NorthStar SiteStar Series Technical specifications

SiteTel Sweden AB Haukadalsgatan 8A, SE-164 40 Kista, Sweden
www.northbattery.com
SITESTAR CABINET
MAINTENANCE INSTRUCTIONS
Product No: D000100/3
Revision: R2A

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Copyright
© NorthStar SiteTel 2011. All rights reserved. No part of this document
may be reproduced in any form without written permission of the copyright
owner.
Disclaimer
The contents of this document are subject to revision without notice due to
continued progress in methodology, design and manufacturing.
NorthStar SiteTel shall have no liability for any error or damage of any kind
resulting from the use of this document.
Contents
1INTRODUCTION............................................................................................................4
1.1 Target Group ................................................................................................................4
1.2 Documents ...................................................................................................................4
1.3 Illustrations ...................................................................................................................4
1.4 Prerequisites.................................................................................................................4
1.5 Abbreviations................................................................................................................4
2HEALTH AND SAFETY INFORMATION..............................................................................5
2.1 Batteries .......................................................................................................................5
2.2 Electrical Equipment.....................................................................................................7
2.3 Refrigerant....................................................................................................................8
2.4 RoHS/WEEE.................................................................................................................9
2.5 In Case of Fire..............................................................................................................9
2.6 Damages....................................................................................................................10
3TOOLS AND EQUIPMENT.............................................................................................10
4GENERAL TORQUES DURING MAINTENANCE................................................................11
5OPEN AND CLOSE THE CABINET DOOR .......................................................................12
6PREVENTIVE MAINTENANCE .......................................................................................13
6.1 Re-tightening the EQ Zone 4 Cabinet to the Foundation.............................................13
6.2 Re-tightening the Earth Ground Connection................................................................13
6.3 Cleaning of the Climate Unit .......................................................................................14

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6.4 Checking Batteries......................................................................................................18
6.5 Re-tightening the Battery Cable Connectors...............................................................18
7TROUBLESHOOTING...................................................................................................19
7.1 Alarm..........................................................................................................................19
7.2 Mechanics ..................................................................................................................20
7.3 DC Output...................................................................................................................20
7.4 Cooling –Heating .......................................................................................................21
7.5 Leakage......................................................................................................................21
8RECONFIGURING THE EXTERNAL ALARM .....................................................................22
9REPLACING BATTERIES..............................................................................................24
9.1 Remove Batteries .......................................................................................................24
9.2 Installing Batteries.......................................................................................................28
10 SPARE PARTS .......................................................................................................36

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1 INTRODUCTION
This document describes maintenance routines to follow when operating
the SiteStar Cabinet, an outdoor battery backup system.
1.1 TARGET GROUP
The target group for this document is the personnel involved in the
maintenance of the site.
1.2 DOCUMENTS
The following documents are available to provide detailed information on
the SiteStar Cabinet and its handling:
D000100/1, SiteStar Cabinet Description
D000100/2, SiteStar Cabinet Installation
D000100/4, SiteStar Spare Parts
1.3 ILLUSTRATIONS
Illustrations in this document can show alternative designs.
1.4 PREREQUISITES
All performance statement in this document relies on the following:
Only approved hardware are used
Proper hardware handling
Maintenance instructions as well as documentation for external
equipment are followed
1.5 ABBREVIATIONS
Abbreviations used in this document.
AC
Alternating Current
CB
Circuit Breaker
CCU
Climate Control Unit
CLU
Climate Unit
DC
Direct Current

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DCCU
Direct Current Connection Unit
EN
European Norm
ESD
Electro Static Discharge
EQ
Earthquake
GWP
Global Warming Potential
LED
Light Emitting Diode
PE
Protective Earth
PSU
Power Supply Unit
RoHS
Restriction of Hazardous Substances
SPD
Surge Protection Device
WEEE
Waste Electrical and Electronic Equipment
2 HEALTH AND SAFETY INFORMATION
2.1 BATTERIES
Warning!
High energy levels are present in this unit. Improper handling of the unit
can lead to short circuiting that can result in serious injury. Exercise care
when working with this unit.
Warning!
To avoid battery thermal runaway, the batteries must be connected to an
external PSU with thermal compensated charging. Furthermore, the
external PSU must shut off the battery system if the temperature
reaches 50°C inside the cabinet.

