Mitsubishi Electric BC16 Instruction manual
Mitsubishi Electric Power Products, Inc.
BC16 Battery Cabinet
Installation, Operation, & Maintenance Manual
Built for Mitsubishi Electric Power Products, Inc. by
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This manual contains proprietary and confidential information of C&C Power, Inc., and has been
prepared for the use of Mitsubishi Electric Power Products, Inc., for use in conjunction with
equipment provided by C&C Power, Inc. unauthorized reproduction, in whole or in part, without
written permission of C&C Power, Inc., is prohibited.
Copyright © 2011 C&C Power, Inc.
All rights reserved.
C&C Power, Inc.
949 N. Larch Ave.
Elmhurst, IL 60126
www.ccpower.com
Technical Support:
Phone: (630) 617-9022
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TABLE OF CONTENTS
1. Important Information About This Manual................................................................................. 6
1.1 Manual Symbols.................................................................................................................... 6
2. Introduction: ................................................................................................................................ 7
3. Safety Precautions ....................................................................................................................... 8
4. Inspection Upon Receipt of Goods............................................................................................ 10
4.1 General ................................................................................................................................ 10
4.2 Visible Damage ................................................................................................................... 10
4.3 Concealed Damage.............................................................................................................. 10
4.4 Return of Damaged Goods .................................................................................................. 10
5. System Overview ...................................................................................................................... 11
6. System Specifications................................................................................................................ 12
6.1 Batteries............................................................................................................................... 12
6.2 System Grounding............................................................................................................... 12
6.3 DC Output ........................................................................................................................... 12
6.4 General Specifications......................................................................................................... 13
7. Installation ................................................................................................................................. 14
7.1 Preparation........................................................................................................................... 14
7.1.1 Equipment Inspection................................................................................................... 14
7.1.2 Necessary Equipment and Tools .................................................................................. 14
7.1.3 Installation Safety Precautions ..................................................................................... 14
7.2 Installation Steps ................................................................................................................. 15
7.2.1 Equipment Location ..................................................................................................... 15
7.2.2 Equipment Mounting.................................................................................................... 15
7.2.3 Equipment Grounding .................................................................................................. 15
7.2.4 DC Connections ........................................................................................................... 16
7.2.5 System Operation ......................................................................................................... 16
8. System Maintenance.................................................................................................................. 17
8.1 Battery Replacement ........................................................................................................... 17
9. Reference Materials................................................................................................................... 19
10. Warranty.................................................................................................................................. 22
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1. IMPORTANT INFORMATION ABOUT THIS MANUAL
SAVE THESE INSTRUCTIONS! This manual contains important information that is needed
during the installation and maintenance of the system.
1.1 MANUAL SYMBOLS
Warning:
Indicates information provided to protect the user against personal injury and/or
safety hazards.
Caution:
Indicates information provided to protect the user against safety hazards and/or
possible equipment damage.
Important:
Indicates information provided as an installation or operating instruction or tip as
well as general important installation and system information.
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2. INTRODUCTION:
The C&C Power family would like to thank you for choosing a C&C Power Inc. product for your
equipment needs. We know there are a lot of choices in the industry and we appreciate the
opportunity to supply each of our customers with the highest quality power products
manufactured in the United States today. All of C&C Power’s solutions are factory tested to some
of the highest standards is the industry. Every battery cabinet system is Hi Pot tested to UL
standards at our facility prior to shipment.
Sales support for future equipment needs or upgrades is provided by our regional sales staff and
qualified representatives. All technical questions and service issues should be directed to our
main office by dialing the number listed below. This is a 24-hour, 7-day service number. After
normal working hours, please leave a detailed message with your phone number on the voice mail
system and a qualified service representative will contact you as quickly as possible.
C&C Power, Inc.
949 N. Larch Ave.
Elmhurst, IL 60126
www.ccpower.com
Technical Support:
Phone: (630) 617-9022
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3. SAFETY PRECAUTIONS
Before installing or maintaining this system, it is extremely important to read this
manual and be sure that all system drawings and schematics are reviewed and
clearly understood. If there are any questions concerning this manual or any of the
installation or maintenance procedures and/or requirements please contact a C&C
Power representative before proceeding.
