Eaton ExoCab34 Manual

USER’S AND INSTALLATION GUIDE
ExoCab34
Outdoor Enclosure

ExoCab34 outdoor cabinet User and Installation Guide
©Eaton Corporation 2018. All rights reserved. Revision 0.1 Page 2 of 35
Copyright © 2018 Eaton Corporation. All rights reserved.
This manual contains important instructions that you should follow during installation and maintenance of the
enclosure . Please read all ins t ruc t ions before operating the equipment and save this manual for future r ef erence.
The contents of this manual are the copyright of the publisher and may not be reproduced
(even extracts) without
the written approval of Eaton Corporation. Every care has been taken to ensure the accuracy of the information
contained in this manual, but no liability can be accepted for any errors or omission. The ri ght t o make design
modifications is reserved.
Unauthorized copying and lending are prohibi t ed.
Eaton Power Quality Company
106 Wrights Road
Christchurch
New Zealand
Approvals and version history
REVISION DATE DESCRIPTION OF CHANGE APPROVED BY

ExoCab34 outdoor cabinet User and Installation Guide
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Contents
Contents.................................................................................................................................................................................3 
1. How to read this manual ...................................................................................................................................................4 
1.1  Safety-related signs ....................................................................................................................................................4 
1.2  Safety symbols...........................................................................................................................................................4 
1.2.1  Hazard symbols ....................................................................................................................................................4 
1.2.2  Prohibited action symbols.....................................................................................................................................5 
1.3  Conventions used in this document ..........................................................................................................................5 
2. Safety Instructions............................................................................................................................................................6 
2.1  Audience ....................................................................................................................................................................8 
3. Introduction to Eaton ExoCab34 ......................................................................................................................................9 
3.1  Overview.....................................................................................................................................................................9 
3.2  Cooling options ...........................................................................................................................................................9 
3.3  Thermal Overview.....................................................................................................................................................10 
3.4  Battery cooling ..........................................................................................................................................................11 
3.5  Exploded views.........................................................................................................................................................11 
3.6  Equipment mounting options.....................................................................................................................................13 
3.7  Cabinet Equipment Mounting Dimensions.................................................................................................................14 
3.8  Equipment Mounting Restrictions..............................................................................................................................15 
4. Preparation ......................................................................................................................................................................16 
4.1  Unpack and inspect equipment .................................................................................................................................16 
4.2  Cautions ...................................................................................................................................................................16 
5. Install cabinet ..................................................................................................................................................................16 
5.1  Overview of tasks......................................................................................................................................................16 
5.2  Concrete foundation..................................................................................................................................................16 
5.3  Place cabinet ............................................................................................................................................................19 
5.4  Fit air conditioner roof (if required) ............................................................................................................................20 
5.5  Fit heat exchanger door (if required) .........................................................................................................................20 
5.6  Install cables .............................................................................................................................................................21 
5.6.1  Other cabling (if required) ...................................................................................................................................21 
5.7  Install batteries..........................................................................................................................................................21 
6. Mount equipment.............................................................................................................................................................22 
7. Power up cabinet.............................................................................................................................................................22 
7.1  Pre-start up checklist ................................................................................................................................................22 
7.2  Apply AC Power........................................................................................................................................................22 
8. Maintenance.....................................................................................................................................................................22 
8.1  Overview...................................................................................................................................................................22 
8.2  Maintenance .............................................................................................................................................................22 
8.3  Troubleshooting ........................................................................................................................................................23 
8.4  Replacing the heat exchanger fan controller .............................................................................................................23 
8.5  Replacing a cooling fan (Heat exchanger cooled cabinet).........................................................................................24 
9. Appendix A – 93PS20 / 93PS40 UPS options.................................................................................................................28 
9.1  Layout.......................................................................................................................................................................28 
10. Appendix B – 9PX UPS option......................................................................................................................................29 
11. Appendix C Wiring diagrams.......................................................................................................................................30 
11.1  ExoCab34 with heat exchanger door or air conditioner .............................................................................................30 
12. Appendix D ExoCab 34 outdoor enclosure datasheet...............................................................................................31 
13. Appendix E Concrete plinth drawing ..........................................................................................................................34

