BC7 BATTERY CABINET INSTALLATION / OPERATION / MAINTENANCE

BC7 BATTERY CABINET INSTALLATION / OPERATION / MAINTENANCE

1. INTRODUCTION... 3 2. PRECAUTIONS... 3 3. INSPECTION UPON RECEIPT OF GOODS... 4 3.1 GENERAL... 4 3.2 VISIBLE DAMAGE... 4 3.3 CONCEALED DAMAGE... 4 3.4 RETURN OF DAMAGED GOODS... 4 4. SYSTEM OVERVIEW... 5 5. GENERAL SYSTEM SPECIFICATIONS... 6 5.1 DC OUTPUT CHARACTERISTICS... 6 5.2 BATTERIES... 6 5.3 GROUNDING... 6 5.4 ENVIRONMENTAL CONDITIONS... 6 6. INSTALLATION PROCEDURES... 7 6.1 PREPARATION... 7 6.1.1 EQUIPMENT INSPECTION... 7 6.1.2 NECESSARY EQUIPMENT AND TOOLS... 7 6.1.3 SAFETY PRECAUTIONS... 7 7. INSTALLATION STEPS... 8 7.1 CABINET LOCATION... 8 7.2 CABINET MOUNTING... 8 7.3 DC CONNECTIONS... 8 7.4 GROUNDING... 9 7.5 SYSTEM OPERATION... 9 8. SYSTEM MAINTENANCE... 10 8.1 REPLACING A BLOWN FUSE... 10 8.2 BATTERY REPLACEMENT STEPS... 10 9. SYSTEM DRAWINGS/SCHEMATICS... 10 10. WARRANTY... 11 03/05/04 2

1. INTRODUCTION C&C Pwer, Inc. 949 N. Larch Ave. Elmhurst, IL 60126 www.ccpwer.cm C&C Pwer s BC7 battery cabinet systems are shipped fully assembled, internally pre-wired, and cme standard with ver current fuse prtectin. The BC7 battery cabinet is designed t accmmdate varius battery sizes and cnfiguratins, and cmes with a remvable battery tray accessible frm the frnt cver fr easy maintenance. As with all f C&C Pwer equipment, systems are Hi-Pt tested t UL standards at ur facility prir t shipment. All system settings are als adjusted at this time accrding t the specificatin sheet attached t the unit r per custmer requirements. Sales supprt fr future equipment r upgrades is prvided by ur reginal sales staff and qualified representatives. All technical questins and service issues shuld be directed t ur main ffice by dialing the number listed belw. This is a 24-hur, 7-day service number. After nrmal wrking hurs, please leave a detailed message with yur phne number n the vice mail system and a qualified service representative will cntact yu as quickly as pssible. C&C Pwer, Inc. 949 N. Larch Avenue, Elmhurst, Illinis Phne: (630)-617-9022; Fax: (630)-617-9023 Emergency Service: (630)-617-9022 2. PRECAUTIONS It is very imprtant t read, understand and fllw the instructins in this manual. Als nte all SAFETY PRECAUTIONS befre beginning the installatin f this system. If there are any questins, cncerns r precautins that are nt clearly understd r stated in this manual, cntact a C&C Pwer representative fr further clarificatin. DC Pwer and Batteries are dangerus and have extremely high shrt circuit current. Severe burns r death can result frm a system shrt. They als can leak ptentially explsive gas (hydrgen). Never enclse batteries r battery cabinets in a sealed rm. It is imperative that nly qualified persnnel wrk n this system and installatin, maintenance r upgrades be perfrmed with insulated tls. When installing this battery system, fllw all applicable federal, state and lcal regulatins and industry guidelines t insure a prper installatin. Jewelry and watches must be remved prir t installing r servicing this system. Never leave a panel ff with system unattended. 03/05/04 3

