ONLITE central CPS. Installation instruction

ONLITE central CPS Installation instruction

Legal notes Traemarks ONLITE is a registere traemark of Zumtobel Lighting GmbH, Dornbirn. Copyright Copyright 2008 Zumtobel Lighting GmbH All rights reserve. Manufacturer Zumtobel Lighting GmbH Schweizerstraße 30 A-6850 Dornbirn/Austria Tel. +43-(0)5572-390-0 Fax +43-(0)5572-22826 luxmate@zumtobel.com www.zumtobel.com Document number CPS_MA_25.06.08 en

1 Contents Contents 1 1 Introuction an safety regulations 3 1.1 General information 3 1.2 Safety an anger notes 4 1.3 Designate use 5 1.4 Notes on illustrations an block iagrams 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 monitore sub istribution 13 3.3.2 Connecting the line monitors in a single monitore sub istribution 13 3.4 Connecting the emergency circuits 14 3.4.1 Connecting the emergency ciruits in a circuit monitore sub istribution 14 3.4.2 Connecting the emergency ciruits in a single monitore sub istribution 15

2 3.5 Connecting the 230 V AC / 400 V AC voltage supply 16 3.6 Installing an 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 istributions 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 Appenix 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 SEALED VENT-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, ischarging 33 C.6 Battery service an maintenance 34 C.7 Warranty 35 C.8 Table of torques for the battery connectors 35

3 1 Introuction an safety regulations 1.1 General information Valiity an technical state of this installation instruction This installation instruction is vali for the following ONLITE central CPS evices: Type Orer 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 Harware version: B Signs an symbols use in the ocumentation The following signs an symbols are use in this ocumentation: Symbol p a V i Description One step text instructions in instructions for action are marke with p. The iniviual steps of multiple step instructions for action are numbere. Inicates the result for the action step after several action steps. These results are marke with an a symbol at the beginning of the line. Requirements which nee to be checke before operation are highlighte with V. Notes are marke with the symbol i. Warning notes are marke with the symbol. Warning notes also contain the source of the anger as well as the consequence of the anger. Warning notes are combine with the following signal wors: Danger: Warns of amage to persons (eath or severe injury). Caution: Warns of amage to persons (eath or severe injury) which are epenent on further actions. Warning: Warns of material amages.

4 Who may perform the installation? The installation may only be performe by suitably qualifie professional electrical specialists who have been briefe on local an operational conitions. 1.2 Safety an anger notes The central battery system ONLITE central CPS is part of the emergency an general lighting system an consequently part of a builing's safety equipment. Installation an commissioning of the system must be performe with the appropriate care an precision. Danger Please note that the luminaires are supplie with 216 V DC in case of emergency operation. Mortal anger by electrical shock! Danger Only qualifie electrical specialists may perform work on the 230 V mains. Wiring of current-carrying lines as well as signal an control lines must be one in accorance with the relevant guielines an stanars. National guielines an regulations applicable in the country in which the system is being installe an operate have to be observe. Danger Improper use of the batteries or battery-powere parts of the system can cause risk of injury or mortal anger from high current or arcs that can occur briefly on battery ischarge. Ensure that the batteries are connecte to the correct poles! Danger Non-authorise or non-professional system installation an hanling may result in outages of the safety equipment. This implies immeiate anger for people an the security equipment itself. In aition, amages to machines an plants as well as loss of prouctions are possible consequences at prouction sites. Caution Non-authorise or non-professional system installation an hanling may result in amages of the batteries. The containe electrolyte sulphuric aci is extremely caustic an can lea to heavy injuries!

5 Caution Only luminaires with an operation voltage of 230 V AC (50 / 60 Hz) an 230 V DC may be connecte to the outputs for the emergency lighting en circuits of the ONLITE central CPS system. Disregaring the instructions may result in amages to system an luminaires. Caution Short circuits an incorrect polarity may amage the batteries or parts of the system. Caution Pay attention to the line lengths of the output circuits. The maximum length of 300 m may not be exceee. Disregaring the instructions may result in outages of the emergency lighting, because the proper communication between the system components is not guarantee. Caution The batteries may not be store without maintaining for longer than 3 months. Disregaring the instructions may result in amages to the batteries. When storing the batteries without conservation charging, the battery capacity ecreases up to the efect of the battery. 1.3 Designate use The central battery system ONLITE central CPS is esigne for controlling an monitoring an emergency lighting system. Any use in excess thereof is not allowe. The ajustment an operation of the system is restricte to authorise technical staff. Personal angers may occur in case of improper use isregaring the safety regulations The central battery system ONLITE central CPS an connecte parts of the system may only be operate if all system components are in perfect technical conition an in compliance with the safety an anger notes containe in this installation instruction, the operating an safety instructions stipulate by the system operator, the commissioning notes an instruction manual supplie with the central battery system ONLITE central CPS, the technical ata liste in the appenix. Failures which cannot be remove by acknowleging are to be reporte to the responsible service person. Operating an safety regulations arise from this installation instruction as well as from organisational instructions an from general as well as technical guielines an regulations for accient prevention.