When installing this power system, follow all applicable federal, state and local
regulations as well as industry guidelines to insure proper system installation.
Only qualified electricians or DC power technicians should attempt to install or
service this equipment.
System installation and maintenance should always be performed with heavily
insulated tools. It is also recommended to wear rubber gloves, boots, and use
insulating mats to stand on when working on this equipment.
Always wear eye protection when installing or maintaining batteries and/or power
equipment.
Battery cabinet systems are extremely heavy. Use a minimum of two people when
unloading and setting equipment in place.
Do not smoke or present open flames near any battery system.
For the safety of others, never leave an open cabinet or panel unattended.
To reduce the risk of fire, replace fuses with the same type and rating of fuses
supplied with the system.
DC Power and Batteries can be very dangerous and have extremely high short
circuit current. Electrical shock, severe burns, fire or death can result from a system
short.
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To avoid personal injury including electrical shock, severe burns and possible
death, all jewelry including bracelets, rings and watches must be removed prior to
installing or servicing this system.
Do not open or mutilate batteries. Opened or severely damaged batteries can
release toxic electrolyte which is harmful to the skin and eyes.
Never lay loose cables, metal parts or tools on top of batteries.
Under certain conditions, batteries can vent potentially explosive gas (hydrogen).
Never enclose batteries or battery cabinets in a sealed room.
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4. INSPECTION UPON RECEIPT OF GOODS
4.1 GENERAL
Special precautions and care have been taken to ensure the system arrives safe and undamaged.
However, upon receipt, you should inspect the entire shipment, including the crate and any boxes
for evidence of damage that may have occurred during transit.
4.2 VISIBLE DAMAGE
It is the responsibility of the person receiving the shipment to inventory and fully inspect all
materials against the bill of lading or weigh bill IMMEDIATELY while the carrier representative
is still present. Insure that all items are accounted for, including number of skids and quantity of
boxes. Also note any visible external damage that may have occurred during transit. Make all
applicable notations on the delivery receipt before signing and file a damage report with the
carrier.
4.3 CONCEALED DAMAGE
Within 3 to 30 days of receipt (depending on courier), unpack the system and check for any
concealed damage. Check the materials received against the detailed packing list to verify the
quantity and the condition as complete and satisfactory.
Note any damage to the internal packaging, then request an inspection by the carrier and file a
concealed damage claim. If there is a material shortage, contact a C&C Power representative at
the main office to file a claim.
Please contact your shipping company for all shipping damage.
C&C Power is not responsible for any shipping damage.
4.4 RETURN OF DAMAGED GOODS
Should equipment be damaged and require return to C&C Power for repair, a representative will
provide instructions along with an RMA number to expedite the return.
A RMA number must be obtained before returning equipment to C&C Power, Inc.
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5. SYSTEM OVERVIEW
During normal operating conditions the UPS supplies power to the load as well as the necessary
power required to keep the batteries at the proper float voltage. When AC power fails, the
batteries will discharge in order to provide the necessary backup power to the load. It is the
responsibility of the customer to make sure the batteries are not discharged below manufactures
recommendations. After any battery discharge has occurred, the batteries should be recharged as
soon as possible. Batteries will be damaged if not properly recharged right away. See the UPS
manual for more information on charging the batteries.
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6. SYSTEM SPECIFICATIONS
6.1 BATTERIES
Please refer to system drawings for model specific information.
Type: Valve Regulated Lead Acid (VRLA), sealed, non-spillable
Voltage: 12 VDC Nominal
Battery Strings: The cabinet can accommodate two (2) 288 VDC battery strings. Each string is
composed of four (4) trays of five (5) 12 VDC batteries each and a single tray of four (4) 12VDC
batteries for a resulting 288VDC battery string.
6.2 SYSTEM GROUNDING
Cabinet Safety Ground: Each cabinet is supplied with a #14-1/0 mechanical ground lug, located
on the lower right corner of the breaker pan, which accepts bare wire from #6 AWG to 300 MCM
cable.