3. INSPECTION UPON RECEIPT OF GOODS 3.1 General Special precautins and care have been taken t ensure the system arrives safe and undamaged. Hwever, upn receipt, yu shuld inspect the entire shipment, including the skid and any bxes fr evidence f damage that may have ccurred during transit. 3.2 Visible Damage It is the respnsibility f the persn receiving the shipment t inventry and fully inspect all materials against the bill f lading r weigh bill IMMEDIATELY while the carrier representative is still present. Insure that all items are accunted fr, including number f skids and quantity f bxes. Als nte any visible external damage that may have ccurred during transit. Make all applicable ntatins n the delivery receipt befre signing and file a damage reprt with the carrier. 3.3 Cncealed Damage Within 3 t 30 days f receipt (depending n curier), unpack the battery system and check fr any cncealed damage. Check the materials received against the detailed packing list t verify the quantity and the cnditin as cmplete and satisfactry. Nte any damage t the internal packaging, then request an inspectin by the carrier and file a cncealed damage claim. If there is a material shrtage, cntact a C&C Pwer representative at the main ffice t file a claim. Please cntact yur shipping cmpany fr all shipping damage. C&C Pwer is nt respnsible fr any shipping damage. 3.4 Return f Damaged Gds Shuld equipment be damaged and require return t C&C Pwer fr repair, a representative will prvide instructins alng with an RMA number t expedite the return. An RMA number must be btained befre returning equipment t C&C Pwer, Inc. 03/05/04 4

4. SYSTEM OVERVIEW Enclsed battery cabinet systems prvide the necessary DC backup pwer required in UPS and Telecm applicatins. Over-current fuse prtectin is supplied standard n the ht side f the system. All DC cnnectins are easily accessible and made via jumper cable with quick cnnects at the rear f each cabinet. Refer t the attached layut and schematic fr these cnnectins. During nrmal cnditins the UPS r charger supplies the lad pwer and the necessary pwer required t keep the batteries at the prper flat vltage. When AC fails, the batteries discharge in rder t prvide the necessary backup pwer. It is the respnsibility f the custmer t make sure the batteries are nt discharged belw manufacturer s recmmendatins. Always recharge batteries as sn as pssible. Batteries will be damaged if nt recharged right away. See the UPS r DC system manual fr mre infrmatin. 03/05/04 5

5. GENERAL SYSTEM SPECIFICATIONS 5.1 DC OUTPUT CHARACTERISTICS (refer t equipment label) 5.2 BATTERIES Vltage: (Telecm Applicatin) 48 r 24VDC Nminal Vltage: (UPS Applicatin) 12 t 360VDC Nminal Fuse: Supplied n ht side. Wire Size and Type: Per NEC and/r lcal building and electrical cdes. Type: Valve Regulated Lead Acid (VRLA), sealed, nn-spillable Vltage: 12 Vlt r 6 Vlt DC Nminal. 5.3 GROUNDING All grunding shuld be derived frm the main building grund surce. Nte: All battery cabinets require grunding. 5.4 ENVIRONMENTAL CONDITIONS Cabinet Dimensins: BC7: 17.9 W X 29.9 D X 27.8 H Fr further dimensins, please refer t cabinet layut drawing. Cabinet Weight:(Empty) BC7: 74 lbs. Fr weight with batteries, please refer t cabinet layut drawing. Temperature: Nrmal perating temperatures are between 68-77 F Nte: This is based n the charger fr the batteries. Batteries typically shuld be at 77 F fr ptimum life and perfrmance. Ventilatin/Cling: Cabinet ventilatin is thrugh luvers in the rear cver. A minimum clearance f fur inches is required behind the cabinet fr ventilatin and crd clearances. Clearance arund this cabinet shuld be as suggested by NEC and lcal cdes. Warning! Batteries can generate ptentially explsive gas (hydrgen). Never enclse batteries r battery cabinets in a sealed, airtight rm. 03/05/04 6

6. INSTALLATION PROCEDURES 6.1 PREPARATION 6.1.1 Equipment Inspectin Remve the equipment frm the packaging material and inspect fr any shipping damage that may have been verlked upn receipt f gds. Verify the system has all cmpnents and cables fr installatins. 6.1.2 Necessary Equipment and Tls Heavily insulated assrtment f hand tls Digital Vltmeter 6.1.3 Safety Precautins BEFORE PROCEEDING WITH INSTALLATION READ THE FOLLOWING: DC VOLTAGE WARNING! Hazardus DC vltages are present in the battery cabinet. This hazard will always be present, even when the battery system is ff-line. Accidental shrt circuit f the psitive and negative terminals will cause tremendus currents t flw resulting in severe burns, fire and pssible death. Use extreme cautin! IMPORTANT SAFETY INSTRUCTIONS!! All discnnecting means shuld be in the pen/ff psitin befre servicing. All installatin drawings and schematics shuld be reviewed and clearly understd befre hking up this system. Only qualified DC pwer technicians r electricians shuld attempt t wrk n and install this equipment. All jewelry, rings and watches shuld be remved when wrking n this equipment. All tl handles and shafts must be heavily insulated with electrical tape r therwise prtected. D nt rest any tls r lse cables n tp f batteries. Make sure all cnnectins are prperly trqued and secure. D nt smke r present flames near r arund any battery system. Always wear safety glasses and glves and use insulating mats t stand n when wrking n this system. D nt allw bare skin t cme int cntact with battery cabinet while tuching battery terminals, as this culd result in an electrical shck. D nt install any cable terminatins until it has been verified that such a terminatin will nt create a shrt circuit. SAVE THESE INSTRUCTIONS!! 03/05/04 7

