240V UPS Typical Installation Guide

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Russell Perkins
5 years ago
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1 240V UPS Typical Installation Guide Warning!!! High Battery DC Voltages can Cause Serious Injury or Death. Installation should only be done by suitable qualified personal. Aug,

2 Mechanical Drawings BEM (Battery Energy Meter) Aug,

3 12V MMM (Monoblock Management Module) Components and Tools Required Components And Tools Qty Comment 240V BEM (Battery Energy Meter) with Shunt Protection Lid 1 1mm² Red PVC Multi Strand Flex Panel Length Battery Battery Positive Connection (Red) Wire (2.9mm OD) Specific 1mm² Blue PVC Multi Strand Flex Panel Length Battery Battery Positive Connection (Blue) Wire (2.9mm OD) Specific Inline Fuse (>battery Vdc rating) Inline switch (>battery Vdc rating) 2 2 Inline fuse and switch on BOTH positive and negative battery wires 1mm² Black PVC Multi Strand Flex Length Battery Communications wire connection (Black) Panel Wire (2.9mm OD) Specific Monoblock Inter link wire + lugs. Battery specific 12V MMM 1 per Monoblock 20 x 12V MMM For 240V UPS application 12V MMM (Monoblock Management 1 per MMM Module) IDC Push on Cap Cable Ties 4.8mm(t) x 122mm(L) Parallel Pliers 1 Plastic or well insulated Side Cutter 1 Aug,

If connected reverse polarity then NO lights will come on. IMPORTANT NOTES!! 1. Keep the monoblock inter links (yellow wires above) as short as possible. 2.

4 Installation 1. Attach/Connect MMM Attach MMM's Power terminals to Monoblock by using the 6mm bolt, making sure of polarity. When connected correctly, the 12V MMM will turn on the Blue light for three seconds. There afterwards it will flash 3 consecutive flashes every three seconds indicating waiting for configuration. If connected reverse polarity then NO lights will come on. IMPORTANT NOTES!! 1. Keep the monoblock inter links (yellow wires above) as short as possible. 2. Keep the MMM red and blue wires as short as possible. 3. The MMM lugs should go on top of the monoblock inter link lugs Complete connecting up the whole battery pack with monoblock inter links and MMM s except for the centre of the pack inter link. This is where the BEM will be connected. Aug,

2. Connect All Required monoblocks and MMM's The above diagram shows a

MMM's. The centre of the Pack is not yet connected together.

breaker is off. Then follow stages below to connect BEM. NOTE!

5 2. Connect All Required monoblocks and MMM's The above diagram shows a Typical 240v UPS battery pack using 20 x 12V monoblocks and 20 x 12V MMM's. The centre of the Pack is not yet connected together. Make sure there is NO load on battery and the battery contacted or breaker is off. Then follow stages below to connect BEM. NOTE!! Keep the monoblock inter connect links (yellow wires above) as short as possible. Aug,

6 3. Locate Centre Of Pack Locate the centre of the battery pack and remove cell Interlink. Centre of pack is between Monoblock 10 and 11 as indicated in picture. Aug,

7 4. Position BEM. Connect Integrated Current Shunt Position BEM near centre and connect Integrated Shunt with longer or shorter Monoblock Inter Connect Links on M6 Shunt Take Off with M6 Brass Nuts. 5. Install M6/Shunt Cover Lid Install M6 Isolation Lid with 2.5mm² screw Aug,

6. Connect MMM Communication Wire to MMM NOTE!

Hence for good communication it is very important to route the communication wire along

They should in effect form a twisted pair and be cabled tied together in as many places

For communication wire 1, start on negative terminal of Monoblock 1 and attach wire by

8 6. Connect MMM Communication Wire to MMM NOTE!!! The communication wire uses the battery itself as a return path. Hence for good communication it is very important to route the communication wire along the monoblock interconnects and also along the MMM s. They should in effect form a twisted pair and be cabled tied together in as many places as necessary to keep the loop area to a minimum. For communication wire 1, start on negative terminal of Monoblock 1 and attach wire by placing wire in MMM IDC Cap and pushing it on MMM's IDC Push Connector. End on the BEM comms 1 port. For communication wire 2, start on positive terminal of Monoblock 20 and attach wire by placing wire in MMM IDC Cap and pushing it on MMM's IDC Push Connector. End on the BEM comms 2 port. 7. Cable Tie the communications Wire to monoblock connect links and MMM Aug,

9 8. Complete Routing the communications wires Both communication wire 1 & 2 should follow the battery path as close as possible until they connect into the BEM. This is shown below Aug,

9. Connect Communication Wire To BEM Communications wire 1 should be used on the monoblocks in the bottom half of

Communications wire 2 should be used on the monoblocks in the top half of the pack (positive side) and connected

Connect the communications wire 1 to the BEM by stripping the wire 8mm and pushing it into the BEM push in

10 9. Connect Communication Wire To BEM Communications wire 1 should be used on the monoblocks in the bottom half of the pack (negative side) and connected to coms port 1. Communications wire 2 should be used on the monoblocks in the top half of the pack (positive side) and connected to coms port 2. Connect the communications wire 1 to the BEM by stripping the wire 8mm and pushing it into the BEM push in terminal marked COM1. Connect communications wire 2 into COM2 in the same way. 10. Thermistor Option of connecting external Thermistor in BEM at THM+ and THM- 11. Protector Option of connecting Balancell Battery Protector in BEM at PRO1 and PRO2 Aug,

12. BEM Power Cut desired length of 1mm 2 Blue/Red

add inline fuse and switch to BOTH positive and

11 12. BEM Power Cut desired length of 1mm 2 Blue/Red wire from BEM to Battery Power Terminals Important to add inline fuse and switch to BOTH positive and negative wires as close as possible to the battery positive and negative terminals. Make sure the inline switches are OFF during installation. Aug,

13. Crimp Lug on Wire, add inline fuse and

Crimp Lug on first end of BEM Power Wires,

12 13. Crimp Lug on Wire, add inline fuse and inline switch on BOTH wires. Crimp Lug on first end of BEM Power Wires, followed by fuse and inline switch. Then Connect on Battery Positive and Negative Terminals with 6mm Bolt making sure of polarity. Then route wire to BEM and cut to correct length. Make sure the inline switch is OFF and then strip end and connect to BEM as shown below. 14. Connect Wire To BEM Aug,

13 Strip one end of wire 8mm long and push firmly in corresponding Negative or Positive Push In Connector on BEM. The BEM can now be turned on via the inline switches and setup with configuration tool. 15. Configuration tool Aug,

Deluxe High Amp Switch Kit - 12 Volt Wiring Instructions

Deluxe High Amp Switch Kit - 12 Volt Wiring Instructions 1404 N. Marshall Ave. El Cajon C 92020 WLH 09/01/16 514-0139 OUT IN 16 ga. Black wire 16 ga. Green wire Yellow Black Blue 50 AMP BREAKER MOTOR 16 ga. White wire ROCKER SWITCH (IN CAB) BATTERY 607-0139