Battery Installation Manual V12.docx
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Battery Installation Manual V12.docx
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BatteryInstallationManualV12
BatteryInstallationManual
Version:
V1.2
Date:
25February2009
RevisionUpdateHistory
Version
Description
Revisedby
ApprovedbyTeamLeader
Date
V1.0
Draftversion
LawYatKwan
BiPengSong
29/12/2008
V1.1
Review:
Step1
LawYatKwan
BiPengSong
24/2/2009
V1.2
Review:
AddContents,BatteryCommissioningandRecord
LawYatKwan
BiPengSong
25/2/2009
Contents
1.Background
1.1SafetyInstructions………………………………………...…………..P.4
2.Installation
2.1Connectionofbatterygroup.………………………………………...P.5
2.2Batterygrouping…………….………………………………………...P.6
2.3BatteryPowerUp……………………………………………………...P.6
2.4BatteryTemperatureSensorConnection...………………………...P.9
2.5LocationforInstallingBatteryTemperatureSensor………………P.11
3.BatteryCommissioning
3.1CheckList………………....………………………………………..P.12
3.2BatteryRecord……………………………………………………...P.13
1.Background
1.1SafetyInstructions
Readthesafetyinstructionsbeforeanyoperationontheequipment.Thesafetyprecautionsmentionedinthismanualareasupplementtothelocalsafetycodes.
Onlytrainedprofessionalsareallowedtoinstall,operateandmaintaintheequipment.ZTEbearsnoliabilitytotheconsequencesincurredbyviolationofthegeneralsafetyoperationrequirements,orviolationofthesafetystandardsfordesigning,manufacturingandusingtheequipment.
Doobservethelocalsafetycodesduringtheequipmentinstallation;theinstallationpersonnelmustbequalifiedforhighvoltageandACpoweroperations.
Neverwearanyconductiveobject,suchaswatch,handchain,braceletandringduringtheoperationoftheequipment.
Preventanymoisturefromenteringtheequipmentduringoperations.
Highvoltagedanger:
Theequipmentispoweredwithhighvoltage.Directcontactorindirectcontactwithoutproperprecautionsisdangerous.Payattentiontocautionsignsontheequipment.
Usespecificallypurposetools:
Besuretousespecial-purposetoolsinsteadofcommontoolsandpersonaltoolswhenworkingwithhighvoltagesandACpowersupplies.
Electrostatic:
Staticelectricitygeneratedbyhumanbodymaydamagecomponents.Beforetouchingaplug-inboard,circuitboardoranICchip,alwayswearanantistaticwriststrapwiththeotherendwellgrounded.
Neverinstallordisconnectpowercableswithpoweron:
Switchoffthepowersupplybeforeinstallingordisconnectingapowercable.Beforeconnectingacable,makesurethatthecableanditslabelmeettherelatedrequirements
DCshortcircuitdanger:
TheZXDU58/68systemprovidesDCpowerofconstantvoltage.DCshortcircuitcausesfataldangeranddamagetotheequipment.
2.Installation
Asetofthebatteryshouldbeincluded:
-2groupsof48V-Battery(forBattery1andBattery2)
-Connectioncables(betweenthepowersupplyoutputandbatteryterminals)
-Connectionbars(betweenthebatteryunits)
-2BatteryTemperaturesensors(forBattery1andBattery2)
-BatteryRack(exceptW121)
2.1ConnectionofBatterygroup
EnsurethebatterycablesareconnectedcorrectlyasFig2.1,allthescrewsofthebatteryterminalsandtheconnectionbarsbetweenterminalsaretightenedsecurely,andalsothepolarityiscorrectlyasFig2.2
Fig2.1PositivecablesareconnectedtoBATT(+)
AndNegativecablesareconnectedtoBATT(-)
Fig2.2Allconnectionbarsaretightenedsecurely
2.2Batterygrouping
Battery1isdefinedfortheupperdeck,andtheBattery2isdefinedforthelowerdeckasFig2.3:
Fig2.3
Battery1:
connectedtoBATT1(+)(-)ConnectionTerminal
Battery2:
connectedtoBATT2(+)(-)ConnectionTerminal
Remark:
Batterycablesare2pairsfromtheconnectorasFig2.1,theconnectionshouldfollowthemarkingontheConnectionTerminalofDCdistributionunit,e.g.BATT1(-)isapairwithBATT1(+)theyareconnectedtoBattery1.DonotpairupthecableasBATT2(-)withBATT1(+).
