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ONLITE central CPS
Installation instruction
Legal notes
TrademarksONLITE® is a registered trademark of Zumtobel Lighting GmbH, Dornbirn.
CopyrightCopyright © 2008 Zumtobel Lighting GmbH
All rights reserved.
ManufacturerZumtobel Lighting GmbHSchweizerstraße 30A-6850 Dornbirn/AustriaTel. +43-(0)5572-390-0Fax +43-(0)[email protected]
Document number CPS_MA_25.06.08 en
1
Contents
Contents 1
1 Introduction and safety regulations 3
1.1 General information 3
1.2 Safety and danger notes 4
1.3 Designated use 5
1.4 Notes on illustrations and block diagrams 6
2 Installing the switch cabinet 7
2.1 System types 7
2.1.1 Compact station CPS K 7
2.1.2 Main station CPS H 8
2.2 Installation 9
2.3 Preliminaries 10
3 Installation 11
3.1 Connecting the relay outputs 11
3.2 Connecting the ONLITE central CPS Remote Interface 12
3.3 Connecting the line monitors 13
3.3.1 Connecting the line monitors in a circuit monitored sub distribution 13
3.3.2 Connecting the line monitors in a single monitored sub distribution 13
3.4 Connecting the emergency circuits 14
3.4.1 Connecting the emergency ciruits in a circuit monitored sub distribution 14
3.4.2 Connecting the emergency ciruits in a single monitored sub distribution 15
2
3.5 Connecting the 230 V AC / 400 V AC voltage supply 16
3.6 Installing and connecting the batteries 17
3.6.1 Connecting the batteries of an ONLITE central CPS K system(compact station) 17
3.6.2 Connecting the batteries of an ONLITE central CPS H system(main station) 19
3.6.3 Possible set-ups for battery sets 20
4 Connecting external sub distributions 22
4.1 Connecting the system bus 22
4.2 Connecting the voltage supply 24
5 Switching on the system 25
6 Completing the installation 26
Appendix 27
A Technical Data 27
A.1 General 27
A.2 Compact station CPS K 27
A.3 Main station CPS H 28
A.4 Sub station CPS U 29
B Fuses 29
C HANDLING INSTRUCTIONS FOR SEALEDVENT-REGULATED LEAD ACID BATTERIES 31
C.1 Safety instructions 31
C.2 Storage instructions 32
C.3 Commissioning 32
C.4 Operating regulations 32
C.5 Charging, discharging 33
C.6 Battery service and maintenance 34
C.7 Warranty 35
C.8 Table of torques for the battery connectors 35
3
1 Introduction and safety regulations
1.1 General information
Validity and technical state of this installation instruction
This installation instruction is valid for the following ONLITE central CPS devices:
Hardware version: B
Signs and symbols used in the documentation
The following signs and symbols are used in this documentation:
Type Order number
ONLITE central CPS K (compact station) 22 154 689
ONLITE central CPS H (main station) 22 154 690
ONLITE central CPS U E00 (substation in E0 version) 22 154 691
ONLITE central CPS U E30 (substation in E30 version) 22 154 692
ONLITE central CPS BS (battery cabinet) 22 154 693
ONLITE central CPS BG (battery rack) 22 154 694
ONLITE central CPS Touch PC 22 161 687
ONLITE central CPS Remote Interface 22 154 740
Symbol Description
p One step text instructions in instructions for action are marked with p. The individual steps of multiple step instructions for action are numbered.
a Indicates the result for the action step after several action steps. These results are marked with an a symbol at the beginning of the line.
V Requirements which need to be checked before operation are highlighted with V.
i Notes are marked with the symbol i.
d Warning notes are marked with the symbol d. Warning notes also contain the source of the danger as well as the consequence of the danger.
Warning notes are combined with the following signal words:Danger: Warns of damage to persons (death or severe injury).
Caution: Warns of damage to persons (death or severe injury) which are dependent on further actions.
Warning: Warns of material damages.
4
Who may perform the installation?
The installation may only be performed by suitably qualified professional electrical specialists who have been briefed on local and operational conditions.
1.2 Safety and danger notes
The central battery system ONLITE central CPS is part of the emergency and general lighting system and consequently part of a building's safety equipment. Installation and commissioning of the system must be performed with the appropriate care and precision.
d DangerPlease note that the luminaires are supplied with 216 V DC in case of emergency operation. Mortal danger by electrical shock!
d DangerOnly qualified electrical specialists may perform work on the 230 V mains. Wiring of current-carrying lines as well as signal and control lines must be done in accordance with the relevant guidelines and standards. National guidelines and regulations applicable in the country in which the system is being installed and operated have to be observed.
d DangerImproper use of the batteries or battery-powered parts of the system can cause risk of injury or mortal danger from high current or arcs that can occur briefly on battery discharge.Ensure that the batteries are connected to the correct poles!
d DangerNon-authorised or non-professional system installation and handling may result in outages of the safety equipment. This implies immediate danger for people and the security equipment itself. In addition, damages to machines and plants as well as loss of productions are possible consequences at production sites.
d CautionNon-authorised or non-professional system installation and handling may result in damages of the batteries. The contained electrolyte sulphuric acid is extremely caustic and can lead to heavy injuries!