6 The manufacturer will not assume warranty or liability for consequential amages that occur ue to: improper use isregaring the regulations unauthorise moifications or moifications mae by technically non-competent persons to evice connections an settings of the ONLITE central CPS system the use of not allowe or unsuitable system parts Danger Also pay attention to all laws, stanars an guielines applicable in the country in which the system is being operate. Caution Verify whether electrical installations comply with the application environment. Special environmental conitions (e.g. areas subject to explosion hazars or areas with an aggressive atmosphere) require special equipment an installations. Caution Verify whether all use ballasts an luminaires fulfil the requirements of an emergency lighting system an the operation at an ONLITE central CPS system. Caution If mains, which supplies the ONLITE central CPS system, is interrupte longer than three ays, the battery has to be isconnecte to prevent from eep ischarge an thus amage of the battery. 1.4 Notes on illustrations an block iagrams Illustrations an block iagrams in these installation instruction are partly for emonstration purposes only. Drawings an plans that were especially create for the emergency lighting system an are in accorance with local requirements must be observe.

7 2 Installing the switch cabinet i The ONLITE central CPS systems shown in this installation instruction can iffer in the moular esign on elivery. Special features of customer-specific systems are escribe in the project ocumentation which must be orere 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 monitore sub istribution an one iniviually monitore sub istribution. 1 2 3 4 (1) Charging unit LE (2) Circuit monitore sub istribution S (3) Iniviually monitore sub istribution E (4) Battery compartment

8 2.1.2 Main station CPS H The following figure shows an ONLITE central CPS H system with two circuit monitore sub istributions. 1 2 3 (1) Charging unit LE (2)/(3) Circuit monitore sub istributions S Flange plate for connection cables The connection cables are route into the cabinet through the rillings in the flange plate on top of the cabinet (see following figure). The flange plate contains rubber bushings for ifferent cable iameters (8 mm to 44 mm). Each switch cabinet has three flange plates.

9 2.2 Installation The switch cabinets of the ONLITE central CPS system must only be installe on flat surfaces proviing enough carrying capacity. Enough space must be provie to the sies an the back of the cabinets to provie sufficient work space for the installation an future maintenance work. Ensure that the oors of the switch cabinet can be opene completely. The connections for the power supply of the ONLITE central CPS system must be provie by the customer accoring to the technical ata given in appenix A an the wiring iagrams. i We recomme to ensure at least 1 m free work space on each sie of the switch cabinet. The switch cabinet imensions are liste in appenix 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 an -2F10.2 Battery fuses: -2F4, -2F5, -2F6 an -2F7 Outgoing fuses in the iniviual sub istributions: F1 to F20, both for phase L (re labelle fuses) an for the neutral wire N (blue labelle 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 escribe in chapter "Hanling instructions for seale vent-regulate lea aci batteries" (see chap. C on page 31). i Alreay installe an connecte batteries must be remove taking into account the battery installation orer.

11 3 Installation 3.1 Connecting the relay outputs Connection of the relay outputs has to be performe in accorance with the schematic rawing shown below an the plans an rawings vali for the conitions at the installation site. The charging unit of the ONLITE central CPS system provies five potential-free relay outputs which can be use either as normally close or normally open contact each. 1. Route the connection cables into the cabinet through the flange plate at the top sie 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 moule (see following figure). -2x5 1 2-2x4 1 2 3 4 5 6 7 8 9 1011 12 13 14 15 24VDC 0V Ö4 C4 S4 Ö5 C5 S5 Ö6 C6 S6 Ö7 C7 S7 Ö8 C8 S8 Internal signal voltage supply Relay output 4 Relay output 5 Relay output 6 Relay output 7 Relay output 8 i The relay outputs are implemente potential-free. If a signal voltage is require, the internal 24 V DC voltage supply is provie at terminal block -2X5. The 24 V DC voltage must be wire to the mile contact (Common) of the corresponing relay. Danger Leave no connection cables temporarily loose an unsecure.

