DISTRIBUTION CODE: RG01 Lucent Technologies Whippany Physical Design Installation Instructions Interface Kit for attachment of the 60EC or 60ECv2 Battery Cabinet to the Outdoor Flexent Modular Cell 3.0/ 4.0 with integrated power ISSUE RECORD Engineer Issue Reason for Page/Pages Date No. Reissue Marco Garcia 2.0 Base Line All 03/28/05 This is a Word Document PC generated drawing. Any changes must be made within the file. The file is located at the Lucent Technologies Whippany facility, NJ 1 of 42
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Table of Contents ISSUE RECORD... 1 1. PURPOSE / SCOPE... 5 2. REFERENCE DOCUMENTS... 6 3. ESD REQUIREMENTS... 6 4. ENVIRONMENTIAL/ HEALTH SAFETY REQUIREMENTS... 6 5. GENERAL GUIDELINES NOTES... 6 6. REQUIRED TOOLS... 7 7. REQUIRED PARTS... 8 8. TORQUE REQUIREMENTS... 9 9. 60EC OR 60ECV2 BATTERY CABINET AND INTERFACE KIT INSTALLATION... 10 STEP 1. - POSITIONING... 10 STEP 2. ANCHORING... 12 STEP 3. GROUNDING... 12 STEP 4. INSTALLATION OF THE TWO LIQUID TIGHT FLEX 2 CONDUITS AND CABLES... 13 4.1 Preliminary Steps before Starting Conduits and Cables Installation... 144 4.2 Pre-assembling the Liquid Tight Flex 2 Conduit, Hardware and Cables... 14 4.3 Installation of Pre-Assembled Upper Liquid Tight Flex 2 Conduit and Cables... 18 4.4 Installation of Pre-Assembled Lower Liquid Tight Flex 2 Conduit and Cables... 18 STEP 5. PREPARE 60ECOR 60ECV2 BATTERY CABINET FOR THE INTERFACE KIT INSTALLATION... 19 5.1 Preliminary Required Steps for Field Upgrades( for existing cell sites)... 19 5.2 Removal of Four DC Cables Coiled Inside Battery Cabinets... 19 ( for new cell sites)...19 5.3 Replace The Fuse, Inside 60 ECv2 Battery Cabinet Only... 19 5.4 Replace The Fuse and Bus Bar Assemblies, Inside 60 EC Battery Cabinet Only.... 20 STEP 6. CONNECTING THE THERMAL PROBE, ALARMS & FOUR DC CABLES AND THE AC & FOUR DC CABLES TO THE BATTERY CABINET... 25 6.1 Connecting the Thermal probe, Alarms And Four DC Cables to the Battery Cabinet... 25 6.2 Connecting the AC & Four DC Cables to the Battery Cabinet... 29 STEP 7. CONNECTING THE THERMAL PROBE, ALARMS, AC & EIGHT DC CABLES TO THE OUTDOOR FLEXENT MODULAR CELL 3.0/ 4.0 CABINET.... 32 7.1 Connecting the Thermal Probe, Alarms and Eight DC Cables to the Modular Cell 3.0/4.0... 32 7.2 Connecting AC Cables inside HPDA of the Modular Cell 3.0/ 4.0... 38 10. COMPLETE THE INSTALLATION OF THE OUTDOOR MODULAR CELL 3.0/ 4.0 AND THE BATTERY CABINET... 41 3 of 42
Table of Figures Figure 1. Conduit final assembly... 5 Figure 2. Anchoring layout without mounting bases... 10 Figure 3. Anchoring layout with mounting bases*... 11 Figure 4 Interface plates location... 13 Figure 5. Pre-assembling of flex conduit, 90 deg. connector w/fittings, Thermal probe and alarm cables... 17 Figure 6. Pre-assembling of flex conduit, 90 deg. connector w/fittings, AC and four DC cables... 17 Figure 7. Two Liquid Tight Flex 2 Conduit Installation... 17 Figure 8. 24VDC return bus bar fuse... 20 Figure 9. 60EC and 60ECv2 Bus Bar Connections (Exploded View)... 22 Figure 10. 60EC and 60ECv2 Bus Bar Connections(Assembled View)... 23 Figure 11. 60EC and 60ECv2 Alarm Cable Connections for Small Bus Bar... 24 Figure 12. DC cable routing in the 60EC/60ECv2 Battery Cabinet... 28 Figure 13. AC connection for one or two battery cabinets... 30 Figure 14. HPDA, List 1 (with fuses only) in Modular Cell 3.0/ 4.0... 32 Figure 15. + 24 V DC Bus inside HPDA, List 4 (with breakers on top) or List 6 (with breakers on top and fuses at bottom) at the Modular Cell 3.0/ 4.0...Error! Bookmark not defined. Figure 16. Intrusion alarm switch in Modular Cell 3.0... 34 Figure 17. Intrusion Alarm connections... 35 Figure 18. 9-Pin D sub in front of Power Module... 36 Figure19. + 24 V DC Bus inside HPDA List 1 (with fuses only) of Modular Cell 3.0/ 4.0... 37 Figure20. + 24 V DC Bus inside HPDA, List 4 (with breakers on top) or List 6 (with breakers on top and fuses at bottom) at the Modular Cell 3.0/ 4.0 Figure 21. Return Bus Bar inside HPDA... 38 Figure 22. AC PDA in Modular Cell 3.0/ 4.0 Cabinet... 40 Figure 23. Din rail latch located at the bottom of circuit breaker... 40 Table of tables Table 1. Reference Documents...6 Table 2 Required Tools Supplies...7 Table 3 Parts List for 60EC/ 60 Ecv2 Battery Cabinet to Outdoor Modular Cell 3.0/4.0 Interface Kit...8 Table 4 Torque for all electrical connections...9 Table 5. Anchoring...12 4 of 42
1. PURPOSE / SCOPE This document provides the instructions to locate the 60ECv2 or 60EC Battery Cabinet on the concrete pad, with or without mounting bases(maintaining the standard 6 separation between cabinets) and connect it to the Outdoor Flexent Modular Cell 3.0/ 4.0 cabinet. This is not a stand alone document. The Outdoor Fexent Modular Cell 1.0 & 2.0 Installation Manual is to be used to complete this installation; where chapter 5A is applicable to one battery cabinet (60ECv2 or 60EC) and chapter 5B is for two battery cabinets (60ECv2 or 60EC). The Modular Cell 3.0 / 4.0 and the 60ECv2/60EC Battery Cabinets shall be de-energized when installing the AC, DC, thermal probe and alarm cables in the Modular Cell and the Battery cabinets. Follow strictly all safety procedures stated herein and as applicable to the reference documents under section 2 of this document. This document supports the interface kit installation for new or existing 60ECv2/60EC battery cabinets, including a fully configured system of a Modular Cell 3.0/4.0 cabinet with integrated power and two 60ECv2 or 60EC battery cabinets. Figure 1 below shows the final conduit assembly of the upper and lower liquid tight flex 2 conduit hardware assembly at the top part of the modular cell and the battery cabinet. Figure 1. Conduit final assembly 5 of 42