ExoCab34 outdoor cabinet User and Installation Guide
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1. How to read this manual
1.1 Safety-related signs
The following table explains the safety-related signs used in t his docu ment .
DANGER
DANGER indicates a hazard with a high level of risk w hich, if not
avoided, will result in serious injury or death.
WARNING WARNING indicates a
hazard with a medium level of risk which,
if not avoided, could result in serious injury or death, or damage
to your m a chine.
CAUTION
CAUTION indicates a hazard with a low level of risk w hich, if not
avoided, could result in minor or moderate injury or damage to
your m a chine.
NOTE: Notes are used to indicate important information and useful tips.
1.2 Safety symbols
1.2.1 Hazard symbols
These symbols indicate a hazardous situation or action. Symbols are used to warn of situations which may cause
environmental damage and
personal injury.
General warning symbol Explosion and fire hazard
Electrical hazard Corrosive hazard
Battery hazard

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1.2.2 Prohibited action symbols
These symbols are used to indicate an action that should not be taken.
General symbol for prohibited
action
No smoking
Limited or restricted access
Mandatory action symbols
These symbols are used to indicate an action that must be taken
General symbol
for mandatory
action
Disconnect
from power
source
Read the manual
or instructions
1.3 Conventions used in this document
This document uses the following type conv ent ions :
 Bold type highlights important concepts in discussions, key terms in procedures and menu options, or
represents a command or opt ion that you type or enter at a pro mpt .
 Italic type highlights notes and new terms when they are def ined.
 Screen type represents information that appears on the screen or LCD.

ExoCab34 outdoor cabinet User and Installation Guide
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2. Safety Instructions
DANGER
Important safety instructions
Save these instructions!
This document contains important instructions that must be
f oll ow ed during the installation, operation and
maintenance of the cabinet, UPS and batteries. Read all of the instructions before operating the equi pme nt . Keep
this manual for future r ef erenc e.
The
UPS operates with mains, battery or bypass power. It contains components that carry high currents and
voltage.
DANGER
The UPS carries lethal voltages. All repairs and service must be performed by authorized personnel
only. There are no user-serviceable parts inside the UPS.
DANGER
Operations inside the UPS must be performed by a service engineer from the manufacturer or from an
agent authorized by the manufacturer.
WARNING
The UPS is powered by its own energy source (batteries). The output terminals may be energized
even when the UPS is disconnected from an AC source.
Before you start any installation or service work, make sure that all AC
and DC power sources are disconnected. Power may come from multiple sources. Also ensure system
grounding / PE continuity.
In a parallel system, the output terminals may be energized even when the UPS is turned off.
Batteries can present a risk of electrical shock or burn from high short- circuit current.
Electric energy hazard. Do not attempt to alter any battery wiring or connectors. Attempting to alter
wiring can cause injury.
Do not open or mutilate batteries. Released electrolyte may be toxic and is harmful to the skin and
eyes.
IMPORTANT: The battery may consist of multiple parallel strings. Make sure that you disconnect all
strings before installation.

ExoCab34 outdoor cabinet User and Installation Guide
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CAUTION
Only qualified service personnel knowledgeable of batteries and the required precautions are allowed
to perform installation or service work on batteries. Keep unauthorized personnel away from the
batteries. Before you install or replace batteries, consider all the warnings, cautions, and notes
concerning appropriate handling. Do not disconnect the batteries when the UPS is in the Battery
mode.
Make sure that your replacement batteries are of the same number and type as the battery that was
originally installed in the UPS. See more accurate instructions on the UPS.
Before you connect or disconnect battery terminals, disconnect the charging source by opening the
corresponding battery circuit breaker.
Check if the battery is inadvertently grounded. If it is, remove the source of the ground. Contacting any
part of a grounded battery can cause a risk of electric shock. If you disconnect the grounding
connection before you work on the batteries, the risk of an electric shock is less likely.
Dispose of batteries according to your local disposal requirements.
Do not dispose of batteries in a fire. When exposed to flame, batteries may explode.
To ensure proper cooling airflow and to protect personnel from dangerous voltages inside the unit,
keep the UPS door closed and the front panels installed.
Do not install or operate the UPS system close to gas or electric heat sources.
Keep the operating environment within the parameters stated in this document.
Keep the surroundings of the UPS uncluttered, clean, and free from excess moisture.
Observe all DANGER, CAUTION, and WARNING notices affixed to the inside and outside of the
equipment.

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2.1 Audience
The intended audience of this document is as f oll ow s :
• People who plan and perform the installation of the ExoCab34.
• People who use the ExoCab34.
This document provides guidelines for how to install, commission and operate the ExoCab34 and a UPS installed
in the ExoCab34.
The reader is expected to know the fundamentals of electricity,
w iring, electrical components and electrical
schematic symbols. This doc um ent is written for a global reader.