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Warning!
It is important that every battery is connected with the ventilation tube,
and that the first battery in the chain is plugged. The tube must be routed
out of the cabinet.
There is a risk that explosive gases are accumulated in the cabinet.
Caution!
Improper handling of batteries can result in the batteries short-circuiting,
which can result in serious injury due to high energy levels. Exercise the
necessary care when working with batteries.
Caution!
Batteries can leak electrolyte if improperly handled. Electrolyte in contact
with skin or eyes can cause injury. In the event of electrolyte injuries,
rinse the affected area with water and seek medical attention
immediately. Use protective equipment when replacing batteries.
Caution!
Excessive heat can cause battery casing to soften and warp, potentially
allowing acid to escape. In contact with the skin, acid can cause injury,
and if breathed in, can affect the airways. Use protective equipment
when replacing batteries.

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Caution!
Heavy batteries can cause injuries when lifting incorrectly. Risk of
personal injury.
Caution!
Handling of the batteries in an incorrect way may cause pinching. Risk of
personal injury.
Caution!
Heavy batteries can cause damages to the property when installed
incorrectly.
Warning!
If the SiteStar cabinet is configured without the DCCU it is of vital
importance that the Battery cables are provided with adequate
protection at the site to ensure compliance to national wiring regulations.
Risk of personal injury and property damage.
2.2 ELECTRICAL EQUIPMENT
Installation personnel should exercise care when working on or around
electrical equipment. In addition to this safety information, the specific
safety instructions for all products involved in the installation procedure
should be adhered to.
When work is being done in a power cabinet, the power supply system
must be de-energized. The mains supply and, if applicable, all batteries
must be disconnected.

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Installation personnel must have competence for electrical installation
according to local regulations.
Warning!
High energy levels are present in this unit. Improper handling of the unit
can lead to short circuiting that can result in serious injury. Exercise care
when working with this unit.
2.3 REFRIGERANT
The refrigerant consists of R134a (1,1,1,2 –Tetrafluoroethane), which has
a GWP of 1300. The required service intervals must be followed and
proper care to avoid leakage at service and end of life must be taken.
Hazards
Inhalation of high concentrations may irritate the respiratory tract
and cause drowsiness and dizziness. At very high levels there is a
risk of breathing difficulties.
Skin contact or splashing in the eyes of the liquefied gas may cause
frostbite.
All handling must take place so that inhalation and skin and eye contact is
avoided. Avoid the steam coming into contact with the welding arcs. Avoid
the steam coming into contact with hot surfaces (decomposition). If there
is a suspicion of leakage from the cooling system, ventilate and leave the
place. Call for a competent cooling technician.
In case of fire, the refrigerant, R134a, develops toxic and corrosive gases.
The cabinet must be standing upright for at least 1 hour before starting.
Caution!
The cabinet must be standing upright for at least 1 hour before starting.

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Caution!
Inhalation of high concentrations may irritate the respiratory tract and
cause drowsiness and dizziness. At very high levels there is a risk of
breathing difficulties.
Skin contact or splashing in the eyes of the liquefied gas may cause
frostbite.
2.4 ROHS/WEEE
For information, see document “DOC-081 –End of Life Treatment Plan”
This document is available on request.
2.5 IN CASE OF FIRE
Take care of any injured persons –Call for help –Try to extinguish the fire.
Only use approved fire extinguisher for extinguishing electrical equipment.
After a fire the cabinet insulation might has been damaged. In this case
the cabinet strength will be considerably reduced and can cause the
cabinet to collapse when opening the door.
Warning!
In case of fire, toxic and corrosive gases will be formed.
Caution!
Excessive heat can cause battery casing to soften and warp, potentially
allowing acid to escape. In contact with the skin, acid can cause injury,
and if breathed in, can affect the airways. Use protective equipment
when replacing batteries.

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2.6 DAMAGES
If the cabinet gets a dented area in size of a hand, with a depth of 10 mm,
the cabinet strength is reduced and has to be replaced.
If the door has been warped so much so that it can’t close securely, it has
to be replaced.
3 TOOLS AND EQUIPMENT
The following tools are required for the cabinet installation:
8 mm wrench
13 mm wrench
18 mm wrench
Allen wrench 5 mm
Torque set 1 –80 Nm
Spirit level
Screwdriver 0.4x2.5xL
Screwdriver PZ #2
Torx T20 screwdriver (only when changing from left hanged door to
right hanged door)
Torx T25 screwdriver
Torx T30 screwdriver
Torx T45 screwdriver
Insulated tools for battery and busbar connections
Insulation tape

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4 GENERAL TORQUES DURING MAINTENANCE
Dimension
Torque
Note
M12
80 Nm
M8
15 Nm
M8
8 Nm
For battery poles
M6
9 Nm
Generally
St 4.8
4 Nm
Self drilling and self tapping screws.
End torque, start torque is higher.
St 4.2
1 Nm
St 3.5
1 Nm
Self drilling and self tapping screws.
End torque, start torque is higher.