Table of Figures Figure 1. Conduit final assembly... 5 Figure 2. Anchoring layout without mounting bases... 10 Figure 3. Anchoring layout with mounting bases*... 11 Figure 4 Interface plates location... 13 Figure 5. Pre-assembling of flex conduit, 90 deg. connector w/fittings, Thermal probe and alarm cables... 17 Figure 6. Pre-assembling of flex conduit, 90 deg. connector w/fittings, AC and four DC cables... 17 Figure 7. Two Liquid Tight Flex 2 Conduit Installation... 17 Figure 8. 24VDC return bus bar fuse... 20 Figure 9. 60EC and 60ECv2 Bus Bar Connections (Exploded View)... 22 Figure 10. 60EC and 60ECv2 Bus Bar Connections(Assembled View)... 23 Figure 11. 60EC and 60ECv2 Alarm Cable Connections for Small Bus Bar... 24 Figure 12. DC cable routing in the 60EC/60ECv2 Battery Cabinet... 28 Figure 13. AC connection for one or two battery cabinets... 30 Figure 14. HPDA, List 1 (with fuses only) in Modular Cell 3.0/ 4.0... 32 Figure 15. + 24 V DC Bus inside HPDA, List 4 (with breakers on top) or List 6 (with breakers on top and fuses at bottom) at the Modular Cell 3.0/ 4.0...Error! Bookmark not defined. Figure 16. Intrusion alarm switch in Modular Cell 3.0... 34 Figure 17. Intrusion Alarm connections... 35 Figure 18. 9-Pin D sub in front of Power Module... 36 Figure19. + 24 V DC Bus inside HPDA List 1 (with fuses only) of Modular Cell 3.0/ 4.0... 37 Figure20. + 24 V DC Bus inside HPDA, List 4 (with breakers on top) or List 6 (with breakers on top and fuses at bottom) at the Modular Cell 3.0/ 4.0 Figure 21. Return Bus Bar inside HPDA... 38 Figure 22. AC PDA in Modular Cell 3.0/ 4.0 Cabinet... 40 Figure 23. Din rail latch located at the bottom of circuit breaker... 40 Table of tables Table 1. Reference Documents...6 Table 2 Required Tools Supplies...7 Table 3 Parts List for 60EC/ 60 Ecv2 Battery Cabinet to Outdoor Modular Cell 3.0/4.0 Interface Kit...8 Table 4 Torque for all electrical connections...9 Table 5. Anchoring...12 4 of 42
6. REQUIRED TOOLS Table 2. Required Tools Supplies Description 7/16 thin wall socket driver Door panel Level, 1.5m (4 ft) Measuring tape, steel Safety glasses or goggles (R-3055) Socket set metric, 10 mm up to 19 mm Used For Torque wrench Tightening anchors Wrench adjustable, (3/4 in/20 mm) open-ended or set of fixed open-ended wrenches Crimp tools Terminal terminal lugs c-taps Socket set Wire cutters/strippers Antioxidant compound Cable, #2 AWG (35 mm 2 ) grounding Cabinet grounds (provided as part of site preparation) Cable ties, 8 long or equivalent 7 of 42
7. REQUIRED PARTS The components in the kit are shown in the parts list in Table 3. Check for material discrepancies before proceeding. Table 3. Parts List for 60EC/ 60 Ecv2 Battery Cabinet to Outdoor Modular Cell 3.0/4.0 Interface Kit Item Comcode Description Qty 1 848917654 Assembly, cover port hole right side Modular Cell 3.0/4.0 1 2 848996755 Conduit, metallic liquid-tight flex 50.8 mm(2.0 ) 2 3 Sealing ring, liquid tight 2 4 4 90 degree connector 4 5 408151140 Fuse (1000 amp) 1 6 900329830 Nut, ¼ - 20 18 7 900329723 Lock washer, ¼ 16 8 900327453 Flat washer, SS, ¼ 2 9 408703015 15 amp single pole AC Circuit Breaker 2 10 848866240 DC Cable Assembly (load) 4 11 848866604 DC Cable Assembly (return) 4 12 848866216 Intrusion Alarm Cable Assembly 1 13 848840609 Temperature probe 2 14 848866208 Fuse alarm Cable Assembly 1 15 848866224 Fan Power & Alarm Cable Assembly 1 16 848866232 Thermal Probe MPM24 Cable assembly 1 17 848869269 AC cable 3-conductor #14AWG,stred insul. 1 18 405762857 Tie, Cable 12 19 848092334 Busbar, Upper 1 20 848303277 Large Busbar Assembly 1 21 848303269 Small Busbar Assembly 1 22 109559757 Installation Instruction 1 8 of 42
8. TORQUE REQUIREMENTS Table 4 Torque for all electrical connections 9 of 42
9. 60EC or 60ECV2 BATTERY CABINET AND INTERFACE KIT INSTALLATION Step 1. - Positioning Without mounting bases - Mark on the concrete pad the location of the anchor holes for the battery cabinet using the dimensions shown in Figure 2, or using the template CC 848596474. Figure 2. Anchoring layout without mounting bases With mounting bases- See Figure 3. Position the front sides of the two mounting bases inline at a distance of 6.0 inches apart. Mark the hole locations on the concrete pad using the mounting base for the battery cabinet as a template. 10 of 42
Figure 3. Anchoring layout with mounting bases* 1052.4 [41.4] 1839 [72.4] Modcell 3.0/ 4.0 60ECv2/ 60ECBattery Cabinet Front sides to be in-line 152.4 [6.0] Make sure the surface with the Power label is on top 306 [12.1] * This anchoring layout is the same as the ones for the existing cell sites 11 of 42