5
d CautionOnly luminaires with an operation voltage of 230 V AC (50 / 60 Hz) and 230 V DC may be connected to the outputs for the emergency lighting end circuits of the ONLITE central CPS system. Disregarding the instructions may result in damages to system and luminaires.
d CautionShort circuits and incorrect polarity may damage the batteries or parts of the system.
d CautionPay attention to the line lengths of the output circuits. The maximum length of 300 m may not be exceeded. Disregarding the instructions may result in outages of the emergency lighting, because the proper communication between the system components is not guaranteed.
d CautionThe batteries may not be stored without maintaining for longer than 3 months. Disregarding the instructions may result in damages to the batteries. When storing the batteries without conservation charging, the battery capacity decreases up to the defect of the battery.
1.3 Designated use
The central battery system ONLITE central CPS is designed for controlling and monitoring an emergency lighting system. Any use in excess thereof is not allowed.
The adjustment and operation of the system is restricted to authorised technical staff.
Personal dangers may occur in case of
• improper use• disregarding the safety regulations
The central battery system ONLITE central CPS and connected parts of the system may only be operated if all system components are in perfect technical condition and in compliance with
• the safety and danger notes contained in this installation instruction,• the operating and safety instructions stipulated by the system operator,• the commissioning notes and instruction manual supplied with the central battery system
ONLITE central CPS,• the technical data listed in the appendix.
Failures which cannot be removed by acknowledging are to be reported to the responsible service person.
Operating and safety regulations arise from this installation instruction as well as from organisational instructions and from general as well as technical guidelines and regulations for accident prevention.
6
The manufacturer will not assume warranty or liability for consequential damages that occur due to:
• improper use• disregarding the regulations• unauthorised modifications or modifications made by technically non-competent persons
to device connections and settings of the ONLITE central CPS system• the use of not allowed or unsuitable system parts
d DangerAlso pay attention to all laws, standards and guidelines applicable in the country in which the system is being operated.
d CautionVerify whether electrical installations comply with the application environment. Special environmental conditions (e.g. areas subject to explosion hazards or areas with an aggressive atmosphere) require special equipment and installations.
d CautionVerify whether all used ballasts and luminaires fulfil the requirements of an emergency lighting system and the operation at an ONLITE central CPS system.
d CautionIf mains, which supplies the ONLITE central CPS system, is interrupted longer than three days, the battery has to be disconnected to prevent from deep discharge and thus damage of the battery.
1.4 Notes on illustrations and block diagrams
Illustrations and block diagrams in these installation instruction are partly for demonstration purposes only. Drawings and plans that were especially created for the emergency lighting system and are in accordance with local requirements must be observed.
7
2 Installing the switch cabinet
i The ONLITE central CPS systems shown in this installation instruction can differ in the modular design on delivery.Special features of customer-specific systems are described in the project documentation which must be ordered separately.
2.1 System types
2.1.1 Compact station CPS K
The following figure shows an ONLITE central CPS K system with one circuit monitored sub distribution and one individually monitored sub distribution.
(1) Charging unit LE(2) Circuit monitored sub distribution S(3) Individually monitored sub distribution E(4) Battery compartment
1 2 3
4
8
2.1.2 Main station CPS H
The following figure shows an ONLITE central CPS H system with two circuit monitored sub distributions.
(1) Charging unit LE(2)/(3) Circuit monitored sub distributions S
Flange plate for connection cablesThe connection cables are routed into the cabinet through the drillings in the flange plate on top of the cabinet (see following figure). The flange plate contains rubber bushings for different cable diameters (8 mm to 44 mm). Each switch cabinet has three flange plates.
1 2 3
9
2.2 Installation
The switch cabinets of the ONLITE central CPS system must only be installed on flat surfaces providing enough carrying capacity. Enough space must be provided to the sides and the back of the cabinets to provide sufficient work space for the installation and future maintenance work. Ensure that the doors of the switch cabinet can be opened completely.
The connections for the power supply of the ONLITE central CPS system must be provided by the customer according to the technical data given in appendix A and the wiring diagrams.
i We recommed to ensure at least 1 m free work space on each side of the switch cabinet. The switch cabinet dimensions are listed in appendix A of this installation instruction.
