EC200T-01_V1 3 User Manual

EC200T/01 Outdoor TEC Battery Cabinet User Manual Version: V1.3 Revision date: August 10, 2009 BOM31011451 Emerson Network Power provides customers with technical support. Users may contact the nearest Emerson local sales office or service center. Copyright © 2007 by Emerson Network Power Co.,Ltd. All rights reserved. The contents in this document are subject to change without notice.

Safety Guidelines

Prohibitions

1. Non-professionals are prohibited to install or commission the battery cabinet alone.

2. As hazardous voltages are present within the battery cabinet, only an Emerson technician or an

Emerson-authorized technician is permitted to open it. Failure to observe this could result in electric shock risk

and invalidation of any implied warranty.

3. Never dispose of the batteries in a fire, as it may explode and jeopardize personnel safety when exposed to

flame.

Matters needing attention

1. The battery cabinet contains batteries; therefore, its output terminals may carry live voltages even when it is

not connected to DC power supply.

2. Cut off its input and output before moving or re-wiring the battery cabinet. Failure to observe this could result

in electric shock risk.

3. To ensure human safety and normal operation, the battery cabinet must be solidly and adequately grounded

before use.

4. The operating environment affects the battery cabinet lifetime and reliability. It is advisable not to use the

battery cabinet for long in the following environments:

� places where the temperature and relative humidity are outside the specifications (temperature: -10°C ~

55°C, relative humidity: ≤ 93%)

� places subject to vibrations or shocks

5. Verify that the cabling and battery polarities are correct before switching on the battery cabinet.

6. The battery cabinet installation must be firm and solid. Before installation, remove metallic finger rings and

bracelets, and use insulated installation tools to avoid shortcircuit.

7. In case of fire, use dry chemical fire extinguisher to put out the fire. Using foam fire extinguisher may cause

electric shock.

8. High ambient temperature shortens the battery lifetime. To ensure normal operation of the battery cabinet and

adequate battery backup time, replace the batteries periodically. Only Emerson-authorized technicians are

permitted to replace the batteries.

9. If the battery cabinet will remain idle for a long period, it must be stored in a dry environment. The storage

temperature should range between -40°C and +70°C (excluding batteries).

10. Do not open or damage the batteries, as the battery electrolyte is harmful to human skin and eye. If

electrolyte comes into contact with the skin, wash the affected area with plenty of clean water immediately and

go to the hospital for a check.

Others

When the battery cabinet is purchased to deliver power to the equipment listed below, please discuss with the

distributor in advance about the applicability, settings, management and maintenance of the battery cabinet, as

these need special considerations during design and development.

� life-supporting medical apparatus

� facilities such as lifts/elevators where adequate care has to be taken to avoid any fatal eventuality

endangering human life

� any other mission-critical equipment like the above

Contents

Chapter 1 Product Description ............................................................................................................................................ 1

1.1 Overview............................................................................................................................................................... 1

1.2 Model Information ................................................................................................................................................. 1

1.3 Structure ............................................................................................................................................................... 1

1.4 Features................................................................................................................................................................ 1

1.5 Specifications........................................................................................................................................................ 2

Chapter 2 Installation .......................................................................................................................................................... 3

2.1 Unpacking Inspection............................................................................................................................................ 3

2.2 Field Survey.......................................................................................................................................................... 3

2.3 Installation Preparation ......................................................................................................................................... 3

2.3.1 Installation Notes ....................................................................................................................................... 3

2.3.2 Installation Tools........................................................................................................................................ 3

2.3.3 Cable Specifications .................................................................................................................................. 4

2.4 Installing Battery Cabinet ...................................................................................................................................... 4

2.5 Opening And Closing Battery Cabinet Door.......................................................................................................... 5

2.6 Installing Batteries................................................................................................................................................. 6

2.7 Connecting Cables................................................................................................................................................ 7

2.7.1 Cabling Holes ............................................................................................................................................ 7

2.7.2 Connection Procedures ............................................................................................................................. 8