Step 2. Anchoring Drill four anchor holes per cabinet to proper size depth as specified in Table 5. Table 5. Anchoring Seismic Anchor Type Hole Size Wrench Torque Zone Newton- Meters Foot Pounds 0,1,2 ½ drop in 5/8 bit, 2 ¾ 24 Nm 18 ft-lb deep 3,4 12mm expansion stud 11/16 bit, 4 min deep 19mm 79 Nm 58 ft-lb Place the battery cabinet (or mounting base, then cabinet, if applicable) into position. Remove the front panel and the lower rear panel to access the mounting holes using the 7/16 thin-walled nut driver. Align the cabinet mounting holes with the anchor holes. Level the cabinet using the supplied shims. Install the anchor hardware. Hand tighten the anchors. DO NOT torque them down at this point. They will be tightened after the conduits between the Modular Cell and the Battery Cabinet are installed. Replace the lifting eyebolts, if present, with the bolts supplied with the cabinet. Step 3. Grounding The cabinet requires two grounding cables that connect it to the grounding system. Terminal lugs, with installation hardware, are pre-installed at the rear bottom of the cabinet. Locate the two #2-AWG (35mm 2 ) cables that were installed during site preparation. Remove the double-hole terminal lug provided on the cabinet. Cut the cable to the proper length, crimp on the double-hole lug. Make sure the grounding surface is free of paint. If not, polish the cabinet grounding lug locations. Using antioxidant compound, connect both grounding cables to the rear of the cabinet. Torque the bolts according to Table 4. Locate the #6 green ground cable coiled up inside the rear of cabinet. Remove and discard. 12 of 42
Step 4. Installation of the Two Liquid Tight Flex 2 Conduits and Cables. 4.1 Preliminary steps before starting conduits and cables installation 1. Determine type of battery cabinet: For 60ECv2 Battery Cabinet: There are three cover plates on the left side of the battery cabinet. Remove only the two bottom 2 cover plates. Do not remove the top 2 ½ cover plate. See Figure 4. For 60EC Battery Cabinet: There are only two cover plates on the left side of the battery cabinet. Remove the two bottom 2 cover plates. Note: The conduit, hardware and cables (items listed below) supplied inside the 60EC/60ECv2 Battery Cabinet will not be required for this application:! (2) 2 X 5 ¾ long steel conduits! (4) 2 sealing rings! (4) 2 chase nipples! (4) 2 lock nuts! (2) temperature probes, 6 pin connector. 2. Remove the square cover plate from the right side of outdoor Modular Cell 3.0/4.0 cabinet as shown in Figure 4. Save the nuts and washers from the cover plate. Figure 4. MODULAR CELL 3.0/4.0 RIGHT SIDE Interface plates and holes location BATTERY CABINET 60 EC/ECv2 LEFT SIDE (60 EC with no 2 ½ hole access) 13 of 42
4.2 Pre-assembling the Liquid Tight Flex 2 Conduit, Hardware and Cables 4.2.1 Routing Thermal Probe, Alarm and DC Cables Through 2 Flex Conduit. Refer to Figure 5. Obtain the parts for one liquid tight flex 2 conduit and 90 deg. connector with fittings. Also, obtain the thermal probe, alarm and four DC Cables( two plus and two returns). Lay out the conduit assembly and cables away from the radio and battery cabinets to start pre-assembling these parts nearby. Caution! 1. Before start pulling cables through the flex conduit and 90 deg. connector with fittings, measure the length of the above cables between each final connection point inside the radio cabinet to the square plate interface where the 90 deg. connector is to be plugged. (Do not measure cables hanging loose with too much slack, since cables might be short at the battery cabinet end). 2. Mark all cable assembly distances at the square plate interface to determine how much cable length will be routed out of the 90 deg. connector fitting, for the Modcell cabinet end. Once marked, cables are ready to be pulled through the conduit and fittings. Cables should be taped together and staggered for easy pulling. As a reminder, see also section 6.1, this is a critical step since cable length can not be adjusted once they are installed inside the conduit. 3. The thermal probe and alarm cables are connectorized and should be pulled into the liquid tight flex 2 conduit, one at a time or stagger the connector for easy pulling, together with four DC cables (two loads plus two returns). Extra care shall be exercised not to damage the alarm cable connectors. 14 of 42
Take one of the two 55 long liquid tight flex 2 conduits. Then cut it two inches shorter to make it 53 long. The recommended pulling method is to run the Battery cabinet cable leads through the first 90 deg. connector, to the conduit and then to the second 90 deg. connector. In other words, the thermal probe cable equipped with 9 pin D-sub at Modular Cell cabinet end is to be kept outside, pull the other end of the cable equipped with two Mate N-Lock connectors going from the Modular Cell 3.0/ 4.0 into Battery cabinet. Figure 5. Pre-assembling of flex conduit, 90 deg. connector w/fittings, Thermal probe and alarm cables. Cables protruding for the Modcell end should be run up to the marks determined in the previous step. After cables are pulled, assemble the 53 flex conduit to each 90 deg. connector through the conduit fittings. 15 of 42