10
2.3 Preliminaries
Before installing the ONLITE central CPS system, open the following fuses:
• Main fuses: -2F1, -2F2, -2F10.2 and -2F10.2• Battery fuses: -2F4, -2F5, -2F6 and -2F7• Outgoing fuses in the individual sub distributions: F1 to F20, both for phase L (red labelled
fuses) and for the neutral wire N (blue labelled fuse).
If the battery case (ONLITE central CPS K) or the battery cabinets (ONLITE central CPS H) contain any batteries, you have to remove them prior to installation. In this case, also note the instructions described in chapter "Handling instructions for sealed vent-regulated lead acid batteries" (see chap. C on page 31).
i Already installed and connected batteries must be removed taking into account the battery installation order.
11
3 Installation
3.1 Connecting the relay outputs
Connection of the relay outputs has to be performed in accordance with the schematic drawing shown below and the plans and drawings valid for the conditions at the installation site. The charging unit of the ONLITE central CPS system provides five potential-free relay outputs which can be used either as normally closed or normally open contact each.
1. Route the connection cables into the cabinet through the flange plate at the top side of the switch cabinet (see chap. 2.1.2 on page 8).
2. Connect the relay outputs to the terminal block -2X4 of the charging unit relay module (see following figure).
i The relay outputs are implemented potential-free. If a signal voltage is required, the internal 24 V DC voltage supply is provided at terminal block -2X5. The 24 V DC voltage must be wired to the middle contact (Common) of the corresponding relay.
d DangerLeave no connection cables temporarily loose and unsecured.
24
VD
C
0V
-2x5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
-2x4
Ö4 C4 S4 Ö5 C5 S5 Ö6 C6 S6 Ö7 C7 S7 Ö8 C8 S8
1 2
Rel
ay o
utpu
t 4
Rel
ay o
utpu
t 5
Rel
ay o
utpu
t 6
Rel
ay o
utpu
t 7
Rel
ay o
utpu
t 8
Inte
rnal
sig
nal
volta
ge s
uppl
y
12
3.2 Connecting the ONLITE central CPS Remote Interface
Connection of the ONLITE central CPS Remote Interface (Art. No. 22 154 740) has to be performed in accordance with the schematic drawing shown below and the plans and drawings valid for the conditions at the installation site.
d DangerComply with the national regulations and guidelines for indicating and signalling when using a remote switch or remote indicator for emergency lighting systems.
The ONLITE central CPS Remote Interface is powered by the internal 24 V DC voltage supply of the ONLITE central CPS system.
d CautionDo not use an external 24 V DC voltage supply. Disregarding the instructions may result in outages of the emergency lighting because the proper communication between the system components may not be guaranteed.
Connect the ONLITE central CPS Remote Interface as follows:
24
V
0V
2x5
1 2 3 4 5 6 7 8 9 10 11 12 1314 15
-2x4
S2
S3
S4
S5
S6
S7
ONLITE central CPSRemote Interface
Ma
ins
op
era
tio
n
Ba
tte
ryo
pe
ratio
n
Fa
ilure
OF
F
S5+ S5- Rel5 Rel6 Rel7
Ö4 C4 S4 Ö5 C5 S5 Ö6 C6 S6 Ö7 C7 S7 Ö8 C8 S8
Fan
err
or m
essa
geM
aint
aine
d lig
ht O
n/O
ffF
ree
Block system
Fre
eF
ree
13
3.3 Connecting the line monitors
3.3.1 Connecting the line monitors in a circuit monitored sub distribution
Connect the line monitors to the input terminals S1 to Sx of the circuit monitored sub distribution (depending on the configuration of the ONLITE central CPS system).The terminal block is labelled -4X1 (see following figure).
3.3.2 Connecting the line monitors in a single monitored sub distribution
Connect the line monitors to the input terminals S1 to Sx of the single monitored sub distribution (depending on the configuration of the ONLITE central CPS system).The terminal block is labelled -5X1 (see following figure).
14
3.4 Connecting the emergency circuits
d CautionNote the line length limitation of the output circuits. The maximum length of 300 m may not be exceeded. Disregarding the instructions may result in outages of the emergency lighting because the proper communication between the system components is not guaranteed.
d CautionConnect the luminaires to the emergency circuits according to the specifications of the luminaires manufacturer. Disregarding the instructions may result in damages to the system and luminaires.
3.4.1 Connecting the emergency ciruits in a circuit monitored sub distribution
A maximum of 20 emergency circuits can be connected to each sub distribution. Each circuit is fused by two outgoing fuses.
