedover to the person responsible for the site.

5 All doors are closed and locked.

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