Once pre-assembled, the flex conduit, 90 deg. connector w/fittings and cables will be installed between the UPPER HOLE of square plate OF MODCELL CABINET and UPPER HOLE of left rear side of BATTERY CABINET (See Figure 7). Figure 6. Pre-assembling of flex conduit, 90 deg. connector w/fittings, AC and four DC cables. 4.2.2 Routing the AC and Four DC Cables Through the 2 Flex Conduit. Repeat the above procedure step 4.2.1 to do the outer liquid tight flex 2 conduit installation, except for the following: Use the 55 long liquid tight flex 2 conduit to do this conduit assembly installation. Note : DO NOT CUT THIS CONDUIT. THIS CONDUIT MUST REMAIN 55 LONG. Route cables through one liquid tight flex 2 conduit assembly and fittings. The recommended pulling method is to run the Modcell cabinet cable leads through the first 90 deg. connector, to the conduit and then to the second 90 deg. connector, as shown in Figure 6. 16 of 42
Once pre-assembled, the flex conduit, 90 degree connector w/fittings and cables will be installed between the LOWER HOLE of square plate of MODCELL CABINET and the LOWER HOLE of left rear side of BATTERY CABINET (See Figure 7). Figure 7. Two Liquid Tight Flex 2 Conduit Installation Top View Rear 90 deg. connector w/sealing ring, conduit fitting & locknut. TOP HOLE OF BATTERY CABINET. Conduit Fitting Sealing Ring Locknut 90 deg. connector w/sealing ring,conduit fitting & locknut. LOWER HOLE OF BATTERY CABINET. 53 Liquid Tight Flex Conduit Conduit Fitting Locknut 60ECv2/ 60EC Battery Cabinet UPPER CONDUIT INSTALLATION LOWER CONDUIT INSTALLATION Modcell 3.0/4.0 (sq. cover plate) Sealing Ring 90 deg. connector w/sealing ring, conduit fitting & locknut. UPPER HOLE OF SQUARE PLATE. 90 deg. connector w/sealing ring, conduit fitting & locknut. LOWER HOLE OF SQUARE PLATE. Front 17 of 42
4.3 Installation of Pre-Assembled Upper Liquid Tight Flex 2 Conduit and Cables Refer to Figure 7. Obtain the parts pre-assembled in previous section 4.2.2 with conduit assembly, thermal probe, alarms and four DC cables(two plus and two returns). Attach the new square cover plate supplied with the kit to the Modular Cell cabinet, replacing the one that was removed earlier. The new cover plate has two holes to accept the liquid tight flex 2 conduits. The lower hole should be positioned closer to the front of the Modular Cell cabinet. Reach into the battery cabinet, insert the cables through the 2 conduit top hole (see figure 4) located on the left side of the battery cabinet. Place the 90 deg. connector with the sealing ring so that it is flush to the outside of the battery cabinet. The sealing ring will be compressed between the cabinet and the 90 deg. connector. Thread the locknut into the 90 deg. connector without making a full contact with the metal part of the cabinet. Reach into the Modcell cabinet, insert the other end with cables and 90 deg. connector through the upper 2 conduit hole in the square cover plate of the Modular Cell cabinet. As before, the sealing ring will be compressed between the cabinet and the 90 deg. connector. Again, thread the locknut into the 90 deg. connector. Tighten up both locknuts or ends of conduit. 4.4 Installation of Pre-Assembled Lower Liquid Tight Flex 2 Conduit and Cables Repeat the above procedure step 4.3 to do the outer liquid tight flex 2 conduit installation with AC and Four DC Cables(two plus and two returns).. After finishing all steps, as outlined in step 4.3, tighten up the four cabinet anchors to the torque values as specified in Table 4. 18 of 42
Step 5. Prepare 60ECor 60ECv2 Battery Cabinet for the Interface Kit Installation 5.1 Preliminary Required Steps for Field Upgrades( for existing cell sites). 1. Open, using the 7/16-inch nut driver, and lift the front door away from the battery cabinet. 2. Disconnect all ten of the P/J 401-1 through P/J 401-10 connectors from ALL BATTERY CABINETS, two on each shelf, to cut power from all batteries to the bus bars. 3. Disconnect and remove ALL external cables, both the load and return cables from the battery cabinet. 4. If batteries are already installed, remove batteries on the second and fourth shelf to make room for routing the new cables through the cabinet. 5.2 Removal of Four DC Cables Coiled Inside Battery Cabinets ( for new cell sites) There are four DC cables (two red, two black) that are coiled in the bottom of the battery cabinet. They need to be removed and replaced by the cable assemblies supplied with this kit. 1. Remove the covers from both 24 VDC bus bars. 2. Remove the two cables from the +24 VDC load bus bar (upper one). 3. Remove the two cables from the 24 VDC return bus bar (lower one). 4. Save the nuts and washers to install the replacement cables. IMPORTANT! : SKIP NEXT STEP 5.3 IF INSTALLING A 60 EC BATTERY CABINET 5.3 Replace The Fuse, Inside 60 ECv2 Battery Cabinet Only In the battery cabinet, remove the existing 400 amp fuse, replace it with the supplied 1000 amp fuse using the supplied (larger) flat washers and nuts as shown in Figure 8. IMPORTANT! : SKIP NEXT STEP 5.4 IF INSTALLING A 60 ECv2 BATTERY CABINET 19 of 42