1. Route the connection cables into the cabinet through the flange plate at the top side of the switch cabinet.
2. Connect each emergency circuit to the terminal blocks -4X2 and the PE terminal block in the switch cabinet of the ONLITE central CPS system or the external sub distribution (as shown in the following figure).
PE(yellow/green)
N (blue)
L (red)
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3.4.2 Connecting the emergency ciruits in a single monitored sub distribution
A maximum of 20 emergency circuits can be connected to each sub distribution. Each circuit is fused by two outgoing fuses.
1. Route the connection cables into the cabinet through the flange plate at the top side of the switch cabinet.
2. Connect each emergency circuit to the terminal blocks -5X1 (DALI terminals and PE terminal block) and -5X2 in the switch cabinet of the ONLITE central CPS system or the external sub distribution (as shown in the figure below).
i For connecting the emergency circuits of a single monitored sub distribution a 5-pin cable is used because two DALI connections D1 and D2 must be wired additionally to the voltage supply.
PE(yellow/green)
N (blue)
L (red)
DALI connection D1 and D2(brown/grey)
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3.5 Connecting the 230 V AC / 400 V AC voltage supply
The ONLITE central CPS system is powered by the general 230 V AC / 400 V AC mains or in emergency operation by the batteries (battery cabinet or battery rack) or an emergency generator.
Before connecting the voltage supply, ensure that
• the system and the supply lines are switched dead,• the fuses 2F1, 2F2, 2F10.1 and 2F10.2 are opened (removed).
d DangerWhen disregarding the preliminaries there is a risk of mortal danger due to live parts!
Proceed as follows to connect the ONLITE central CPS system to 230 V AC / 400 V AC mains:
1. Switch the system dead by opening the external main switch and protect the system against re-engagement.
2. Route the connection cables into the cabinet through the flange plate at the top side of the switch cabinet.
3. Connect the 230 V AC / 400 V AC mains and the earth wire to the screw terminals L1, L2, L3, N and PE of the terminal block -2X1 of the ONLITE central CPS switch cabinet.
i When connecting the 400 V AC voltage supply, please note that the phasing (L1-L3) corresponds to a clockwise rotating field. For this purpose a phase sequence indicator must be used.
L1 L2 L3 NPE
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3.6 Installing and connecting the batteries
Before connecting the batteries, ensure that
• no persons work on the installation,• all mounting and installation works are completed,• the battery fuses -2F4, -2F5, -2F6 and -2F7 have been removed. Two fuses for each sub
distribution are installed.
d DangerWhen disregarding the preliminaries there is a risk of mortal danger by electrical shock!
d DangerComply with the valid accidental regulations and wear protective clothes and protective goggles.
d CautionAlso note the maximum admissible torques for battery connectors (see chap. C.8 on page 35).
3.6.1 Connecting the batteries of an ONLITE central CPS K system (compact station)
The battery set for an ONLITE central CPS K (compact station) consists of 18 batteries connected in series (see chap. A.2 on page 27). The voltage of the battery set (system voltage) is 216 V DC.
i We recommend the following battery set-up in the compact cabinet switch:When arranging the batteries, the first battery has to be installed in the rear row and the last battery in the first row. This way, access to the battery connectors is easier and additionally the risk of danger is reduced.
The batteries of the battery sets from 24 Ah to 75 Ah are installed on two levels. The first nine batteries have to be installed on the floor board, the other nine batteries on the grating supplied with the system (see chap. 3.6.3 on page 20).
i In the switch cabinet of the compact station CPS K, the battery cabling is already connected to the fuses -2F4 and -2F5. The other two cable ends are ready for connection and can be found in the battery compartment.
Proceed as follows to connect the batteries of a compact station CPS K:
V Prepare the bridges, pole covers and numbering stickers supplied with the system.
18
1. Connect the blue labelled cable to the negative pole (-) of battery 1.
2. Install one of the supplied bridges between the positive pole (+) of battery 1 and the negative pole (-) of battery 2 and fix it accordingly.
3. Repeat step 2. for the other batteries until all batteries are connected in series.4. Connect the red labelled cable to the positive pole (+) of battery 18. The second end of the
cable is already connected to fuse -2F5.a The batteries are connected.
Rear side of the ONLITE central CPS switch cabinet
Floor board
19
3.6.2 Connecting the batteries of an ONLITE central CPS H system (main station)
An ONLITE central CPS H (main station) can be powered with 216 V DC either by a battery cabinet or a battery rack. The connection cables to the batteries must be provided by the customer.
V The connection cables to the batteries are available.
1. In the switch cabinet of the main station, connect the connection cables (+) and (-) to the terminals + and - of terminal block -2X1.
i Mark the connection cables at both ends with a red and blue labelling ring to ensure proper connection.