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 performe in accorance with the schematic rawing shown below an the plans an rawings vali for the conitions at the installation site. Danger Comply with the national regulations an guielines for inicating an signalling when using a remote switch or remote inicator for emergency lighting systems. The ONLITE central CPS Remote Interface is powere by the internal 24 V DC voltage supply of the ONLITE central CPS system. Caution Do not use an external 24 V DC voltage supply. Disregaring the instructions may result in outages of the emergency lighting because the proper communication between the system components may not be guarantee. Connect the ONLITE central CPS Remote Interface as follows: ONLITE central CPS Remote Interface 2x5 24V 0V 1 2 3 4 5 6 7 8 9 1011 12 13 14 15-2x4 OFF Mains operation Fan error message Maintaine light On/Off Free Battery operation Failure Block system Free Free S5+ S5- Rel5 Rel6 Rel7 S2 S3 S4 S5 S6 S7 Ö4 C4 S4 Ö5 C5 S5 Ö6 C6 S6 Ö7 C7 S7 Ö8 C8 S8

13 3.3 Connecting the line monitors 3.3.1 Connecting the line monitors in a circuit monitore sub istribution Connect the line monitors to the input terminals S1 to Sx of the circuit monitore sub istribution (epening on the configuration of the ONLITE central CPS system). The terminal block is labelle -4X1 (see following figure). 3.3.2 Connecting the line monitors in a single monitore sub istribution Connect the line monitors to the input terminals S1 to Sx of the single monitore sub istribution (epening on the configuration of the ONLITE central CPS system). The terminal block is labelle -5X1 (see following figure).

14 3.4 Connecting the emergency circuits Caution Note the line length limitation of the output circuits. The maximum length of 300 m may not be exceee. Disregaring the instructions may result in outages of the emergency lighting because the proper communication between the system components is not guarantee. Caution Connect the luminaires to the emergency circuits accoring to the specifications of the luminaires manufacturer. Disregaring the instructions may result in amages to the system an luminaires. 3.4.1 Connecting the emergency ciruits in a circuit monitore sub istribution A maximum of 20 emergency circuits can be connecte to each sub istribution. Each circuit is fuse by two outgoing fuses. 1. Route the connection cables into the cabinet through the flange plate at the top sie of the switch cabinet. 2. Connect each emergency circuit to the terminal blocks -4X2 an the PE terminal block in the switch cabinet of the ONLITE central CPS system or the external sub istribution (as shown in the following figure). PE (yellow/green) N (blue) L (re)

15 3.4.2 Connecting the emergency ciruits in a single monitore sub istribution A maximum of 20 emergency circuits can be connecte to each sub istribution. Each circuit is fuse by two outgoing fuses. 1. Route the connection cables into the cabinet through the flange plate at the top sie of the switch cabinet. 2. Connect each emergency circuit to the terminal blocks -5X1 (DALI terminals an PE terminal block) an -5X2 in the switch cabinet of the ONLITE central CPS system or the external sub istribution (as shown in the figure below). i For connecting the emergency circuits of a single monitore sub istribution a 5-pin cable is use because two DALI connections D1 an D2 must be wire aitionally to the voltage supply. N (blue) L (re) PE (yellow/green) DALI connection D1 an D2 (brown/grey)

16 3.5 Connecting the 230 V AC / 400 V AC voltage supply The ONLITE central CPS system is powere 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 an the supply lines are switche ea, the fuses 2F1, 2F2, 2F10.1 an 2F10.2 are opene (remove). Danger When isregaring the preliminaries there is a risk of mortal anger ue to live parts! Procee as follows to connect the ONLITE central CPS system to 230 V AC / 400 V AC mains: 1. Switch the system ea by opening the external main switch an protect the system against re-engagement. 2. Route the connection cables into the cabinet through the flange plate at the top sie of the switch cabinet. 3. Connect the 230 V AC / 400 V AC mains an the earth wire to the screw terminals L1, L2, L3, N an PE of the terminal block -2X1 of the ONLITE central CPS switch cabinet. PE L1 L2 L3 N i When connecting the 400 V AC voltage supply, please note that the phasing (L1-L3) correspons to a clockwise rotating fiel. For this purpose a phase sequence inicator must be use.