Figure 8. 24VDC return bus bar fuse DO NOT USE THESE TWO POSITIONS FUSE ACTIVATOR AND SWITCH ASSEMBLY 4 RETURN CABLES SMALL BUS BAR BATTERY CONNECTIONS SMALL BUS BAR CONNECTIONS TO SMALL BUS BAR SIDE VIEW FLAT WASHER (1 OF 2) LARGE BUS BAR 5.4 Replace The Fuse and Bus Bar Assemblies, Inside 60 EC Battery Cabinet Only. 1. Remove the upper bus bar housing cover. Remove the nuts and lock washers from all terminal lugs on the upper (+) bus bar. Retain the nuts and washers for reattaching these cables. 2. Lift the cables off the studs out of the way so you have clear access to the mounting screws for the upper bus bar. Remove the bolts holding the upper bus bar on the standoffs. Remove the upper bus bar. Retain the bolts and lock washers for remounting the new upper bus bar (Item 19). 3. Attach the new upper bus bar to the standoffs using the lock washers and bolts retained in step 2 above. For orientation, the mounting holes are closer to the bottom edge of the bus bar. Tighten the bolts until snug. See Figure 9. 20 of 42
4. Reattach the battery cables to the new upper bus bar. Five of the battery cables will need to piggy-back over five of the terminal lugs. On these studs, the terminal lugs closest to the bus bar need to be arranged so the lug face is against the bus bar the terminal lugs on top rest back-to-back on the bottom terminal lugs. Tighten the nuts until snug. See Figures 9 and 10. 5. Remove the lower bus bar housing cover. Inside the housing, remove the nuts, washers from the switch actuator assembly. The alarm connections may have to be removed to provide access; these will need to be reattached after the new bus bar is installed. See Figures 9 and 11. All of these parts will be retained used with the new large and small bus bars. 6. Remove and retain the nuts, washers from the 400-Amp fuse. The 400-amp fuse can be disposed of properly. Remove and retain the nuts, lock washers from all terminal lugs on the large and small (return) bus bars. 7. Lift the cables off the studs out of the way so you have clear access to the mounting screws for the large bus bar the mounting screws to the small bus bar. 8. Remove the bolts holding the small bus bar on the standoffs. Retain the bolts, lock washers for remounting the new bus bar. Remove the small bus bar. 9. Attach the new small bus bar (Item 21) to the standoffs using the lock washers and bolts retained in step 8 above. Tighten the bolts until snug. 10. Remove the bolts holding the large bus bar on the standoffs. Retain the bolts and lock washers for remounting the new bus bar. Remove the large bus bar. 11. Attach the new large bus bar (Item 20) to the standoffs using the lock- washers and bolts retained in step 11 above. Tighten the bolts until snug. 12. Re-attach the switch actuator assembly from step 5 above to the new large and small bus bars using the nuts and washers retained in step 5. If the alarm connections had been removed to provide access, reattach the cable connections. See Figure 11. 13. Attach the 1000-amp fuse (Item 5) found in the Table 3 for Kit of Parts using the nuts retained in step 6 above flat washers (Item 14) found in the kit. 14. Re-attach the battery cables to the new large bus bar with the same arrangement as the cabinet had prior to changing the bus bars. See Figures 9 and 10. Tighten the nuts until snug. 21 of 42
Figure 9. 60EC and 60ECv2 Bus Bar Connections (Exploded View) Item 19 Existing hardware Existing battery string cables Load cables, item 10 (4 places, connected back to back) Existing hardware Existing battery string cables Existing hardware (20 places) Item 26 Existing battery string cables Existing actuator/switch Existing hardware Item 21 Item 5 Existing hardware Return cables, item 11 (2 places, connected back to back) Item 7 (4 places) Item 6 (4 places) Existing hardware (4 places) 22 of 42
Figure 10. 60EC and 60ECv2 Bus Bar Connections(Assembled View) ( + ) Bus Bars Assembly External load connections No. 1 AWG (Item 10) Internal battery connections ( two lugs on these studs) Large & Small Return Bus Bars External return connections No. 1 AWG, Item 11 (two lugs on these studs) These studs not used 23 of 42
Figure 11. 60EC and 60ECv2 Alarm Cable Connections for Small Bus Bar Existing alarm cable BK RED NC NO COM 24 of 42
Step 6. Connecting the Thermal probe, Alarms & Four DC Cablesand the AC & Four DC Cables to the Battery Cabinet 6.1 Connecting the Thermal probe, Alarms And Four DC Cables to the Battery Cabinet Danger! Installation of the 60EC/60Ecv2 battery cabinets requires connections to be made that require AC power to be turned off at specific circuit breakers in the Modular Cell 3.0/4.0 with integrated power. Also, turn off the AC power at the AC panelboard, located away from the Modular Cell. Failure to follow instructions to turn off these breakers can create an electrical shock hazard. Failure to follow the order of the installation procedure (as written) can also create an electrical shock hazard. The procedures in this manual do not include safety procedures regarding working on energized equipment. When this manual is used to install equipment in an energized system, the appropriate safety procedures must be followed in addition to the procedures in this manual. Follow these rules: 1. Perform installation steps in the order provided. 2. Observe and strictly follow all safety precautions. 3. When completing electrical connections, always use tools that are properly insulated. First of all, check that thermal probe and alarm cables together with the four DC cables (two loads plus two returns) have the proper length to get to the final connection points. If they don t, go back and re-do steps 4.2.1 and 4.3. Follow all safety procedures above outlined and complete steps 6.1.1 through 6.1.5: 25 of 42