2. Now, connect the blue labelled cable to the negative pole (-) of the first battery.3. Insert the supplied bridges between the positive pole (+) of battery 1 and the negative pole
(-) of battery 2 and fix it accordingly.4. Repeat step 3. for the other batteries until all batteries are connected in series.5. Connect the red labelled cable with the positive pole (+) of the last battery and terminal (+)
of the terminal block -2X1.
20
3.6.3 Possible set-ups for battery sets
The following figures show set-up illustrations for the individual battery sets.
Battery set 17 Ah
Rear side of switch cabinet
Floor board
21
Battery sets from 24 Ah to 75 Ah
Rear side of switch cabinet
Gra
ting
Flo
or b
oard
Rear side of switch cabinet
Supply line (-)from charging unit
Supply line (+)from charging unit
22
4 Connecting external sub distributions
4.1 Connecting the system bus
The components of an ONLITE central CPS system communicate via the system bus (LON). For the system bus connection cables of the type JY (St)Y2x2x0.8 must be used.Two cables are required, where two cable wires are used for data exchange and two cable wires provide the 24 V DC-voltage supply.Connect the wires to the bus terminals which are mounted on the terminal block -4X2 (see the following figure).
i The bus system can be configured in line topology or free topology. Please observe the maximum cable lengths of 900 m (line topology) and 500 m (free topology).
Description of the system bus components
Designation Function
(1) 24 V voltage supply Terminals for the 24 V DC voltage supply of the system bus (core colours: re/bk)
(2) System bus (LON) Terminals for the data connection of the system bus (core colours: ye/wh)
(3) System bus connector Connector for plugging in the Touch PC (control unit)
3
2
1
23
Examples of the possible system topologies
i Depending on the used topology, the terminators of the ONLITE central CPS system must be installed and checked.When using the line topology, two terminators are required. In that case, one terminator is installed and connected in the cabinet of the main station CPS H or compact station CPS K ex factory. The second terminator must be connected to the bus terminals of the most remote located sub distribution (see chap. 4.1 on page 22).When using the free topology, only one terminator is required in the main station CPS H or compact station CPS K. This terminator ist already installed and connected ex factory.
- two terminators- max. bus length 900 m- cable type: JY (St)Y2x2x0.8
Line topology
- one terminator- max. bus length 500 m- cable type: JY (St)Y2x2x0.8
Free topology
24
4.2 Connecting the voltage supply
Up to seven (CPS H) or six (CPS K) external sub distributions can be connected to an ONLITE central CPS system.Two outgoing fuses are available for each sub distribution in the switch cabinet of the ONLITE central CPS system. The power supply lines for the sub distributions must be wired directly to the outgoing fuses.
Description of the outgoing fuses
i The cable types and line cross sections required for the voltage supply of the sub distributions can be found in the overall connecting diagram of your ONLITE central CPS system.For a permissible voltage drop also the distance and connected load are to be considered during line dimensioning.
External sub distribution Fuse label
UV03 4F103+ and 4F103-
UV04 4F104+ and 4F104-
UV05 4F105+ and 4F105-
UV06 4F106+ and 4F106-
UV07 4F107+ and 4F107-
UV08 4F108+ and 4F108-
UV09 (only CPS H) 4F109+ and 4F109-
25
5 Switching on the system
Perform the following checks and works while mains supply is switched off before switching on the ONLITE central CPS system:
• Check all works done and compare the established connections with the given plans and drawings.
• Make sure that all connections are firm.
d DangerWhen checking the battery connectors there is a risk of mortal danger.Use only insulated tools. Wear rubber gloves, protective goggles and protective clothes (incl. safety shoes) and take off metallic objects e.g. watches and jewellery.
• Remove all unused cables, insulation and fixing materials, tools and packaging.
To switch on the ONLITE central CPS system, proceed as follows:
1. Switch on the external main switch.2. Check the voltage supply at the terminals L1, L2, L3 and N of the terminal block -2X1. 3. Check the rotational direction of the voltage supply.4. Check whether all outgoing fuses of the circuits (F1 - F20 blue, F1 - F20 red) in the sub
distributions are opened.5. Reinstall the fuses 2F1, 2F2, 2F10.1 and 2F10.2.
d DangerThe System is now connected and energised. Mortal danger by electrical shock.
6. Close the first fuse in the first sub distribution (outgoing fuse F1).a All luminaires installed in this circuit are switched on (status "ON").