17 3.6 Installing an connecting the batteries Before connecting the batteries, ensure that no persons work on the installation, all mounting an installation works are complete, the battery fuses -2F4, -2F5, -2F6 an -2F7 have been remove. Two fuses for each sub istribution are installe. Danger When isregaring the preliminaries there is a risk of mortal anger by electrical shock! Danger Comply with the vali acciental regulations an wear protective clothes an protective goggles. Caution Also note the maximum amissible 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 connecte in series (see chap. A.2 on page 27). The voltage of the battery set (system voltage) is 216 V DC. i We recommen the following battery set-up in the compact cabinet switch: When arranging the batteries, the first battery has to be installe in the rear row an the last battery in the first row. This way, access to the battery connectors is easier an aitionally the risk of anger is reuce. The batteries of the battery sets from 24 Ah to 75 Ah are installe on two levels. The first nine batteries have to be installe on the floor boar, the other nine batteries on the grating supplie 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 alreay connecte to the fuses -2F4 an -2F5. The other two cable ens are reay for connection an can be foun in the battery compartment. Procee as follows to connect the batteries of a compact station CPS K: V Prepare the briges, pole covers an numbering stickers supplie with the system.

18 1. Connect the blue labelle cable to the negative pole (-) of battery 1. Rear sie of the ONLITE central CPS switch cabinet Floor boar 2. Install one of the supplie briges between the positive pole (+) of battery 1 an the negative pole (-) of battery 2 an fix it accoringly. 3. Repeat step 2. for the other batteries until all batteries are connecte in series. 4. Connect the re labelle cable to the positive pole (+) of battery 18. The secon en of the cable is alreay connecte to fuse -2F5. a The batteries are connecte.

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 powere with 216 V DC either by a battery cabinet or a battery rack. The connection cables to the batteries must be provie 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 (+) an (-) to the terminals + an - of terminal block -2X1. i Mark the connection cables at both ens with a re an blue labelling ring to ensure proper connection. 2. Now, connect the blue labelle cable to the negative pole (-) of the first battery. 3. Insert the supplie briges between the positive pole (+) of battery 1 an the negative pole (-) of battery 2 an fix it accoringly. 4. Repeat step 3. for the other batteries until all batteries are connecte in series. 5. Connect the re labelle cable with the positive pole (+) of the last battery an 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 iniviual battery sets. Battery set 17 Ah Rear sie of switch cabinet Floor boar

21 Battery sets from 24 Ah to 75 Ah Rear sie of switch cabinet Supply line (-) from charging unit Supply line (+) from charging unit Rear sie of switch cabinet Grating Floor boar

22 4 Connecting external sub istributions 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 use. Two cables are require, where two cable wires are use for ata exchange an two cable wires provie the 24 V DC-voltage supply. Connect the wires to the bus terminals which are mounte on the terminal block -4X2 (see the following figure). i The bus system can be configure in line topology or free topology. Please observe the maximum cable lengths of 900 m (line topology) an 500 m (free topology). 1 2 3 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 ata connection of the system bus (core colours: ye/wh) (3) System bus connector Connector for plugging in the Touch PC (control unit)

23 Examples of the possible system topologies Line topology - two terminators - max. bus length 900 m - cable type: JY (St)Y2x2x0.8 Free topology - one terminator - max. bus length 500 m - cable type: JY (St)Y2x2x0.8 i Depening on the use topology, the terminators of the ONLITE central CPS system must be installe an checke. When using the line topology, two terminators are require. In that case, one terminator is installe an connecte in the cabinet of the main station CPS H or compact station CPS K ex factory. The secon terminator must be connecte to the bus terminals of the most remote locate sub istribution (see chap. 4.1 on page 22). When using the free topology, only one terminator is require in the main station CPS H or compact station CPS K. This terminator ist alreay installe an connecte ex factory.