2.3BatteryPowerUp
BeforepoweruptheBatterygroups,someparametersareconfiguredonCSU(MonitoringUnit),
2.3.1ChecktheLabelonthebatteryunit.AsshownFig2.4
Fig2.4Checkthevoltageandcapacitybythecodeonthelabel,e.g.HZY12-100FAwhichis12Vbatterywith100Ahcapacity
2.3.2SettingparameteronCSU:
Battery1Capacity:
Setitaccordingtotheactualbatterycapacitytoensurenormalbatterymanagement
Battery2Capacity:
Setitaccordingtotheactualbatterycapacitytoensurenormalbatterymanagement
EnsureCur.Limitedis0.15C
2.3.3Toavoidthelargestartingcurrentandsparkontheswitch,AdjusttheFloatVoltagetothebatteryactualvoltage.Forexample,themeasuredvalueofthebatteryis51.4V(asFig2.5),pleaseadjusttheFloatVoltageto51.4Vaswell.
Fig2.5Measurethevoltageofthebatterygroup
Select[Ctrl]onthemainmenu,andpress[Enter]
Password=0000,andpress[Enter]
Onthe[SetupPara]screen,press[Enter].
ThedefaultvalueofFloatVol.is53.5V,foradjustthevalue,press[Enter].
Adjustthevaluebypressing‘▲’and‘▼’,changeto51.4V(asthebatteryactualvoltage),andthenpress[Enter]toconfirm
2.3.4Switchontheairswitches,andpowerupthebatteryonebyone:
Fig.2.6H151andH900BatteryAirSwitch
Fig.2.7W121BatteryAirSwitch
2.3.5Afterthebatteriesarepoweredup,adjustthefloatvoltagebacktodefaultvalue53.5V.
2.4BatteryTemperatureSensorConnection
TheBatteryTemperaturesensorisalittledevicewithastickeractuallythesameasenvironmenttemperaturesensor.
ForH900,H151andW121,2devicesareplugtotheX4,X5onSIBforBattery1andBattery2.AsshowninFig2.8
Fig2.8BatteryTempSensorconnectedtoSCBofH900/H151/W121
ForT601,2devicesareplugtotheX8,X9onSCBforBattery1andBattery2.AsshowninFig2.9
Fig2.9BatteryTempSensorconnectedtoSCBofT601
2.5LocationforInstallingBatteryTemperatureSensor
Batterytemperaturesensorshouldbeinstallednearthenegativebatteryterminalinthemiddleofabatterystringthatisconnectedinseries.Asthecableconnectionofthebatteryvariesfromsitetosite,theexactlocationofthesensorrelativetotherackmaydifferent.HoweverthelocationofthesensorrelativetothebatteryshouldbethesameamongallimplementationasshowninFig2.10andFig2.11.
Fig2.10:
BatteryTemperatureSensoronIndoorBatteries
Fig2.11:
BatteryTemperatureSensoronOutdoorBatteries
3.BatteryCommissioning
3.1CheckList:
Item
Description
Result
3.1
Everysign,markandlabelshouldbeclear,correctandcomplete.
Y□N□
3.2
Checkbatteryshellandplateshouldbenoelectrolyteflowingout,expansionanddamage
Y□N□
3.3
Ensurethebatteryterminalscanbeprotectedfromthesurroundingmetalwork/componentusingshroudsorsimilar
Y□N□
3.4
Batteryisfreefromdustandfilth
Y□N□
3.5
Allthescrewsaretightenedsecurely,andthenecessaryflatwashersandspringwashersarecompleteandinstalledcorrectly.
Y□N□
3.6
Ensurethebatterycompartmentallowsgasesfromthebatteriestoventintotheatmosphere.
Y□N□
3.7
Thebatterypolarityiscorrectandnotshorted
Y□N□
3.8
Ensurethebatterytemperaturesensorsaresetupandreportingcorrectly.
Y□N□
3.9
Thecablecross-sectionalarea,insulationandmaterialareaccordingtothestandard
Y□N□
3.10
Measuretheactualvoltageofthebatterynotlargerthan0.5Vdifferenceasthevoltagedisplayedonmonitoringunit
Y□N□
3.11
SwitchAC-PowerOfffor5minutes,andcheckthebatteryisoperatednormally.SwitchAC-PowerOnafterfinishtest.
Y□N□
3.2BatteryRecord:
SiteName
InstallationDate
CheckDate
BatchInformationMarkonBattery
ManufacturingDate
BatteryCapacity(Ah)
BatteryVoltage(V)(V)
RoomTemperature(oC)
No
CellID/SerialNo.
Voltage(V)
PhysicalCondition
BatteryTemp(oC)
BatteryType
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
CheckedBy:
Signature:
Remark:
Thebatchinformationmarkonthebatteryisacodetodescribethemanufacturingdate.
Forexample:
HHD25,H=HAZEH=2008(Year)D=APRIL(Month)25=25(Day)
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