7. INSTALLATION STEPS 7.1 CABINET LOCATION Prir t installatin, verify flr lading requirements and all applicable cdes pertaining t the related equipment. Envirnmental cnditins shuld als be reviewed. Prper ventilating and cling must be adequate fr ptimum battery life and perfrmance. A clearance f 4 is recmmended at the rear f the cabinet fr prper ventilatin and crd clearances. Clearance arund this cabinet shuld be as suggested by NEC and lcal cdes. Ambient temperature shuld be between 68-77 F. 7.2 CABINET MOUNTING 1. The BC7 is equipped with fur casters, tw swivel type casters in the frnt and tw rigid type casters in the rear. Rll the cabinet ff f the skid with the prvided ramp and mve the cabinet int the desired lcatin. 2. Lwer the fur leveling feet lcated at each crner t stabilize the cabinet and prevent it frm mving. If the installatin r lcatin requires the cabinet t be blted t the flr, use the shipping brackets prvided r cnsult C&C Pwer fr ther munting ptins. Mark the hles f the bracket n the flr. A minimum f fur blts will be required. 3. Mve the cabinet ut f the way and drill hles fr the munting hardware that is t be used. 4. Mve the cabinet back int place, align the hles, lwer the leveling feet and tighten the hardware t secure the munting brackets. 5. Shuld any drilling be perfrmed n this equipment, make sure all expsed batteries and cnnectins are cmpletely cvered using insulated type mats. 7.3 DC CONNECTIONS CAUTION!! READ ALL SAFETY PRECAUTIONS BEFORE PROCEEDING 1. Remve the frnt cver frm the cabinet and check fr any nticeable prblems r damage that may have ccurred during shipment. 2. Verify that the fuse is remved frm the fuse hlder befre prceeding. 3. Review the attached installatin drawings and schematic prir t making any cnnectins. 4. Check and re-trque internal battery cnnectins, as shipping may have caused these cnnectins t cme lse. Prper trque values are nted n the included system schematic drawing and may als be n the battery case. 5. CAUTION! Be sure UPS r charging surce is discnnected befre making the fllwing cnnectins. Take the crd assembly supplied and cnnect the three lse wires with ring terminals t the UPS r charger surce. The cables will be marked, Psitive, Negative r Grund. CAUTION! DO NOT plug in the cnnectr bx end t the battery cabinet until the lse wires are terminated and secured inside the UPS r charger surce. Refer t the UPS r charger manual fr wiring an external battery surce. Refer t the attached drawing fr a single cabinet layut fr further assistance. 03/05/04 8

6. Cnnect any additinal BC7 battery cabinets in the string at this time. T d this, first remve the plates cvering the cnnectrs at the rear f each cabinet. Then, using the supplied crds with cnnectr bxes n each end, simply plug-in and attach ne end f the cable t ne f the rear cnnectrs n each f the BC7 battery cabinets. Secure the cnnectr bxes int place using the single screw prvided. Refer t the attached drawing fr a multi cabinet layut fr further assistance. 7.4 GROUNDING 1. The grund cable is supplied with the crd assembly as stated previusly in this manual. Be sure this cable is cnnected t the main UPS r charger grund surce. Refer t the UPS r charger manual fr grunding an external battery surce. 7.5 SYSTEM OPERATION 1. Refer t the UPS r charger manual fr start up and system peratin. *DO NOT attempt t adjust the chargers flat r equalize vltage settings. 2. Be sure t install the main fuse supplied with the battery cabinet int the fuse hlder and press firmly int place. Failure t d s will result in partial lss f critical backup time and reduced battery life. 03/05/04 9