7. Check whether the number of switched on luminaires and their installation location comply with the given plan.
8. If the number of luminaires and their installation location is correct, switch off the circuit by opening the fuse.
9. Repeat the luminaires check for all sub distributions and circuits.
26
6 Completing the installation
After having finished the luminaires check of the individual circuits and successfuly compared the installation with the plans, the installation work can be completed.
Perform the following steps to complete the installation:
1. Open all outgoing fuses (F1 up to F20 max.) in the sub distributions (also connected external sub distributions).a The luminaires connected to these circuits are switched off.
2. Remove the fuses 2F103+ and 2F103- up to 2F109+ max. and 2F109- of the connected external sub distributions.
3. Remove the battery fuses 2F4, 2F5, 2F6 and 2F7.4. Reinstall the fuse elements 2F1, 2F2, 2F10.1 and 2F10.2.5. Switch the system dead by opening the external main switch and protect the system
against re-engagement.a The system is now out of operation.
27
Appendix
A Technical Data
A.1 General
A.2 Compact station CPS K
Set of batteries available for the compact station CPS K:
Circuit monitored Individually monitored
Circuits 0 - 20 0 - 20
Number of luminaires 0 - 400 400
Max. power (W) 4700 4700
Max. power per circuit (W) 1300 1300
Fuse per circuit (A) 10 10
Outgoing terminals (mm²) 4 4
Digital inputs 8 - 16 8 - 16
Dimensions (H x W x D) 1800 x 850 x 600 mm
Total power 7 - 30 kVA
Outgoing circuits to UVS 0 - 8 pcs.
Fuse protection UVS up to 35 A
Outgoing terminals UVS 16 mm²
Battery voltage (18 blocks) 216 V DC
Max. battery capacity 17 - 75 Ah
Ethernet port 1 pcs.
Potential-free outputs 5 pcs.
Set of batteries Weight (kg) Total weight (kg)
17 Ah 107 257
24 Ah 162 312
28 Ah 175 325
28
i The total weight results from the weight of the set of batteries and the switch cabinet.
A.3 Main station CPS H
Battery cabinets available for the main station CPS H:
33 Ah 211 361
45 Ah 267 417
55 Ah 324 475
75 Ah 432 582
Dimensions (H x W x D) 1800 x 850 x 600 mm
Total power 7 - 30 kVA
Max. outgoing circuits 3 x 20 pcs.
Outgoing circuits to UVS 0 -9 pcs.
Fuse protection UVS up to 35 A
Outgoing terminals UVS 16 mm²
Battery outgoing terminals 35 mm²
Max. battery capacity 17 - 75 Ah
Ethernet port 1 pcs.
Potential-free outputs 5 pcs.
Set of batteries Dimensions(H x W x D) in mm
Weight set of batteries (kg)
Total weight (kg)
33 Ah 1600 x 600 x 600 211 331
45 Ah 1600 x 600 x 600 267 387
55 Ah 1600 x 600 x 600 324 444
75 Ah 1600 x 600 x 600 432 552
80 Ah 1800 x 850 x 600 472 612
90 Ah 1800 x 850 x 600 540 680
100 Ah 1800 x 850 x 600 540 680
120 Ah 1800 x 950 x 600 679 829
134 Ah 1800 x 950 x 600 765 915
150 Ah 1800 x 1100 x 600 836 996
Set of batteries Weight (kg) Total weight (kg)
29
i The total weight results from the weight of the set of batteries and the switch cabinet.
A.4 Sub station CPS U
The substation models CPS U E00 and CPS U E30 are available.
B Fuses
Charger module:
190 Ah 1800 x 1800 x 600
1800 x x600 x 600
1167 1367
1297
200 Ah 1800 x 1800 x 600
1800 x x600 x 600
1206 1406
1336
Dimensions (H x W x D) in mm Weight (kg)
CPS-U E00 800 x 300 x 140 15
CPS-U E30 909 x 407 x 364 75
Designation Value Type Description
2F1 *a time-lag Mains supply L1
2F2 *1 time-lag Mains supply L2
2F3 *1 time-lag Mains supply L3
2F4 *1 time-lag Battery (+)
2F5 *1 time-lag Battery (-)
2F6 *1 time-lag Battery (+)
2F7 *1 time-lag Battery (-)
2F8 *1 time-lag Battery (+)
2F9 *1 time-lag Battery (-)
2F10.2 *1 time-lag Charging unit
2F10.2 *1 time-lag Charging unit
2F11 3.15 time-lag Mains monitoring L1
2F12 3.15 time-lag Mains monitoring L2
Set of batteries Dimensions(H x W x D) in mm
Weight set of batteries (kg)
Total weight (kg)
30
Module for circuit monitoring (UV S):
Module for individual monitoring (UV E):
2F13 3.15 time-lag Mains monitoring L3
2F14 6.3 time-lag Switching module
2F15 6.3 time-lag Switching module
2F16 3.15 time-lag Measuring module LE
2F17 6.3 time-lag Mains switch-over
2F18 6.3 time-lag Mains switch-over
2F19 6.3 time-lag Mains switch-over
3F81 3.15 time-lag Bus supply
3F82 3.15 time-lag Bus supply
*a These values depend on the system type. A valid list for your system can be found on theinside of the switch cabinet door.