6.1.1 Thermal probe cable (equipped with 9 pin D-Sub) installation Route and dress, inside the 60EC/60 EC v2 battery cabinet, the thermal probe cables from the upper right conduit (facing front) up to the proper shelf for connection to the center of battery retaining bracket. Locate and connect the two-temperature probe (CC 848840609) to the two Mate-N-Lock connectors of newly installed thermal probe cable. Note: Thermal probe sensors are installed to center of battery retaining bracket after all batteries are installed. For installation procedure of various battery type refer to 60ECv2or 60 EC installation manual # 410-710-123, chapter 5A for one battery cabinet, chapter 5B for two battery cabinets. If there is only one battery cabinet that is fully populated, install one of the thermal probe sensor on the center of top battery shelf s retaining bracket and the second thermal probe sensor on the center of the middle battery shelf s retaining bracket. If there is one battery cabinet and it is not fully populated, install one thermal probe on the center of top populated battery shelf s retaining brackets, and the second one on the retaining bracket immediately below the top shelf. If there are two Battery Cabinets, install the shorter thermal probe cable on the retaining bracket of first cabinet s top populated shelf, and the longer thermal probe cable on the second battery cabinet top populated shelf. 6.1.2 Fan Power Alarm cable (312) installation. Locate the existing fan power/alarm cable with connector J3, J312 coiled in the lower rear of the 60EC/60ECv2 battery cabinet and connect it to the P3-1 P312-1 connectors of the new supplied fan power/ alarm cable. If there is a second battery cabinet, locate the existing second battery cabinet s fan power/ alarm cable connectors J3, J312 and connect it to the P3-2 & P312-2 of the new supplied cable. Route the other end of fan power/ alarm cable equipped with one Mate-N-Lock connector through the upper liquid tight flex 2 conduit in to the Modular Cell cabinet. 6.1.3 Fuse Alarm Cable (309) installation. Locate and connect the existing fuse alarm cable connector J309 coiled in the lower rear of the 60EC/60ECv2 battery cabinet to the P309-1 connectors of the supplied new fuse alarm cable. If there is a second battery cabinet, locate and connect its Fuse alarm cable connector J309 to the P309-2 connector of supplied new fuse alarm cable. Route the other end of the fuse alarm cable equipped with 2-circuit Mate-N-Lock connector through the upper liquid tight flex 2 conduit in to the Modular Cell cabinet. 26 of 42
6.1.4 Intrusion Alarm cable (307) installation. Locate and connect the existing intrusion alarm cable connector J307, coiled in the lower rear of the 60EC/60ECv2 battery cabinet, to the P307-1 connector of the supplied new intrusion alarm cable. If there is a second battery cabinet, locate and connect its intrusion alarm cable with the J307 connector to the P307-2 connector of supplied new intrusion alarm cable. Route the other end of Intrusion alarm cable equipped with faston connector through the upper liquid tight flex 2 conduit into the Modular Cell cabinet. 6.1.5 Four DC Cables (Two Loads and Two Returns) installation. Inside the battery cabinet, route the two DC cables with red heat shrink to the upper +24VDC bus bar via the rear hole in the battery shelf. See Figure 12. Apply antioxidant compound and attach two load cables to the upper bus bar, as shown in Figure 8. This figure shows four load cables and only two of them will be connected at this point: connect the first terminal lug located at the bottom left and the second one at the top right on the third set of studs. Torque the nuts according to Table 4. 27 of 42
Figure 12. DC cable routing in the 60EC/60ECv2 Battery Cabinet Inside the battery cabinet, route the two return cables with black heat shrink to the lower, return 24VDC bus bar via the rear hole in the battery shelf. 28 of 42
Refer to Figure 8 and10: Connect the two terminal lugs on the first set of studs as follows: Using antioxidant compound, place one of the two return cables on the threaded studs on the small bus bar with the face of the terminal lug against the bus bar. Place a second return cable on the same threaded stud with the face of the lug facing outward as shown in the side view in Figure 8. Using the supplied ¼ lock washers and nuts, attach the cable terminal lugs to the bus bar. Torque the nuts according to Table 4. Attach the four DC cables to the tie points with cable ties so that they do not interfere with battery installation as shown in Figure 12. 