2.8 Power-On............................................................................................................................................................ 10

2.8.1 Check Before Power-On.......................................................................................................................... 10

2.8.2 Power-On ................................................................................................................................................ 10

Chapter 3 Maintenance..................................................................................................................................................... 11

3.1 Regular Maintenance.......................................................................................................................................... 11

3.2 Replacing TEC.................................................................................................................................................... 12

Appendix 1 Connection Diagram....................................................................................................................................... 15

Chapter 1 Product Description 1

EC200T/01 Outdoor TEC Battery Cabinet User Manual

Chapter 1 Product Description

This chapter describes the model information, structure and specifications of EC200T/01 outdoor TEC battery cabinet

(battery cabinet for short).

1.1 Overview

The battery cabinet can accommodate three battery strings of capacity up to 165Ah. The battery cabinet has built-in

thermoelectricity cooler (TEC) to provide mechanical protection and environmental protection for the battery.

1.2 Model Information

Figure 1-1 provides the model information of the battery cabinet.

200 TEC /

Power of thermal control unit: 200W

Thermal control mode: TEC

Emerson cabinet

01

Version: 01

Figure 1-1 Model information of battery cabinet

1.3 Structure

The battery cabinet consists of a cabinet, batteries, power distribution board and TEC, as shown in Figure 1-2.

Base

Cabinet

TEC Batteries

Power distribution

board

Figure 1-2 Battery cabinet structure

1.4 Features

� To prevent acid gas released by the battery from gathering inside the cabinet, the battery cabinet uses hydrogen

gas outlet.

� The battery cabinet provides dry contact outputs of high temperature alarm (45°C) and door sensor alarm.

� When the temperature inside the cabinet exceeds 30°C, the TEC starts operation. When the temperature inside

the cabinet drops below 20°C, the TEC stops.

� The power supply of the battery cabinet is provided by the power cabinet. Thus the TEC is one load of the

power cabinet. Users can connect the input power cable of the battery cabinet to battery low voltage

disconnection MCB or load low voltage disconnection MCB of the power cabinet according to actual situation.

2 Chapter 1 Product Description


� The battery cabinet can be connected to a mains- failure - signal dry contact to disconnect the power supply of

the TEC upon mains failure. The dry contact is switched off upon mains failure. Refer to 2.7.2 Connection

Procedures for the connection method.

1.5 Specifications

Table 1-1 lists the battery cabinet specifications.

Table 1-1 Battery cabinet specifications

Parameters Specifications

Operating temperature -10°C ~ 55°C

Transportation & storage temperature -40°C ~ 70°C

Operating relative humidity ≤ 93% (30°C ± 2°C, noncondensing)

Transportation & storage relative humidity ≤ 93% (40°C, noncondensing)

Atmosphere 70kPa ~ 106kPa

Environmental

Sunlight radiation 1120W/m2

Input voltage range 43.2Vdc ~ 57.6Vdc

Rated input voltage 48Vdc

Input current range 5A ~ 6.2A

Rated input current 5.6A

TEC

Cooling power 200W

Size 1400mm (H) × 650mm (W) × 720mm (D) (excluding bases)

Space of each layer of the battery chamber 360mm (H) × 597mm (W) × 576mm (D) Mechanical

Weight ≤ 150kg (excluding battery)

Max battery cell size (L × W × H) 570mm × 135mm × 330mm Battery

Battery quantity Max. 12 pcs

Noise 65dB Others

Protection IP55

Chapter 2 Installation 3


Chapter 2 Installation

This chapter provides details on the installation preparation, installation procedures, and commissioning of the battery

cabinet.

2.1 Unpacking Inspection

To ensure smooth installation, you must conduct strict unpacking inspection.

1. Unpack the battery cabinet and visually inspect its appearance to see if it is good condition, specifically,

� Check for distortion and moisture regaining

� Check for loose connection caused by transportation by gently shaking the battery cabinet

� Check for transportation damage

If the above checks proved unsatisfactory, notify the carrier immediately.