ExoCab34 outdoor cabinet User and Installation Guide
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3. Introduction to Eaton ExoCab34
3.1 Overview
The Eaton ExoCab34 outdoor cabinet belongs to a range of versatile, cost effective outdoor cabinets used for
a wide range of electrical applications.
The ExoCab34 can be configured for DC power, UPS, battery, or any other outdoor installation requiring robust
protection for electronics equipment.
Front and rear doors are provided for ease of access.
Cooling options include unvented, fresh air cooled, heat exchanger and air conditioned.
The ExoCab34 includes a galvanised steel or aluminium mounting plinth and lifting eyes.
The cabinet is constructed from marine-grade aluminium and stainless steel for long life in harsh environments.
When fitted with an Eaton UPS or DC power equipment, full remote monitoring by web / SNMP can be provided.
3.2 Cooling options
The ExoCab34 has various cooling options as shown in Figure 1 ExoCab34 cooling options.
The choice of option depends on:
Power dissipation
Operating temperature range
Equipment robustness
.
Refer to the ExoCab34 data sheet for detailed thermal ratings. (refer ‘12. Appendix D ExoCab 34 outdoor
enclosure datasheet’)
Standard Vented Heat Exchanged Air Conditioned
Figure 1 ExoCab34 cooling options

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3.3 Thermal Overview
This overview shows key points for the various cooling options.
Please refer to product data for temperature and power ratings for each option.
Standard
The Standard option provides a fully sealed cabinet with a
maximum level of equipment protection.
Internal air is circulated by equipment fans.
Heat is dissipated through the cabinet wall.
Advantages include;
Low cost
Zero maintenance
High degree of protection from environmental
contaminants
Recommended for low power equipment, including
equipment needing a high level of protection.
Internal temperature is always above outside
temperature. Ensure equipment is rated for the full
range of internal temperatures.
Vented
The Vented option allows a higher heat dissipation than the
Standard option by drawing outside air through the enclosure.
Characteristics include;
Low cost
Air filter provides some protection against
environmental contaminations.
The filter requires periodic cleaning and replacement.
Recommended for clean environments or with
hardened equipment.
Internal temperature is close to ambient.
Heat exchanger
The Heat Exchanger option provides a cost-effective
enclosure providing full environmental protection and an
increased power rating compared to the Standard option.
Characteristics include;
High degree of protection from environmental
contaminants
Internal temperature is always above outside
temperature. Ensure equipment is rated for the full
range of internal temperatures.
Low energy cost and minimal maintenance.
Air conditioner
The Air conditioner option provides a fully sealed cabinet
with a maximum level of equipment protection.
The air conditioner provides a stable internal temperature and
high power dissipation rating.
Characteristics include;
High degree of protection from environmental
contaminants
Recommended for any equipment, including
equipment needing a high level of protection and
equipment with a restricted temperature rating.
Internal temperature is maintained at a stable level.

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3.4 Battery cooling
Where batteries are installed, they may be separated from the main equipment compartment.
The batteries may be cooled by a door mounted TEC cooler.
3.5 Exploded views
The diagrams below show the key parts of each cabinet option.
Standard
Vented
Door or optional rear cover

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Figure 2 Exploded views
Heat exchanger
Air conditioner
Door or o
p
tional rear cover
Door or optional rear cover

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3.6 Equipment mounting options
Full cabinet equipment mounting Large equipment (such as a tower format UPS) may be
bolted directly to the cabinet floor. Alternatively equipment
can be mounted to the 19 inch equipment rails.
Full height 19 inch equipment mounting
34U is available for standard 19 inch equipment mounting.
Split cabinet equipment mounting Equipment requiring different environments can be installed
in separate compartments.
Top + Bottom 19 inch equipment mounting
Optional compartment divider fitted
The compartment divider provides two 19 inch wide
compartments, 18U at the top and 15U below.
Equipment may be mounted directly on the bottom and mid
shelf.
Figure 3 Equipment mounting options
18U
15U
19”
34U
19”

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3.7 Cabinet Equipment Mounting Dimensions
Top View
(cross section of cabinet)
Full Cabinet - Front View Split Cabinet - Front View
Cable entry in bottom
of cabinet and
compartment divider

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3.8 Equipment Mounting Restrictions
Red areas in the diagrams below show spaces where equipment cannot be mounted.
These vary according to the cabinet options.
Vented
Side (Section view)
Keep 20mm mm front and rear clear for
ducting.
Heat exchanger
Side (Section view)
Keep 2U at the top clear.
Keep 125 mm at the front clear.
Allows free air flow.
Keep clear requirements at the top of the cabinet.
If the divider fitted there is a vent to direct air to
the upper cabinet.
Air conditioner
Side (Section view)
Keep 2U at the top clear.
Allows free air flow.