24 4.2 Connecting the voltage supply Up to seven (CPS H) or six (CPS K) external sub istributions can be connecte to an ONLITE central CPS system. Two outgoing fuses are available for each sub istribution in the switch cabinet of the ONLITE central CPS system. The power supply lines for the sub istributions must be wire irectly to the outgoing fuses. Description of the outgoing fuses External sub istribution Fuse label UV03 4F103+ an 4F103- UV04 4F104+ an 4F104- UV05 4F105+ an 4F105- UV06 4F106+ an 4F106- UV07 4F107+ an 4F107- UV08 4F108+ an 4F108- UV09 (only CPS H) 4F109+ an 4F109- i The cable types an line cross sections require for the voltage supply of the sub istributions can be foun in the overall connecting iagram of your ONLITE central CPS system. For a permissible voltage rop also the istance an connecte loa are to be consiere uring line imensioning.

25 5 Switching on the system Perform the following checks an works while mains supply is switche off before switching on the ONLITE central CPS system: Check all works one an compare the establishe connections with the given plans an rawings. Make sure that all connections are firm. Danger When checking the battery connectors there is a risk of mortal anger. Use only insulate tools. Wear rubber gloves, protective goggles an protective clothes (incl. safety shoes) an take off metallic objects e.g. watches an jewellery. Remove all unuse cables, insulation an fixing materials, tools an packaging. To switch on the ONLITE central CPS system, procee as follows: 1. Switch on the external main switch. 2. Check the voltage supply at the terminals L1, L2, L3 an N of the terminal block -2X1. 3. Check the rotational irection of the voltage supply. 4. Check whether all outgoing fuses of the circuits (F1 - F20 blue, F1 - F20 re) in the sub istributions are opene. 5. Reinstall the fuses 2F1, 2F2, 2F10.1 an 2F10.2. Danger The System is now connecte an energise. Mortal anger by electrical shock. 6. Close the first fuse in the first sub istribution (outgoing fuse F1). a All luminaires installe in this circuit are switche on (status "ON"). 7. Check whether the number of switche on luminaires an their installation location comply with the given plan. 8. If the number of luminaires an their installation location is correct, switch off the circuit by opening the fuse. 9. Repeat the luminaires check for all sub istributions an circuits.

26 6 Completing the installation After having finishe the luminaires check of the iniviual circuits an successfuly compare the installation with the plans, the installation work can be complete. Perform the following steps to complete the installation: 1. Open all outgoing fuses (F1 up to F20 max.) in the sub istributions (also connecte external sub istributions). a The luminaires connecte to these circuits are switche off. 2. Remove the fuses 2F103+ an 2F103- up to 2F109+ max. an 2F109- of the connecte external sub istributions. 3. Remove the battery fuses 2F4, 2F5, 2F6 an 2F7. 4. Reinstall the fuse elements 2F1, 2F2, 2F10.1 an 2F10.2. 5. Switch the system ea by opening the external main switch an protect the system against re-engagement. a The system is now out of operation.

27 Appenix A Technical Data A.1 General Circuit monitore Iniviually monitore 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 A.2 Compact station CPS K Dimensions (H x W x D) Total power Outgoing circuits to UVS Fuse protection UVS Outgoing terminals UVS Battery voltage (18 blocks) Max. battery capacity Ethernet port Potential-free outputs 1800 x 850 x 600 mm 7-30 kva 0-8 pcs. up to 35 A 16 mm² 216 V DC 17-75 Ah 1 pcs. 5 pcs. Set of batteries available for the compact station CPS K: Set of batteries Weight (kg) Total weight (kg) 17 Ah 107 257 24 Ah 162 312 28 Ah 175 325

28 Set of batteries Weight (kg) Total weight (kg) 33 Ah 211 361 45 Ah 267 417 55 Ah 324 475 75 Ah 432 582 i The total weight results from the weight of the set of batteries an the switch cabinet. A.3 Main station CPS H Dimensions (H x W x D) Total power Max. outgoing circuits Outgoing circuits to UVS Fuse protection UVS Outgoing terminals UVS Battery outgoing terminals Max. battery capacity Ethernet port Potential-free outputs 1800 x 850 x 600 mm 7-30 kva 3 x 20 pcs. 0-9 pcs. up to 35 A 16 mm² 35 mm² 17-75 Ah 1 pcs. 5 pcs. Battery cabinets available for the main station CPS H: 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