8. SYSTEM MAINTENANCE CAUTION!! READ ALL SAFETY PRECAUTIONS BEFORE PROCEEDING 8.1 REPLACING A BLOWN FUSE If the internal fuse has blwn, first determine the cause and make sure the prblem has been reslved. Next, remve the frnt cver and pen the fuse hlder. Remve the blwn fuse and replace with the same size and type f fuse. Clse the fuse hlder and reinstall the frnt cver. Cautin! Fire Hazard Warning: Replace nly with same type and rating f fuses supplied with the system. 8.2 BATTERY REPLACEMENT STEPS 1. Prepare the new battery/s fr installatin. Check t make sure the battery/s are the same type and amp-hur rating. Measure the battery vltage t make sure it is k. Use a brass wire brush r sctch-brite pad and plish the lead terminals. Apply N-x grease t the terminal t avid crrsin. 2. Discnnect the charger r UPS nly frm the battery cabinet and string that is t be serviced by remving the main fuse lcated behind the frnt cver f the battery cabinet. DO NOT discnnect crd assemblies between the UPS and ther battery cabinets, as this will result in lss f backup time supplied by ther battery cabinets that are cnnected in parallel with the UPS. 3. Remve the center jumper n the battery string t reduce the vltage. If replacing all batteries, cntinue reducing the vltage in this manner. 4. Discnnect the cables frm the battery/s t be replaced. 5. Remve the bad battery/s. 6. Replace with new battery/s. Make sure the new battery/s are installed the same way regarding plarity rientatin and verify with the system schematic drawing!! This is very imprtant, if installed imprperly it will result in a shrt circuit and culd cause serius injury r death!! 7. Recnnect cables t battery/s. Make sure cnnectins are prperly trqued. 8. Recnnect center jumper. Make sure cnnectins are prperly trqued. 9. Check vltage at the cnnectrs lcated at the rear f the cabinet. 10. Reinstall the jumper cable frm the UPS at the rear f the cabinet. 11. Reinstall the main fuse and replace frnt cver. 9. SYSTEM DRAWINGS/SCHEMATICS See attached dcuments 03/05/04 10

10. WARRANTY LIMITED WARRANTY AND EXCLUSIONS C & C Pwer, Inc. strives t prduce quality prducts at reasnable prices. If yu are nt satisfied with ur prduct because f a defect, we will repair r replace the defective part r parts free f charge fr a perid f ne year frm the date f purchase. In the event yu claim that the prduct cntains a defect, simply ntify C & C Pwer, Inc. f the defect, and we will arrange fr repair r replacement. The sle and exclusive remedy against C & C Pwer, Inc. relating in any way t a prduct defect shall be the repair r replacement f defective parts as prvided fr under this LIMITED WARRANTY. N ther remedy, including, but nt limited t, incidental r cnsequential damages fr lst prfits, lst sales, injury t persn r prperty, r any ther incidental r cnsequential lss, is available. This LIMITED WARRANTY shall nt be deemed t have failed f its essential purpse s lng as C & C Pwer, Inc. is willing and able t repair r replace defective parts in the manner prescribed in this LIMITED WARRANTY. Certain integrated prducts, which are nt manufactured by C&C Pwer; will be warranted by the applicable manufacturer. These warranties shall be between the manufacturer and the user. Terms and cnditins may vary. These integrated prducts include, but may nt be limited t, the fllwing prducts: Batteries, Inverters and UPS Systems. Any actin fr breach relating t the sale f a C & C Pwer, Inc. prduct must be cmmenced within ne year after the cause f actin has accrued. THIS LIMITED WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EXPRESS OR IMPLIED, AND ALL SUCH WARRANTIES ARE EXCLUDED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. 03/05/04 11

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EARTHQUAKE BRACKET 1/4" DIA. HILTI KB-II EXPANSION ANCHORS PER ER-4627 2" MIN. EMBED. TYP. 4 PLACES CONCRETE FLOOR MIN. 2000 PSI MIN. CONC. DEPTH 4" WASHER THE BC7 BATTERY CABINET HAS BEEN CERTIFIED TO THE 1997 EDITION OF THE UNIFORM BUILDING CODE. TO MEET UBC SEISMIC ZONE 4 HOLD DOWN SPECIFICATIONS: -CABINET MUST BE ANCHORED WITH (4) HILTI KB-II EXPANSION BOLTS OR EQUIVILENT. BOLT DIAMETER AND MINIMUM EMBEDMENT AS CALLED OUT IN DRAWING. -ALL CONCRETE SPECIFICATIONS PER DRAWING MUST ALSO BE MET. WHIZ LOCK NUT FOR TIGHTENING EARTHQUAKE BRACKET ELEVATOR BOLT 03/05/04 14

Revisins: 08/26/02 REV1 03/05/04 REV2 Remved nte limiting installatin distance t 10 Feet frm the UPS 03/05/04 15