6.2 Connecting the AC & Four DC Cables (through the 2 lower conduit) to the Battery Cabinet After step 6.1 above is completed, check that AC cables together with the four DC cables (two loads plus two returns) have the proper length to get to the final connection points. If not, go back and re-do steps 4.2.2 and 4.4. Follow steps 6.2.1 to 6.2.2 : 6.2.1 AC Cable (item17, 848869269) installation. Locate the existing heater cable assembly coiled in the bottom of the 60 EC/60ECv2 battery cabinet. Install one of the newly supplied plug, part of item 17, (CC 401220587) on its end. Connect the black wire to terminal with bronze screw, the white wire to the terminal with silver screw and the green wire to the terminal with green screw. Refer to Figure 13: If there is a second battery cabinet, locate its heater cable assembly, install a second supplied plug, part of item 17, (CC 401220587) on the cable end inside the first battery cabinet same as above. If there is no second battery cabinet,then connect the second supplied plug (CC 401220587) to the mating end of the second receptacle and leave it in place for future use. Connect the receptacle end of the new AC cable assembly, item 17 (CC 848869269) to the plug of the existing cable (s). The connectorized end of the cable is to be kept inside the battery cabinet, the loose end of cable is to be routed through the lower liquid tight flex 2 conduit into the Modular Cell 3.0 / 4.0. 29 of 42
Figure 13. AC connection for one or two battery cabinets 30 of 42
6.2.2 Four DC Cables (Two Loads and Two Returns) installation Inside the battery cabinet, route the two DC cables with red heat shrink to the upper +24VDC bus bar via the rear hole in the battery shelf.see Figure 12. If the hole does not accommodate all four wires, the other wires may be routed by the alternate DC route in the front. See Figure 12. Apply antioxidant compound and attach two load cables to the upper bus bar as shown in Figure 8. This figure shows four load cables, two of which were previously connected in step 6.1.5. Connect the two terminal lugs located at the top left. Torque the nuts according to Table 4. Replace the upper bus bar cover. See Figure 12. Inside the battery cabinet, route the two return cables with black heat shrink to the lower return 24VDC bus bar. See Figure 12. Refer to Figures 8 and 10: Connect the two terminal lugs on the third set of studs as follows: Using antioxidant compound, place one of the two return cables on the threaded studs on the small bus bar with the face of the terminal lug against the bus bar. Place a second return cable on the same threaded stud with the face of the lug facing outward as shown in the side view in Figure 8. Using the supplied ¼ lock washers and nuts, attach the cable terminal lugs to the bus bar. Torque the nuts according to Table 4. Attach the DC cables to the tie points with cable ties so that they do not interfere with battery installation as shown in Figure 12. Replace the lower bus bar cover. See Figure 12. 31 of 42
Step 7. Connecting the Thermal probe, Alarms, AC & Eight DC Cables to the Outdoor Flexent Modular Cell 3.0/ 4.0 Cabinet. IMPORTANT! : The cell site shall be de-energized during the installation of AC, DC, Thermal probe and Alarm cables inside the Modular Cell Cabinet 7.1 Connecting the Thermal Probe, Alarms and Eight DC Cables to the Modular Cell 7.1.1 Dress the thermal probe and alarm cables in Modular Cell 3.0/ 4.0 Cabinet Dress all cables (fan power/alarm, fuse alarm, intrusion alarm, and thermal probe) inside the Modular Cell Cabinet. These cables should be dressed in such a way that they do not interfere with the HPDA door opening, closing, or installation/ replacement of various parts inside the cabinet. 7.1.2 Connect the fan power/alarm cable in Modular Cell 3.0/ 4.0 Cabinet Loosen the thumb-screw and open the door of the HPDA inside the Modular Cell. Connect the fan power/alarm cable connector (routed from the battery cabinet) to the fan power/alarm cable connector on the circuit board mounted located at the inside of the HPDA (High Power Distribution Assembly) door in Modular Cell cabinet. See Figure 14 for HPDA, List 1and Figure 15 for HPDA, List 4 and 6. Figure 14. HPDA, List 1(with fuses only) in Modular Cell 3.0/ 4.0 32 of 42
Figure15 + 24 V DC Bus inside HPDA, List 4 (with breakers on top) or List 6 (with breakers on top and fuses at bottom) at the Modular Cell 3.0/ 4.0 Fan power and alarm connector Fuse alarm connector 7.1.3 Connect the fuse alarm cable in Modular Cell 3.0/ 4.0 Cabinet. Connect the fuse alarm cable connector J309 (routed from the battery cabinet) to the fuse alarm cable connector P309 located at the HPDA inside the Modular Cell cabinet. See Figure See Figure 14 for HPDA, List 1and Figure 15 for HPDA, List 4 and 6. 7.1. 4 Connect Intrusion Alarm in Modular Cell 3.0/ 4.0 Cabinet Disconnect the existing cable attached to the front intrusion alarm switch (two spade terminal lugs C, NC) by firmly holding the base of the Fast on connector (spade lug). Remove gently. Extra care is to be exercised not to damage the Fast on connector (spade lug). See Figure16. 33 of 42
Figure 16. Intrusion alarm switch in Modular Cell 3.0/4.0 34 of 42
Figure 17. Intrusion Alarm connections Attach the spade lug of the cable disconnected in above step to the double spade lug of the new intrusion alarm cable (routed from the battery cabinet). See Figure 17. Connect the spade of new cable (routed from battery cabinet) to the top intrusion alarm switch COM, NC. 35 of 42