2. Check the accessories against the delivery list.

If there is any discrepancy, contact the Emerson local service center immediately.

2.2 Field Survey

Prior to installation, conduct a construction survey on the installation site. Specifically,

1. Check the wiring devices, including cable chute, wiring rack, wiring holes, ground cable and so on.

2. Confirm the installation position. As the battery cabinet should be installed on an even platform, check if the

platform has been processed and if the processing quality meets relevant requirements.

3. Install the battery cabinet in a cool environment, and do not expose the battery cabinet to direct sunlight.

4. The load capacity of the installation platform should be larger than 1600kg/m2.

5. Make sure that no hazardous objects or metal objects are present.

6. Check that the installation site meets the battery cabinet specifications provided in Table 1-1.

7. Maintain a clearance of at least 1.5m in the front, and at least 20mm on both sides, of the battery cabinet.

2.3 Installation Preparation

2.3.1 Installation Notes

1. During installation, wear gloves and keep the parts clean.

2. During installation, do not scratch the parts.

3. Remove metal objects from fingers and wrists.

4. Connect the ground cable properly.

2.3.2 Installation Tools

Use insulated tools. The installation tools include:

1. Hammer (1.5 pound)

2. Cross screwdriver

3. Adjustable spanner (10’’)

4. Double offset ring spanner (14# ~ 17#)

5. Percussion drill (Φ14 aiguille)

6. Horizontal ruler

4 Chapter 2 Installation


7. Vertical ruler

8. Tape measure (3m)

2.3.3 Cable Specifications

Selecting cables

The cable sectional areas should meet the requirements listed in Table 2-1 and not bigger than 35mm2 (2AWG).

Table 2-1 Cables specifications

Min. cable size Rated current (A)

Sectional area (mm2) AWG or kcmil (sectional area mm

2)

≤ 15 Not defined Not defined

> 16 ~ ≤ 25 5 14 (2)

> 25 ~ ≤ 32 2.5 12 (3)

>32 ~ ≤ 40 4.0 10 (5)

> 40 ~ ≤ 63 6.0 8 (8)

> 63 ~ ≤ 80 10 6 (13)

> 80 ~ ≤ 100 16 4 (21)

> 100 ~ ≤ 125 25 2 (33)

> 125 ~ ≤ 160 35 1 (42)

Selecting cable terminals

Users should select proper battery cable terminals, signal cable terminals and input cable terminals according to the

size of the relative connection terminals. The size of the battery output terminals, input terminals and signal terminals

is shown in Figure 2-1.

10mm M4

16.7mm M6

(1) Size of the signal and input terminals (2) Size of the battery output terminals

Figure 2-1 Terminal size (unit: mm)

2.4 Installing Battery Cabinet

1. Drill anchor holes

Drill four 50mm deep Φ14 anchor holes on the floor according to Figure 2-2.

Door

650.0550.0

554.0694.0

Figure 2-2 Anchor holes (unit in mm)



2. Install battery cabinet

Insert four expansion pipes into the anchor holes on the floor, put the battery cabinet in place aligning the anchor

holes on the bases of the battery cabinet with the four expansion pipes, install and tighten the anchor bolts, as shown

in Figure 2-3.

Cabinet

Anchor bolt

Figure 2-3 Installing battery cabinet

2.5 Opening And Closing Battery Cabinet Door

Procedures for opening and closing the battery cabinet door are as follows:

1. Insert the key into the keyhole, and turn the key clockwise until the door handle pops out.

2. Turn the handle counter-clockwise to the position shown in Figure 2-4, pull the handle, and the door opens.

90°

Figure 2-4 Turn the handle

3. Adjust the door stay bar to the position shown in Figure 2-5 to prevent the door from closing automatically.

门限位支撑杆Door stay bar

Figure 2-5 Door stay bar

4. Restore the door stay bar to its original position before closing the door; finally, turn the handle to its original

position and press it down until a click is heard.