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5 OPEN AND CLOSE THE CABINET DOOR
Warning!
When opening the door before the cabinet is secured to the foundation,
the empty cabinet can tip. Arrange some support for the door.
Risk of personal injury.
Do as follows to unlock and open the cabinet door:
1. Raise the cabinet to a standing position
2. Unlock the swing handle
3. Lift and turn the swing handle
4. Open the door
Figure 1 Unlocking and Opening Swing Handle
Do as follows to close and lock the cabinet door:
1. Release the door latch
2. Close the door
3. Turn and push the swing handle to locked position. The swing
handle will lock automatically

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6 PREVENTIVE MAINTENANCE
Preventive maintenance shall be performed in a 24 month interval in
normal conditions.
Units located in areas with harsh climatic conditions or aggressive
environments may require more frequent servicing. Certain environmental
parameters, such as high temperature together with high humidity or long
time-of-wetness, airborne pollutants and chlorides, are known to create a
higher risk of corrosion.
This section describes:
Re-tightening the EQ Zone 4 cabinet to the foundation
Re-tightening the earth ground connection
Cleaning of the climate unit
Checking batteries
Re-tightening the battery cable connectors
6.1 RE-TIGHTENING THE EQ ZONE 4CABINET TO THE
FOUNDATION
This section is only valid for EQ Zone 4 Cabinets.
Do the following to re-tighten the cabinet to the foundation:
1. Disconnect all power to prevent short circuits
2. Re-tighten the M12 bolts to a torque of 80 Nm
6.2 RE-TIGHTENING THE EARTH GROUND CONNECTION
Re-tighten the fastener connecting the earth grounding cable to a torque of
15 Nm.

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Figure 2 Earth Ground Connection at Cabinet without EQ Zone 4
Reinforcement
Figure 3 Earth Ground Studs in EQ Zone 4 Cabinet
6.3 CLEANING OF THE CLIMATE UNIT
If the condenser is fully clogged with dirt at the first 24 months service, the
service intervals must be narrowed down, to remain a long term reliable
system.
Do the following to clean the climate unit:
1. Remove the swing handle by removing the Torx screw as in the
figure below. Use a T30 screwdriver with a minimum blade length of
75 mm.

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Figure 4 Remove the Swing Handle
2. Dismantle the door cover as in the figure below. Start with the
screws (A) at the sides.

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Figure 5 Dismantle the Door Cover
3. Inspect the climate unit external heat sink for trapped debris and
other matter inside the fin channels.
Note: Do not use a brush with metal bristles as it may damage the heat
sink coating.
4. If the heat sink looks clogged or heavily soiled, cleaning may need
to take place.

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Figure 6 Heat Sink
5. Brush off any loose debris from the louvers at the door cover.
Note: Strong detergents must be avoided as they can be aggressive to
aluminum and potentially cause unwanted corrosion in wiring.

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6.4 CHECKING BATTERIES
See the document SES-544-01 “NorthStar Battery Telecom Application
Manual”for procedure. This document is available on request.
6.5 RE-TIGHTENING THE BATTERY CABLE CONNECTORS
The battery cable connectors needs to be re-tightened after every battery
replacement, and when installing new batteries. Refer to the battery
supplier for recommended torque.

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7 TROUBLESHOOTING
This section describes troubleshooting faults in the SiteStar Cabinet.
7.1 ALARM
Problem
What to do
Internal temperature
outside regulation window,
too high
1. Check if the compressor works
2. Check if the fan works
3. Check if the CCU works correctly
Internal temperature
outside regulation window,
too low
Install optional heater.
If heater is installed, check heater and relay
if equipped.
Compressor fails
Replace door
Heater fails (if equipped)
Replace heater
Fan fails
Replace fan
Controller internal error
Replace controller
External temperature
outside system
specification
See section 7.4
Door switch open
Close door
Power failure
Check mains fuse (external)

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7.2 MECHANICS
Problem
What to do
The door does not close
correctly
Check if there is anything stuck between
the door and the cabinet
Check if the door has been damaged. If
necessary replace the door.
Check if the cabinet has been damaged. If
necessary replace the cabinet.
7.3 DC OUTPUT
Problem
What to do
No voltage
Check battery connection
If equipped, check DCCU fuse
For further guidance check PSU and
battery manuals
Voltage too high or too low
Check if the battery configuration is right
Check battery connection
Check batteries