Torque: 325 lb-in
Wire Size and Type: Ground wire should be sized per NEC and/or all applicable national and
local codes.
Battery Cabinet Breaker or Fuse Size Minimum Copper Ground Wire Size
Up to 200 amps 6 AWG
201-300 amps 4 AWG
301-400 amps 3 AWG
401-500 amps 2 AWG
501-600 amps 1 AWG
6.3 DC OUTPUT
Please refer to system drawings for model specific information.
Voltage: 288 VDC Nominal
Circuit Breaker: UL Listed 600 VDC rated. See system drawings for details.
Battery Tray Fuse Type: Ferraz (Gould) A50QS, A50P or equivalent
Wire Size and Type: Per NEC and/or all applicable national and local codes.
Only cabinets with Flame Retardant Batteries are suitable for computer room
use.
All system ground wires should be derived from the main building ground source.
Wire should be sized for a maximum voltage drop of 0.5 volt.
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6.4 GENERAL SPECIFICATIONS
Cabinet Size: 19.70”W x 26.75”D x 55.12”H
Empty Cabinet Weight: 375 lbs (approximately)
Operating Temperature: 20°C to 25°F (68°F to 77°F) recommended for optimum battery
performance.
Ventilation: Through ventilation slots in front, rear and top panels. A minimum of four inches is
required in front and behind the cabinet. This refers to obstruction of ventilation only. Clearance
around the equipment should be as suggested by NEC and/or all applicable national and local
codes.
Under certain conditions, batteries can vent potentially explosive gas (hydrogen).
Never enclose batteries or battery cabinets in a sealed room.
Batteries should be stored no longer than three months at 25°C (77°F) or lower
before recharging. Exceeding the recommended ambient storage temperature may
cause damage to the batteries.
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7. INSTALLATION
7.1 PREPARATION
7.1.1 EQUIPMENT INSPECTION
Remove the equipment from the packaging material and inspect for any shipping damage that
may have been overlooked upon receipt of goods. Verify that the system includes all necessary
hardware for installation.
7.1.2 NECESSARY EQUIPMENT AND TOOLS
oHeavily insulated assortment of hand tools
oDigital voltmeter
7.1.3 INSTALLATION SAFETY PRECAUTIONS
Before proceeding with system installation, be sure to review and understand all of
the SAFETY PRECAUTIONS in this manual!
DC VOLTAGE WARNING!
Hazardous DC voltages are present in the system. This hazard will always be
present in a battery system including when it is offline. Accidental short
circuit of the positive and negative terminal will cause tremendous currents to
flow resulting in electrical shock, severe burns, fire and possible death! Use
extreme caution when installing and maintaining the system!
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7.2 INSTALLATION STEPS
7.2.1 EQUIPMENT LOCATION
Prior to installation, verify floor loading requirements and all applicable codes pertaining to the
related equipment. Environmental conditions should also be reviewed. Battery systems require
an area with proper ventilation and cooling. An ambient temperature between 20°C to 25°C
(68°F to 77°F) is recommended for optimum battery life and performance. The cabinet has vent
holes located at the front and rear of the system. Never install the cabinet into a sealed
enclosure. Clearance around the equipment should be as suggested by NEC and/or all applicable
national and local codes.
7.2.2 EQUIPMENT MOUNTING
1. The BC16 battery cabinet is equipped with four casters, two swivel types in front and two
rigid types in the back. Move the cabinet into the desired location and lock the front casters.
2. Lower the four leveling feet located at each corner to stabilize the cabinet and prevent it
from moving.
7.2.3 EQUIPMENT GROUNDING
Terminate a cabinet ground wire from the main building ground source to the supplied #14-1/0
mechanical lug located on the breaker pan. See section 6.2 for sizing recommendations. Wire
should be sized per NEC and/or all applicable national and local codes.
Before installing or maintaining this system, it is extremely important to read this
manual and be sure that all system drawings and schematics are reviewed and
clearly understood. If there are any questions concerning this manual or any of the
installation or maintenance procedures and/or requirements please contact a C&C
Power representative before proceeding.