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4. Preparation
4.1 Unpack and inspect equipment
Unpack the equipment and inspect it carefully for possible damage that may have occurred while in transit.
Report any damage immediately, using a completed Equipment Incident Report on page??
Keep the original packaging to use if any item needs to be returned for replacement or repair.
4.2 Cautions
Before commencing installation, review the Warnings and Cautions on page6.
5. Install cabinet
5.1 Overview of tasks
Task Description Reference
1 Concrete foundation See details on page 16.
2 Bolt down Cabinet See details on page 19.
3 Fit air conditioner roof (if required). See details on page 20.
4 Fit heat exchanger door (if required) See details on page 20.
3 Bring in cables. See details on page 20
6 Install equipment See details on page 22 .
Power up cabinet See details on page 22.
5.2 Concrete foundation
Step 1 - Establish a safe working area around the site
Use approved road traffic management protocols, barriers and signage to safeguard the
people working at the cabinet, road users and pedestrians.
Step 2 - Check clearances
The site selected for the cabinet must have adequate clear space around the cabinet for
access and/or ventilation.
Refer to
Figure 4 for clearances needed.
Check there are no cables or pipes below the site that may be damaged by excavation work.

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Top vie w
Door opening s pace requi red
Top vie w
Plinth sect ion bolt do wnho les
Figure 4 Installation clearances
Standard and Fresh Air Cooled
Air Conditioned Heat Exchanger
Figure 5 Overall Cabinet Dimensions
R680
4 - ø 12 Holes
to suit M10 Bolt

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Step 3 - Excavate and prepare formwork
1 Excavate to the size and depth required for the cabinet base (see overall dimensions in
next Step).
2 Position the duct entry pipes at the correct positions (see dimensions in next Step).
3 Compact a layer of suitable base-course material to the correct depth below the finished
surface level.
 Set the depth so that the top of the base will be above finished ground level by more
than any expected flood water.
Step 4 – Install duct pipes
Specific design details for the base are not given here because of varying site conditions and
seismic restraint requirements. In general, the base must:
 be designed to bear the cabinet's mass (when fully equipped) and resist the overturning
forces due to seismic activity.
 have the overall dimensions shown in the following diagram.
 These are the dimensions of the cabinet on a typical base.
be fitted with the cable entry holes in the positions shown.
be fitted with four bolt-down sockets to suit the supplied M10 grade 12.7 galvanized bolts,
in the positions shown.
Concrete Base - Top View
With sectioned cabinet plinth
Cabinet Plinth
Concrete Base
Hold down position
(4 places)
ø 200 Cable entry ducts

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Step 5 – Pour base
Refer to section 13 ‘
Appendix E Concrete plinth drawing ’? for Concrete Base
dimensions.
Step 6 - Install earth rod(s)

1 Check there are no cables or pipes below the cabinet base that may be
damaged by the earth rod(s).
2 If multiple earth rods used they must be the same material to prevent
electrolytic corrosion.
Procedure complete
5.3 Place cabinet
Step 1 - Lift and position cabinet
1 Check that the base is clean and the bolt-down sockets are free of debris.
2 Lift the cabinet (minus batteries) by the four lifting eyes on the top of the cabinet into
position.
 Follow all applicable health and safety regulations.
Lifting points
Step 3 - Bolt down cabinet
1 Remove the access panels in the cabinet plinth.
2 If on an existing concrete floor mark and drill holes.
3 Use the four M10 grade 12.7 galvanized bolts and washers supplied.
4 Re-fasten the plinth access panels to the cabinet.
Plinth access covers
Procedure complete

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5.4 Fit air conditioner roof (if required)
1. Remove roof
2. Remove lifting eyelets
3. Drill out rivets
4. Fit the air conditioner
unit
5. Fasten with M8
fasteners supplied
6. Fit the air conditioner
cover.
7. Fasten through ‘AC
mounting plate’ front
and rear with the 4 x
M6 fasteners supplied.
5.5 Fit heat exchanger door (if required)
1. Open Door 2. Remove circlips from
hinge pins.
3. Remove hinge pins.
IMPORTANT to
support door
4. Remove door.
5. Unscrew hinges from
removed door, hinges to
be used in next step.
6. Fasten door hinge plate to
door using fasteners from
the old door (3 places)
7. Lift into position.
8. Secure with the hinge
pin.
9. Re-fit circlip to the hinge
pin.
A
C Cover
A
C Unit
Eyelets
A
C mounting
plate
(2) Remove circlip
(3) Remove pin
1. Install pin
2. Install circlip