Designation Value (A) Type Description
F1 to F20 6.3 time-lag Outgoing fuses per circuit
Designation Value (A) Type Description
F1 to F20 6.3 time-lag Outgoing fuses per circuit
Designation Value Type Description
31
C HANDLING INSTRUCTIONS FOR SEALED VENT-REGULATED LEAD ACID BATTERIES
C.1 Safety instructions
C.1.1 Electrolyte maintenance / Valve Regulation
The sealed battery blocks are maintenance free only as related to the electrolyte. This presents a safety hazard and voids the warranty and inevitably leads to the destruction of the battery. Nevertheless, the battery system requires regular inspections and service (see chap. C.6 on page 34).
d CautionRisk of damageDo not attempt to remove the vents (valves) from the battery or add water.
C.1.2 Precaution-, safety- & disposal notices
Symbol Description
Observe handling instructions.
Wear full eye protection and protective clothing.
Do not smoke or introduce sparks in the vicinity of the battery.
Danger of Explosion and Fire. Battery systems present a risk of electrical high short circuit currents. Therefore remove all personal metal objects, use insulated tools, do not lay metal tools and hardware on top of the batteries, observe circuit polarities, do not make or break live circuits.
Any gelled or liquid emissions from a VRLA battery is electrolyte which contains dilute sulphuric acid which is harmful to the skin and eyes; is electrically conductive; and is corrosive.
If electrolyte contacts the skin, wash immediately and thoroughly with water. If electrolyte enters the eyes, wash thoroughly for 10 minutes with clean water or a special neutralising eye wash solution and seek immediate medical attention.
Individual batteries may be heavy. Exercise care when handling and moving batteries. Mount on secure surface.
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C.2 Storage instructions
Store batteries in a clean, dry cool but frost free area away from radiant heat sources. Elevated storage temperatures increase the selfdischarge rate of the batteries and reduce the storage time between required freshening charges. Batteries in storage should be given a freshening charge every 6 months or when the open circuit voltage declines to 12.5 V, whichever case occurred first. (see chap. C.5.1 on page 33).
C.3 Commissioning
The ideal operation temperature is 20 °C. Higher temperatures shorten the overall battery life, lower temperatures reduce the operating time (capacity). The battery blocks must be placed in such a way that the temperature between the blocks and the ambient temperature does not differ by more than 3 °C. Prior to initial operation please check the following points: check batteries for damage, check circuit polarity, torque the connection hardware to that specified (see chap. C.8 on page 35), use optional plastic or rubber pole caps.
Proceed as follows to commission the batteries:
1. Connect the battery output cables to the DC load/charger circuit with the load/charger fuse, circuit breaker or disconnect in the OPEN condition.
2. Switch on the charger and recharge accordingly (see chap. C.5.1 on page 33).
C.4 Operating regulations
i The regulations IEC 896-2 (EN 60896-2) and/or any relevant state or individual local laws and regulations regarding the operation of stationary battery systems must be observed.
Lead acid batteries are to be recycled. Batteries contain lead and dilute sulphuric acid. Dispose of in accordance with Federal, State and local regulations. Do not dispose of in a landfill, lake or other unauthorised location. Please contact the supplier or manufacturer if in doubt about disposal.
Symbol Description
33
C.5 Charging, discharging
C.5.1 Charging
A charger with IU-charging characteristics should be used. Depending on the type of system charging can be done in the following modes of operation:
• Continuous battery power supply and buffer modeIn this case the system, the DC-source and the battery are permanently in parallel mode. The charging voltage is same as the battery voltage and as the system voltage.In continuous battery power supply mode the DC-source is always capable of supplying the maximum power for the system as well as for the battery charging. The battery only supplies the power, if the DC-source fails. The charging voltage setting is 2.3 V DC / cell at 20 °C multiplied by the number of cells (+/- 1 %), with measurement taken at the end poles of the battery.In buffer mode the DC-source is not capable of always supplying the maximum system power. which is sometimes higher than the power supply possible from the DC-source. During these periods the battery supplies the energy. As the battery is not fully charged permanently, the charging voltage has to be set user related to 2.3 – 2.4 V DC / cell.