7.1.5 Connect Thermal MPM24 cable in Modular Cell 3.0/ 4.0 Cabinet. Connect the thermal probe 9-pin D-sub of cable supplied in the kit to the 9-pin D-sub (labeled DsubM3) of connector located on front of Power Module, see Figure 18. Figure 18. 9-Pin D sub in front of Power Module 7.1.6 Connecting the Eight DC Cables (Four Loads and Four Returns) Route the four load cables to the +24VDC bus bars inside HPDA of the Modular Cell Cabinet. The four load cables (+ 24 VDC) are to be connected to the four front sets of studs as shown in Figure 19 for HPDA, List 1and Figure 20 for HPDA, List 4 and 6. Remove the nuts and washers from the four front sets of studs inside the HPDA. Save them if they are to be reused. See Figure 19 for HPDA, List 1and Figure 20 for HPDA, List 4 and 6.. Route the four return cables to the 24VDC bus bar located on the sidewall of the Modular Cell inside the HPDA. They are to be connected to the four front sets of studs. See Figure 21. 36 of 42
Figure19. + 24 V DC Bus inside HPDA, List 1 (with fuses only) at the Modular Cell 3.0/ 4.0 Figure20. + 24 V DC Bus inside HPDA, List 4 (with breakers on top) or List 6 (with breakers on top and fuses at bottom) at the Modular Cell 3.0/ 4.0 Fuse alarm connector Positive bus Connect four + 24 VDC load cables from battery cabinet here 37 of 42
Figure 21. Return Bus Bar inside HPDA Remove the nuts and washers from the four front sets of studs of the return bus bar mounted on the side-wall of the Modular Cell inside the HPDA. Save them if they are to be reused. See Figure 21. Apply antioxidant compound and attach the four load (+24 VDC) cables and the four return (-24 VDC) cables to the four front sets of stud. Torque the nuts according to table 4 7.2 Connecting AC Cables inside HPDA of the Modular Cell 3.0/ 4.0 7.2.1. AC Circuit breaker replacement in Modular Cell 3.0/ 4.0 Cabinet CAUTION: 60EC/60ECv2 Battery Cabinets use 120V heaters, not 240V, therefore it is critical that the existing 2-pole, 240 V breaker be replaced with two single pole, 120V breakers supplied in the Kit. 38 of 42
Danger! Installation of the 60EC/60Ecv2 battery cabinets requires connections to be made that require AC power to be turned off at specific circuit breakers in the Modular Cell 3.0/4.0 with integrated power. Also, turn off the AC power at the AC panelboard, located away from the Modular Cell. Failure to follow instructions to turn off these breakers can create an electrical shock hazard. Failure to follow the order of the installation procedure (as written) can also create an electrical shock hazard. The procedures in this manual do not include safety procedures regarding working on energized equipment. When this manual is used to install equipment in an energized system, the appropiate safety procedures must be followed in addition to the procedures in this manual. Follow these rules: 1. Perform installation steps in the order provided. 2. Observe and strictly follow all safety precautions. 3. When completing electrical connections, always use tools that are properly insulated. Remove the rectifier(s) from bottom shelf (if any). Fully loosen the two AC access panel thumb-screws, carefully slide the access panel to the left. Remove it through the front of the power module. 39 of 42
Remove the AC PDA cover by removing four corner screws. Figure 22. AC PDA in Modular Cell 3.0/ 4.0 Cabinet Ac access panel AC PDA cover Din Rail Latch Location Refer to Figure 22. Fully loosen the screws from top and bottom of the 2-pole circuit breaker labeled Battery Heater. Remove the wires from top of the breaker. Caution! After wires are removed, they shall be taped as a preventive step to avoid safety hazards. Refer to Figure 23. Use the flat screwdriver to push down the Din rail latch located at the bottom of the breaker, gently pull out the 2-pole breaker. Remove the power supply feeders from the bottom. Figure 23. Din rail latch located at the bottom of circuit breaker Din Rail Latch 40 of 42
First, insert one of the existing power supply feeders, #12 AWG red wire, to the bottom of the single pole 120 V AC breaker. Tighten the screw. Repeat the same procedure for the second breaker using the existing second power supply feeder #12 AWG for the black wire. Place breakers into position. Push the Din rail to latch up. Route the loose ends of item 23 (848869269) into the left bottom hole of the AC PDA, and then up to the front position of the newly installed single pole breakers. Connect the new conductors of item 23, first, the black one (L-1) into the top terminal of the first single pole breaker. Then, connect the red one (L-2) into the top terminal of the second single pole breaker. Connect the white wire (N) to the neutral terminal (the seventh terminal from the left when facing the front of the cabinet). Connect the green wire (GND) to the ground terminal (the first terminal on the left when facing the front of the cabinet). Re-install the ACPDA cover, the AC access panel and the rectifiers removed previously. 10. Complete the installation of the Outdoor Modular Cell 3.0/ 4.0 and the Battery Cabinet. The specific instructions of this kit end here. Use the Outdoor FLEXENT Modular Cell 3.0 Cabinet Installation Manual (401-703-406), the Outdoor FLEXENT Modular Cell 4.0 Cabinet Installation Manual (401-703-414), the FLEXENT Modular Cell 1.0 & 2.0 Cabinet Installation Manual (401-710-123), Chapter 5A for one battery cabinet (60ECv2 or 60EC) and Chapter 5B for two battery cabinets (60ECv2 or 60EC), for additional information as required to complete the installation. 41 of 42
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