2.6 Installing Batteries

Precaution

The battery cabinet can only use batteries of which negative terminal is at the left side and positive terminal is at the

right side in the front view, as shown in Figure 2-6.

Positive terminalNegative terminal

Figure 2-6 Battery terminals

Installation Procedure

The battery chamber consists of three layers. Each layer can accommodate a battery string comprising four battery

blocks. Assemble the three battery strings according to the battery manufacturer instructions. Install the batteries into

the battery chamber from bottom up, starting from the lowest layer. During installation, do not strike the plastic battery

enclosure or the battery terminals.

1. Open the three battery string air breakers, as shown in Figure 2-7.

Battery string 1 air breaker



Figure 2-7 Battery string air breakers

2. The battery cabinet provides battery connection cables in each layer of the battery chamber. From bottom to top,

the battery strings are numbered BATT 1 to BATT 3. Check visually that the label of the battery cable (for example

“BATT1 +”) is the same with the screenprints on battery output terminal to which the cable is connected.

3. Remove the fixing screws of the battery baffle plates and the power distribution board. See Figure 2-8.

电池挡板固定螺钉

电池挡板固定螺钉

配电板固定螺钉

Fixing screw of battery

baffle plate

Fixing screw of power

distribution board

Fixing screw of battery

baffle plate

Figure 2-8 Fixing screws of battery baffle plates and power distribution board



4. Push the batteries one by one from right to left into the battery chamber, with the battery terminals facing outward.

Maintain a clearance of 10mm between adjacent batteries, and between batteries and battery cabinet walls. Place

the battery strings as close as possible to the middle.

5. Remove the lids on the battery terminals, and connect the plate electrodes between adjacent batteries one by one.

6. Connect the battery connection cables provided in the battery chamber to the batteries: negative cables to

negative terminals of the leftmost batteries, and positive cables to positive terminals of the rightmost batteries. Paste

the acid and alkali integration box delivered with the battery onto the battery cabinet internal wall on the right side.

7. Measure the battery voltage. If it is correct, replace the battery terminal lids.

8. Fix the battery baffle plates onto the battery baffle plate fixing bars (see Figure 2-9), reinstall the power distribution

board, and tighten the fixing screws, so as to keep the batteries from falling.

Each battery baffle plate fixing bar provides several holes. Select the hole closest to the battery to fix the battery

baffle plate.

电池挡板固定条Battery baffle

plate fixing bar

Figure 2-9 Installing battery baffle plate

2.7 Connecting Cables

Note that the cables should be connected and bound up in a way that the battery cabinet door can be opened and

closed freely.

2.7.1 Cabling Holes

The battery cabinet provides nine waterproof cabling holes made of cables tubes, as shown in Figure 2-10. Of the

nine cabling holes, seven are large ones (diameter of the cable routed through: 10mm ~ 14mm) and two are small

ones (diameter of the cable routed through: 5mm ~ 10mm). It is recommended to route the battery cables through the

large cabling holes and route the TEC power cables and signal cables though the small cabling holes.

In cable connection, screw off the tube caps and remove the black rubber on the tube caps, routing the cables

through the cabling holes and reinstall the tube caps.

Cabling holes (large)Cabling holes

(small)Cabling holes

(large)

Figure 2-10 Cabling hole



2.7.2 Connection Procedures

1. Connecting ground cable

The battery cabinet provides four ground terminals (two M6 screws and two M8 screws) on the bottom plate, as

shown in Figure 2-11. Select one of the ground terminals, and connect the ground cable from it to the ground copper

bar in the equipment room.

Ground terminals

Figure 2-11 Location of ground terminals

2. Connecting power cables of TEC

Connect the positive power cable of the TEC between the lower TEC positive input terminal (screenprint INPUT+) on

the power distribution board and the +48V terminal of the power supply. Connect the negative power cable of the

TEC between the lower TEC negative input terminal (screenprint INPUT-) on the power distribution board and the

-48V terminal of the power supply. Figure 2-12 shows the TEC input terminals.