• Switch modeIn this mode the battery is switched of from the system when charged. The max. charging voltage of the battery is 2.4 V DC / cell (boost charge). Charging must be monitored. Should at this constant charging voltage the charge current fall to 0.5 A / 100 Ah then the float charge mode must be activated.
• Float charge modeEquipment with IU charging characteristic should be used and set in such a way that the voltage is 2.3 V DC / cell (+/- 1 %) at 20 °C. Should the battery temperature permanently be higher or lower, the charging voltage has to be adjusted accordingly:
Charging voltage(> 20 °C) = 2,3 V DC / cell - 0,005 V * ∆T (∆T= Temperature difference to 20 °C)
Charging voltage(< 20 °C) = 2,3 V DC / cell + 0,005 V *∆T(∆T = Temperature difference to 20 °C)
Examples:Temperature predominantly around 15 °C, charge voltage = 2.3 V DC / cell + 0.015 V DC /cell = 2.315 V DC / cell.Temperature predominantly around 30° C, charge voltage = 2.3 V DC / cell – 0.030 V DC / cell = 2.270 V DC / cell.
Charging currentsWith float charge mode the charging currents are generally not restricted. With boost charge mode 20-30 A per 100 Ah nominal capacity should not be exceeded.
Ripple currentDuring recharging up to 2.4 V DC / cell in the operation modes continuous battery power supply and buffer mode an effective AC-current of up to 20 A per 100 Ah nominal capacity is acceptable. After recharging and during float charge mode the ripple current must not exceed 5 A per 100 Ah of nominal capacity.
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C.5.2 Discharging
The correct discharge rates are established through the capacities l(disc.) = QL/t. If no other data is available, no more than the so established capacity may be used. To avoid deep discharge and consequently the destruction of the battery, the battery must be shut off from the user before reaching the run time related end point voltage:
d CautionRisk of damageThe system should be reconnected only after mains power supply has returned. After discharge, including deep discharge, the battery has to be recharged immediately.
C.6 Battery service and maintenance
C.6.1 Battery care
The battery is to be kept clean and dry as to avoid stray current creepage. For cleaning, use a cloth moistened in a solution of bicarbonate of soda and water or just plain water. Do not use cleaners of unknown solutions such as window or glass cleaners and solvents.
C.6.2 Inspection of the battery system
It is advisable to perform the following checks and record the findings every 6 months:
• Visual inspection of batteries for cleanliness, terminal damage, container or cover damage and evidence of overheating.
• Check of float charge voltage of the battery system and of each individual battery block.• Check of surface temperature of the battery blocks.• Check ambient temperature.
A regular annual check and recording of the findings is mandatory for the fulfilment of the warranty conditions and comprises the following checks:
• All connection hardware should be retorqued to the value indicated in § 1 with a calibrated torque wrench.
• Repeat the semi-annual checks.• Ideally measure the voltage of the battery system and of the individual blocks with the
charger switched off.
To be performed only in the presence of the system supplier or their authorised representative:
• Record the block voltages at service load (capacity test).
Run time End point voltage
> 3 h 1,80 V DC / cell
1 - 3 h 1,75 V DC / cell
20 min. - 1 h 1,67 V DC / cell
< 20 min. 1,60 V DC / cell
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i Tests are to be executed according to IEC 896-2 (EN 60896-2). In addition eventual state or local regulations may have to be observed.
C.7 Warranty
Warranty claims are subject to proper service and maintenance. In support of claims the following documentation has to be supplied: Detailed description of fault / damage, relevant identification data and the last maintenance reports. Faulty batteries have to be returned for fault analysis.
i The warranty becomes void if these handling instructions are not observed: i.e. in the case of too high ambient temperature, the batteries being left discharged for an extended period, inadequate storage conditions, incorrect float charge setting, failure to maintain the recommended service intervals and service instructions.
C.8 Table of torques for the battery connectors
TypeBSOL BTX(LS)
Torque(Nm)
TypeBSOL BTX(LS)
Torque(Nm)
TypeBSOL BTX(LS)
Torque(Nm)
12-17 6.2 12-33 8.5 12-120 12.4
12-17 LS 6.2 12-33 LS 8.5 12-120 LS 12.4
12-24 6.2 12-40 8.5 12-150 12.4
12-24 LS 6.2 12-45 8.5 12-150 LS 12.4
12-28 6.2 12-45 LS 8.5 12-190 LS 12.4
12-28 LS 6.2 12-55 8.5 12-200 12.4
12-55 LS 8.5 12-200 LS 12.4
12-60 8.5
12-75 LS 8.5
12-80 8.5
12-80 LS 8.5
12-90 LS 8.5
12-100 8.5
12-100 LS 8.5
12-134 8.5