29 Set of batteries Dimensions (H x W x D) in mm Weight set of batteries (kg) Total weight (kg) 190 Ah 1800 x 1800 x 600 1800 x x600 x 600 200 Ah 1800 x 1800 x 600 1800 x x600 x 600 1167 1367 1297 1206 1406 1336 i The total weight results from the weight of the set of batteries an the switch cabinet. A.4 Sub station CPS U The substation moels CPS U E00 an CPS U E30 are available. 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 B Fuses Charger moule: Designation Value Type Description 2F1 *a time-lag Mains supply L1 2F2 *1 time-lag Mains supply L2 2F3 2F4 2F5 2F6 2F7 2F8 2F9 2F10.2 2F10.2 *1 *1 *1 *1 *1 *1 *1 *1 *1 time-lag Mains supply L3 time-lag Battery (+) time-lag Battery (-) time-lag Battery (+) time-lag Battery (-) time-lag Battery (+) time-lag Battery (-) time-lag Charging unit time-lag Charging unit 2F11 3.15 time-lag Mains monitoring L1 2F12 3.15 time-lag Mains monitoring L2

30 Designation Value Type Description 2F13 3.15 time-lag Mains monitoring L3 2F14 6.3 time-lag Switching moule 2F15 6.3 time-lag Switching moule 2F16 3.15 time-lag Measuring moule 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 epen on the system type. A vali list for your system can be foun on the insie of the switch cabinet oor. Moule for circuit monitoring (UV S): Designation Value (A) Type Description F1 to F20 6.3 time-lag Outgoing fuses per circuit Moule for iniviual monitoring (UV E): Designation Value (A) Type Description F1 to F20 6.3 time-lag Outgoing fuses per circuit

31 C HANDLING INSTRUCTIONS FOR SEALED VENT- REGULATED LEAD ACID BATTERIES C.1 Safety instructions C.1.1 Electrolyte maintenance / Valve Regulation The seale battery blocks are maintenance free only as relate to the electrolyte. This presents a safety hazar an vois the warranty an inevitably leas to the estruction of the battery. Nevertheless, the battery system requires regular inspections an service (see chap. C.6 on page 34). Caution Risk of amage Do not attempt to remove the vents (valves) from the battery or a water. C.1.2 Precaution-, safety- & isposal notices Symbol Description Observe hanling instructions. Wear full eye protection an protective clothing. Do not smoke or introuce sparks in the vicinity of the battery. Danger of Explosion an Fire. Battery systems present a risk of electrical high short circuit currents. Therefore remove all personal metal objects, use insulate tools, o not lay metal tools an harware on top of the batteries, observe circuit polarities, o not make or break live circuits. Any gelle or liqui emissions from a VRLA battery is electrolyte which contains ilute sulphuric aci which is harmful to the skin an eyes; is electrically conuctive; an is corrosive. If electrolyte contacts the skin, wash immeiately an thoroughly with water. If electrolyte enters the eyes, wash thoroughly for 10 minutes with clean water or a special neutralising eye wash solution an seek immeiate meical attention. Iniviual batteries may be heavy. Exercise care when hanling an moving batteries. Mount on secure surface.

32 Symbol Description Lea aci batteries are to be recycle. Batteries contain lea an ilute sulphuric aci. Dispose of in accorance with Feeral, State an local regulations. Do not ispose of in a lanfill, lake or other unauthorise location. Please contact the supplier or manufacturer if in oubt about isposal. C.2 Storage instructions Store batteries in a clean, ry cool but frost free area away from raiant heat sources. Elevate storage temperatures increase the selfischarge rate of the batteries an reuce the storage time between require freshening charges. Batteries in storage shoul be given a freshening charge every 6 months or when the open circuit voltage eclines to 12.5 V, whichever case occurre first. (see chap. C.5.1 on page 33). C.3 Commissioning The ieal operation temperature is 20 C. Higher temperatures shorten the overall battery life, lower temperatures reuce the operating time (capacity). The battery blocks must be place in such a way that the temperature between the blocks an the ambient temperature oes not iffer by more than 3 C. Prior to initial operation please check the following points: check batteries for amage, check circuit polarity, torque the connection harware to that specifie (see chap. C.8 on page 35), use optional plastic or rubber pole caps. Procee as follows to commission the batteries: 1. Connect the battery output cables to the DC loa/charger circuit with the loa/charger fuse, circuit breaker or isconnect in the OPEN conition. 2. Switch on the charger an recharge accoringly (see chap. C.5.1 on page 33). C.4 Operating regulations i The regulations IEC 896-2 (EN 60896-2) an/or any relevant state or iniviual local laws an regulations regaring the operation of stationary battery systems must be observe.