Under certain conditions, batteries can vent potentially explosive gas (hydrogen).
Never enclose batteries or battery cabinets in a sealed room.
Battery cabinet systems are extremely heavy. Use a minimum of two people when
unloading and setting equipment in place.
All system ground wires should be derived from the main building ground source.
For multi cabinet systems, each cabinet needs to have a designated cabinet ground
wire derived from the main building ground source.
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7.2.4 DC CONNECTIONS
1. Open the front door on the cabinet and check for any noticeable problems or damage that
may have occurred during shipment.
2. Review the attached installation drawing and schematic.
3. Check and re-torque internal battery connections, as shipping may have caused these
connections to come loose. Proper torque values are noted on the drawing and also on the
battery case.
4. Connect main cables from the UPS or charger source to the battery cabinet output. The
main output connection point is directly to the circuit breaker. Review the supplied cabinet
drawing for information on the battery cabinet output. All cables should be sized per NEC
and any other local codes pertaining to this equipment. Refer to the UPS or charger manual
for wiring external batteries. Note! Make sure any charging source is disconnected before
making these connections.
b 7.2.5 SYSTEM OPERATION
Please refer to the UPS system manual for system start up and operation information.
Review the attached system drawings and schematics for model specific
information on DC output connections.
Wire should be sized for a maximum voltage drop of 0.5 volt.
Battery cabinets that are not supplied with an incorporated DC output disconnect
device must have an appropriate disconnect device provided external to the cabinet.
Verify that the output breaker is in the off/open position before making any DC
connections to additional cabinets or to the UPS. Also verify that the UPS charger
is not running.
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8. SYSTEM MAINTENANCE
8.1 BATTERY REPLACEMENT
1. Locate the shelf with a suspected malfunctioning battery.
2. Disconnect the UPS from the battery string by opening the circuit breaker in the battery
cabinet.
3. Remove the shelf from the cabinet.
4. Test the individual batteries residing in the shelf to isolate the malfunctioning battery.
5. Remove the retaining bar that holds down the batteries in the shelf.
6. Disconnect the malfunctioning battery from the string.
7. Prepare the new battery for installation. Verify that the battery is the same type and amp-
hour rating as the batteries that are in the system.
8. Using a digital voltmeter, measure the battery voltage to verify that it is 12.4 VDC or
above.
9. Use a brass wire brush or abrasive pad to polish the battery terminals.
10. Apply no-ox type terminal grease to the battery terminals to avoid corrosion.
11. Remove the bad battery.
Before proceeding with system maintenance, be sure to review and understand all
of the SAFETY PRECAUTIONS in this manual!
Verify that the output breaker is in the off/open position before servicing the
system.
Only qualified electricians or DC power technicians should attempt to diagnose a
battery malfunction, remove a malfunctioning battery and replace a battery.
When batteries are replaced they must be properly installed paying special attention
to terminal polarity orientation! If wired incorrectly it will cause a short in the
system and can result in electrical shock, severe burns, fire and possible death! Be
sure to review the system schematics before terminating any battery cables.
Do not dispose of batteries in a fire. The batteries may explode. Contact your local
hazardous waste or recycling center for battery disposal requirements.
Do not discard batteries in the trash. This product contains sealed lead acid
batteries. Contact your local hazardous waste or recycling center for battery
disposal requirements.
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12. Put the new battery into place. Make sure new battery is installed properly regarding
polarity orientation. Use the supplied wiring drawing found inside the battery cabinet
door to verify the cabinet wiring.
13. Reconnect the cable and connecting bar to the installed battery and make sure the
connections are properly torqued.
14. Check the battery string voltage of the shelf; 60VDC for shelves 1 through 4 and 48VDC
for shelf 5.
15. Re-install the retaining bar that holds down the batteries in the shelf.
16. Re-install the shelf in the cabinet making sure it is fitted properly into the cabinet
backplane.
17. Check the battery string voltage at the input side of the circuit breaker.
18. Reconnect the UPS to the battery string by closing the circuit breaker in the battery
cabinet.
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9. REFERENCE MATERIALS
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