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2004
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1. FUNCTIONAL DESCRIPTION

Installation manual for DC power plant.

This document is specially designed to be used on site. It describes the MP power plants
installation method.

Reference documents: SPP (Site Particular Preparation) and drawings package.


2. RECEIVING THE EQUIPMENT

Upon receipt of the equipment, inspect it for eventual shipping damage.

Before disposing of the package, check its contents against the delivery slip.

The rectifier modules, batteries, accessories kits are shipped in separate packages.

If damage or partial loss is found, file a claim with the carrier without delay and take
any necessary steps to protect your rights.

For storage before installation, place the equipment in a dry ventilated place and keep
away from rain, water projection and chemicals.


3. INSTALLATION AND CONNECTION KITS

The installation kits available are:

- Terminals on roof kit,
- Floor adjustment kit,
- Wall mounting set,
- Installation kit for 80 A single-phase mains,
- Installation kit for 40 A single-phase mains or 30 A three-phase mains.



INSTALLATION MANUAL
MP75 AND MP150








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- Connection kit for battery rack associated with type 80 battery,
- Connection kit for battery rack associated with type 270 battery
(high power > 8 KW),
- Connection kit for battery rack associated with type 270 battery
(medium power < 8 KW).

For further informations, refer to corresponding data sheets.


Breaker specification for mains protection:

MP75 MP150
Size and tripping curve :
Differential circuit breaker
(single-phase)
50 A / C 100 A / C
Rating of the differential tripping 300 mA 300 mA
Differential circuit breaker
(three-phases)
25 A / C 40 A / C
Rating of the differential tripping 300 mA 300 mA
Mains cable size :
Mini (mm
2
) 6 10
Maxi (mm
2
) 10 10


The necessary electrical accessories to make the installation are:

- AC mains cables,
- DC cables,
- Battery cables,
- Alarm cable,
- Coupling strap for three or single phase mains connection,
- Link for grounding plate,
- Braid for ground connection.





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4. INSTALLATION PROCEDURE FOR MP POWER PLANT

4.1 NECESSARY TOOLS

Multimeter.
Standard tools for installation.
Isolated screw driver.
Isolated nut driver.
Torque wrench.

Before any installation, make sure that :

- The mechanical floors resistance is compatible with the cabinet weight.
- The mains sizing is sufficient to supply power plant and other equipment (such as heater,
air conditioner, lights)
- Site protection against lightning effect is properly dimensioned.


4.2 INSTALLATION AND FASTENING

WARNING : CONFORMITY WITH THE SPP SPECIFICATIONS

The Site Particular Preparation (SPP) document describes all the installation and site
requirements to follow in order to have a correct working of the equipment. The installation
and the connection of the equipment should be made in compliance with the SPP related to
the equipment.


Battery rack installation

The battery rack is delivered as a set of mechanical sub-assemblies to be mounted on site. For
further informations, refer to the mounting procedure provided.

The floor adjustment kit can be used to stabilize the MP systems mounted on battery rack. It
contains necessary accessories to compensate the floor lack of flatness (up to 15 mm). If
necessary, refer to battery rack installation manual to fix the adjustable legs on the fixing
frame.





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MP power plant installation

According to the option chosen, the MP power plant can be fixed on battery rack or on wall
brackets.

- For mounting on battery rack : put the MP on the top of the battery rack as shown on
the photo below.


Fasten the MP on the roof of the battery rack using the 2 screws with washers delivered with
the battery rack.


Fixing screw with
washer under the
roof of the battery
rack





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- For wall mounting : put the MP on the brackets and fix it using the 2 screws and
washers delivered with the wall mounting kit. Two mounting positions are possible
depending on the site configuration (with or without back cable way).

Front face Front face
Cable way


External assembly of the ground bar

Remove the ventilation grid located on the MP power plant roof.

Unscrew the two ground bar supports fixed at the rear of the MP power plant.

Unscrew the ground bar of these supports.

Fix the two supports outside the power plant.

Make the external assembly of the ground bar on these supports.

Put back the ventilation grid on the MP power plant roof.



External groung bar





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4.3 CONNECTIONS (REFER TO THE DRAWINGS PACKAGE)

Preliminary control and recommendations
ANY OPERATIONS SHOULD BE CARRIED OUT BY QUALIFIED PERSONNEL,
AWARE OF SPECIFIC HAZARDS AND PRECAUTIONS TO BE TAKEN.

The connections should be made with the system de-energized and the disconnection
devices in the open position :

- External mains protection open,
- Battery fuse-disconnection switches open,
- Load protective device open.

Check that the associated batteries are installed and that the battery cells are correctly
connected.

MP installed on a battery rack : all cables come inside the cabinet through the top or
the rear panel.

MP installed on wall mounting accessories : all cables come inside the cabinet through
the top or through the bottom (for battery cables only).


Interconnection between 0V and ground

When delivered, connection between 0V and ground bar of the MP power plant is
made as a standard feature. This connection may be removed on site, depending on
site configuration.

Connect the site ground to cabinets ground bar.


Connection to the mains

Connection to the mains is made on terminal block X1.

Make sure to connect the ground terminal.

Make sure that the terminal block configuration is in compliance with the mains voltage
(refer to figures on the following page).





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Terminal block for MP power plant (single-phase 230 V)

















This terminal block configuration is used for :

- a single-phase mains 230 V between line and neutral,
- two-phase 208 V line to line (in that case, a bipolar protection circuit breaker should be
connected upstream instead of a Phase +Neutral type).