33 C.5 Charging, ischarging C.5.1 Charging A charger with IU-charging characteristics shoul be use. Depening on the type of system charging can be one in the following moes of operation: Continuous battery power supply an buffer moe In this case the system, the DC-source an the battery are permanently in parallel moe. The charging voltage is same as the battery voltage an as the system voltage. In continuous battery power supply moe 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 multiplie by the number of cells (+/- 1 %), with measurement taken at the en poles of the battery. In buffer moe 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 perios the battery supplies the energy. As the battery is not fully charge permanently, the charging voltage has to be set user relate to 2.3 2.4 V DC / cell. Switch moe In this moe the battery is switche of from the system when charge. The max. charging voltage of the battery is 2.4 V DC / cell (boost charge). Charging must be monitore. Shoul at this constant charging voltage the charge current fall to 0.5 A / 100 Ah then the float charge moe must be activate. Float charge moe Equipment with IU charging characteristic shoul be use an set in such a way that the voltage is 2.3 V DC / cell (+/- 1 %) at 20 C. Shoul the battery temperature permanently be higher or lower, the charging voltage has to be ajuste accoringly: Charging voltage (> 20 C) = 2,3 V DC / cell - 0,005 V * T ( T= Temperature ifference to 20 C) Charging voltage (< 20 C) = 2,3 V DC / cell + 0,005 V * T( T = Temperature ifference to 20 C) Examples: Temperature preominantly aroun 15 C, charge voltage = 2.3 V DC / cell + 0.015 V DC / cell = 2.315 V DC / cell. Temperature preominantly aroun 30 C, charge voltage = 2.3 V DC / cell 0.030 V DC / cell = 2.270 V DC / cell. Charging currents With float charge moe the charging currents are generally not restricte. With boost charge moe 20-30 A per 100 Ah nominal capacity shoul not be exceee. Ripple current During recharging up to 2.4 V DC / cell in the operation moes continuous battery power supply an buffer moe an effective AC-current of up to 20 A per 100 Ah nominal capacity is acceptable. After recharging an uring float charge moe the ripple current must not excee 5 A per 100 Ah of nominal capacity.

34 C.5.2 Discharging The correct ischarge rates are establishe through the capacities l (isc.) = Q L /t. If no other ata is available, no more than the so establishe capacity may be use. To avoi eep ischarge an consequently the estruction of the battery, the battery must be shut off from the user before reaching the run time relate en point voltage: Run time En 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 Caution Risk of amage The system shoul be reconnecte only after mains power supply has returne. After ischarge, incluing eep ischarge, the battery has to be recharge immeiately. C.6 Battery service an maintenance C.6.1 Battery care The battery is to be kept clean an ry as to avoi stray current creepage. For cleaning, use a cloth moistene in a solution of bicarbonate of soa an water or just plain water. Do not use cleaners of unknown solutions such as winow or glass cleaners an solvents. C.6.2 Inspection of the battery system It is avisable to perform the following checks an recor the finings every 6 months: Visual inspection of batteries for cleanliness, terminal amage, container or cover amage an evience of overheating. Check of float charge voltage of the battery system an of each iniviual battery block. Check of surface temperature of the battery blocks. Check ambient temperature. A regular annual check an recoring of the finings is manatory for the fulfilment of the warranty conitions an comprises the following checks: All connection harware shoul be retorque to the value inicate in 1 with a calibrate torque wrench. Repeat the semi-annual checks. Ieally measure the voltage of the battery system an of the iniviual blocks with the charger switche off. To be performe only in the presence of the system supplier or their authorise representative: Recor the block voltages at service loa (capacity test).

35 i Tests are to be execute accoring to IEC 896-2 (EN 60896-2). In aition eventual state or local regulations may have to be observe. C.7 Warranty Warranty claims are subject to proper service an maintenance. In support of claims the following ocumentation has to be supplie: Detaile escription of fault / amage, relevant ientification ata an the last maintenance reports. Faulty batteries have to be returne for fault analysis. i The warranty becomes voi if these hanling instructions are not observe: i.e. in the case of too high ambient temperature, the batteries being left ischarge for an extene perio, inaequate storage conitions, incorrect float charge setting, failure to maintain the recommene service intervals an service instructions. C.8 Table of torques for the battery connectors Type BSOL BTX (LS) Torque (Nm) Type BSOL BTX (LS) Torque (Nm) Type BSOL 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