TEC negative input terminalTEC positive input terminal

TEC air breaker

Figure 2-12 TEC input terminals

3. Connecting battery output cables

The three battery strings are connected into the battery cabinet through the battery connection cables provided in the

battery chamber, and are connected to battery output cables through the battery output terminal block on the power

distribution board. The other end of the battery output cables should be connected to the power supply.

Confirm that the three battery string air breakers (see Figure 2-13) are open.

The power distribution board provides a battery output terminal block, as shown in Figure 2-13. The screenprints on

the battery output terminal block are shown in Figure 2-14.

Battery output terminal block




Figure 2-13 Terminals on power distribution board

BATT1+ BATT2+ BATT3+ BATT1- BATT2- BATT3-

Figure 2-14 Screenprints on battery output terminal block



As shown in Figure 2-14, the BATT1+ terminal is the positive output terminal of battery string 1, the BATT1- terminal

is the negative output terminal of battery string 1, and so on. Connect the positive output cables to the corresponding

battery positive output terminals, and connect the negative output cables to the corresponding battery negative output

terminals. Connect the other end of the output cables to the power supply.

4. Connecting door sensor signal cable and high temperature signal cable

The door sensor signal terminal and high temperature signal terminal are shown in Figure 2-15. The screenprints are

shown in Figure 2-16.

If users need to use the door alarm function and the high temperature alarm function, they need to connect signal

cables to the lower door sensor signal terminal (screenprint “DA+” and “DA-”) and to the lower high temperature

signal terminal (screenprint “TA+” and “TA-”). Connect the signal cables to the dry contact input port of the host to

realize remote- alarm function, as illustrated in Figure 2-16.

High temperature signal terminalDoor sensor signal terminal

Figure 2-15 Door sensor and high temperature signal terminals

BACKUP-BACKUP+ INPUT-INPUT+ TEC+

input port of the host

TA-TA+DA-DA+TEC-

Connected to the dry contact

Figure 2-16 Screenprints on the terminal block and cable connection

5. Connecting the signal cable of the mains- failure - signal dry contact

If the power supply system that supplies power to the battery cabinet has mains- failure - signal dry contact (the dry

contact is switched off upon mains failure), user can connect the signal cable to the lower terminals of the backup

terminal + (screenprint “BACKUP+”) and the backup terminal - (screenprint “BACKUP-”). Remove the cable (W11)

that is connected between the upper terminals of the backup terminal + and the backup terminal -. In this case, the

TEC shall not work upon mains failure. The backup terminal + and the backup terminal – are shown in Figure 2-17.

The screenprints are shown in Figure 2-16.

Backup terminal -Backup terminal +

Figure 2-17 Backup terminals

� Note

The capacity of the mains- failure - signal dry contact should be not smaller than 0.5A.

If users do not need this function, they do not need to do the cable connection.



2.8 Power-On

2.8.1 Check Before Power-On

Checking battery cabinet

1. Check that the cabinet is installed horizontally, firmly and stably.

2. Check that all screws are tightened. Especially pay attention to the electrical connections. Check that all flat

washers and spring washers are properly installed.

3. Check that no irrelevant objects are present in the battery cabinet.

4. Check that the cabinet is not damaged and has no paint peeling. If it has paint peeling, repaint it immediately to

protect it from erosion.

5. Clean the cabinet.

6. Check that the door can be freely opened and closed, that the door lock is normal, and that the door stay bar is

fixed.

Checking electrical connections

1. Measure the resistance between the positive and negative terminals on the DC circuits, confirm there is no

shortcircuit.

2. Check that all battery connection cables and battery output cables are connected to the right terminals and their

polarities are correct; check that all cable connections are correct and reliable.

3. Check that the ground cable is connected properly.

4. Check that all breakers are open.

5. Check that the wiring is neat and tidy, and that the cable binding meets the process specifications.

2.8.2 Power-On

If the preceding checks proved satisfactory, close the three battery string air breakers and the TEC air breaker, and

the battery cabinet begins to work. At this point, check that:

1. the battery output voltage is normal using a multimeter.