Terminal block for MP power plant (three-phase 400 V + neutral)














THREE-PHASE 400 V + N
50Hz / 60Hz
X1
10 mm
2
max.
53 52 51 50
L1 L2 L3 N
X1
10 mm
2
max.
230 V SINGLE-PHASE
50Hz / 60Hz
53 52 51 50
L1 L2 L3 N
strap





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Battery temperature probe connection

At the delivery, the battery temperature probe is located inside the MP power plant.



Unroll the connection cable and clamp the probe at the rear of central battery plate
(make the connection cable going through a battery rack column).



Battery temperature probe





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Connection to the battery

WARNING : a battery, even a single block, contains a high energy potential inside. A short
circuit between the two output terminals represents a danger due to arcing.

it is recommended to use isolated tools,
it is recommended to connect first the blocks to the battery outputs of the MP power
plant, and after the blocks together, in order to avoid arcing during connection on the
MP power plant.
it is recommended to remove the battery fuses before the connection to the MP power
plant.
it is recommended to put the protective covers provided on the output terminals of each
battery.


According to the delivered equipment :






In the case of several battery strings to be connected to the MP power plant, the battery strings
should be dispatched on the two bus bars provided, in order to avoid to have all the battery
strings connected on one single battery fuse.
Battery (-): to bus bars (-) Battery (+): to bus bar (+)





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To facilitate the installation, it is recommended to begin by the bottom battery plate and to
make the connection cables going through the battery rack colums.



Battery installation for 1 string 48 V / 80 Ah:

Installation layout on 1 battery plate:

Battery cable
+
-
+ + +
- - -
-
+
Battery rack front panel





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Battery installation for 1 string 48 V / 270 Ah:

Installation layout on 4 battery plates:






+
- -
-
-
-
-
+
+ +
+
+
+
- -
-
-
-
-
+
+ +
+
+
+
- -
-
-
-
-
+
+ +
+
+
+
- -
-
-
-
-
+
+ +
+
+
+
- -
-
-
+
+
+
-
-
-
+
+
+
+
-
-
-
+
+
+
-
-
-
+
+
+
-
2V battery blocks: 4V battery blocks:





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Connection to the load on circuit-breakers

The connection to the load is made on circuit-breakers (refer to the figure below).





Circuit-breakers Q11 to Q18 Bar + 0V

Bar
+0V
DC
+U -U
D5
Q15
+U -U
D6
Q16
+U -U
D7
Q17
+U -U
D8
Q18
+U -U
D1
Q11
+U -U
D2
Q12
+U -U
D3
Q13
+U -U
D4
Q14





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5. ALARMS

Connection is made on connector P18 (type SUB-D 25) located on the interface board A1.
Relay contact breaking characteristics : 100 V maxi - 0.5 A.


Alarms on 5 pairs cable
P18 connector

NO 1 Light blue

NC 2 White

C 3 Light blue



NO 4 Dark blue

NC 5 Light blue

C 6 Yellow



NO 7 Light blue

NC 8 Braun

C 9 Light blue



NO 10 Black

NC 11 Light blue

C 12 Red




Contacts definition (NO : Normally Open; NC : Normally Closed) is set for
an energized system (all power supplies on) and without faults.
Mains off
Urgent Alarm
Non Urgent Alarm
Fan failure
}
Pair N1
}
Pair N2
}
Pair N3
Pair N4
}
Pair N5
}
Pair N6
}





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APPENDIX 1: INSTALLATION CHECK LIST


P18 Connector type SUB-D





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APPENDIX 1
INSTALLATION CHECK LIST

1. IDENTIFICATION

Customer
name :
Customer
application :
Site
name :
Site
address :

Power station
type :
Ref. SAFT's Code Ref. ALCATEL's Code
Serial
number :
Ex work
date :
Battery
type :
Last charge (date) :
Ref. SAFT's Code Ref. ALCATEL's Code
Serial
number :
Ex work
date :
CUBICLE EQUIPMENT :
- SM1600 n....................... n....................... ACM 1D n.......................
n....................... n.......................
n....................... n.......................
n....................... n.......................
n....................... n.......................
- Spare n.......................
Information on the site :
Global site power VA
Upstream MCB rating tripping curve A / curve
Differential current protection level mA
MTP infeed MCB rating A
Differential current protection level mA
Current capacity of lightning protection KA
Mains : One phase +
neutral
or two-phase
Three-phase





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2. REFERENCE DOCUMENTS

Document Ed Date Document Ed Date



3. SIGNATURE AND COMMENTS OF CONCERNED PEOPLE

Name

Signature Name Signature
Name

Signature Name Signature
Start date

End date

Time spent on site

COMMENTS



4. REPORT

Record the results as the work proceeds :
Tick a corresponding box : Yes | No | NA (Not Applicable).
Enter the information or measurements in the boxes provided.
Enter the comments on the space above.





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5. RESULTS

Steps Title Yes No NA

1 FLOOR FIXATION
01 Floor fixation

2 BATTERY INSTALLATION
01 Battery polarities connections

02 Inter-cell polarities connections

03 Battery connections in parallel

04 Battery connection tightning

3 ELECTRICAL CONNECTION
01 Opening of protective devices

02 Mains type 230 V single-phase

03 Mains type 400 V three-phase + neutral

4 CONNECTION
01 Check Phases and neutral connection (Three-phase mains)

02 Check earth connection

03 In case of single-phase mains, check coupling of terminals 51;
52; 53


04 Connection of site ground to cabinets ground bar

05 Interconnections between 0V and ground made on the DC
system.


5 MODULE INSTALLATION
01 Plug the SM1600 rectifier into its drawer by pulling it

6 ALARM RELAY CONTROL
01 SUB-D 25 connector (P18) on A1 interface board

7 END OF INSTALLATION
01 Site clean and services finished


END OF DOCUMENT