2. the TEC is normal using the following methods:

1) If a heating device is available, use it to heat up the air around the temperature sensor (under the cover on the

right side of the power distribution board) to 30°C ± 3°C, the TEC should start and work.

2) If no heating device is available, remove the cover on the right side of the power distribution board, short the two

pins of the temperature relay with a cable, the TEC should start and work.

Chapter 3 Maintenance 11


Chapter 3 Maintenance

This chapter expounds the regular maintenance of the battery cabinet and the TEC replacement procedures.

3.1 Regular Maintenance

Inspect the battery cabinet on a regular basis, and resolve the problems if any. Every time when inspecting the

battery cabinet,

1. Check that the ventilation holes are not obstructed in the front, on both sides and at the bottom of the shield of the

TEC. Dust the ventilation holes using a brush.

Ventilation holes of TEC

Figure 3-1 Ventilation holes of TEC

2. Check that the battery appearance is in good condition, measure the battery voltage and make sure it is normal,

check that the battery terminal screws are tightened to the torques specified in the battery manufacturer instructions.

3. Check that the TEC starts, operates and stops normally.

4. Check that the battery cabinet has no permeable membrane peeling on the hydrogen exhaust holes on the top.

See Figure 3-2.

排氢气孔Hydrogen exhaust holes

Figure 3-2 Hydrogen exhaust holes

12 Chapter 3 Maintenance


If the permeable membrane is damaged, replace it immediately.

� Note

The permeable membrane should cover the hydrogen exhaust holes completely.

3.2 Replacing TEC

If the internal fan and the external fan of the TEC do not start at 30°C ± 3°C, the TEC might have failed. The handling

method is described below:

1. Measure the voltage and the current between the TEC positive input terminal and the TEC negative input terminal.

Check if the voltage value and the current value are within the normal range (voltage range: 43.2Vdc ~ 57.6Vdc;

current range: 5A ~ 6.2A). If the voltage and the current are normal, carry out the next check.

2. Check if the high temperature signal terminal is closed. If the signal terminal is closed while the TEC does not

operate, the TEC fails and needs replacement.

The procedures of replacing TEC are as follows:

1. Open the cabinet door, and unplug the power cable of the TEC, as shown in Figure 3-3.

Figure 3-3 Unplugging the power cable

2. Remove the eight fixing screws of the TEC shield inside the cabinet door using a screwdriver, as shown in Figure

3-4.

Fixing screws of the shield

Figure 3-4 Removing the fixing screws of the TEC shield

Chapter 3 Maintenance 13


3. Remove the TEC shield from outside the door, as shown in Figure 3-5.

Figure 3-5 Removing the TEC shield

4. Remove the eight fixing screws of the TEC outside the cabinet door, as shown in Figure 3-6.

Fixing screws of the TEC

Figure 3-6 Removing the fixing screws of the TEC

When removing the fixing screw at the top and at the bottom, put the screwdriver through the holes to reach the

screw.

Figure 3-7 Removing the fixing screw at the top

14 Chapter 3 Maintenance


5. Remove the TEC, as shown in Figure 3-8.

Figure 3-8 Removing the TEC

6. Replace the TEC. Reverse the preceding procedures to install the TEC.

Appendix 1 Connection Diagram 15


Appendix 1 Connection Diagram

INPUT-

INPUT+

TEC+

TA-

TA+

DA-

DA+

TEC-

QF1

KM1

DA

KT2High Temperature Alarm

Door Alarm

KT1

DC Input

-48V

0V

Figure 1 Connection diagram (1)

BATT1-

BATT1

BATT2

BATT3

QF2

QF3

QF4

BATT2-

BATT3-

BATT1+

BATT2+

BATT3+

Figure 2 Connection diagram (2)

EC200T-01_V1 3 User Manual

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