Zumtobel ONLITE central CPS K User manual

ONLITE central CPS
Installation instruction

Legal notes
Trademarks
ONLITE®is a registered trademark of Zumtobel Lighting GmbH, Dornbirn.
Copyright
Copyright © 2008 Zumtobel Lighting GmbH
All rights reserved.
Manufacturer
Zumtobel Lighting GmbH
Schweizerstraße 30
A-6850 Dornbirn/Austria
Tel. [phone]
Fax [phone]
[email protected]
www.zumtobel.com
Document number
CPS_MA_25.06.08 en

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Contents
Contents 1
1 Introduction and safety regulations 3
1.1 General information 3
1.2 Safety and danger notes 4
1.3 Designated use 5
1.4 Notes on illustrations and block diagrams 6
2 Installing the switch cabinet 7
2.1 System types 7
2.1.1 Compact station CPS K 7
2.1.2 Main station CPS H 8
2.2 Installation 9
2.3 Preliminaries 10
3 Installation 11
3.1 Connecting the relay outputs 11
3.2 Connecting the ONLITE central CPS Remote Interface 12
3.3 Connecting the line monitors 13
3.3.1 Connecting the line monitors in a circuit monitored sub distribution 13
3.3.2 Connecting the line monitors in a single monitored sub distribution 13
3.4 Connecting the emergency circuits 14
3.4.1 Connecting the emergency ciruits in a circuit monitored sub distribution 14
3.4.2 Connecting the emergency ciruits in a single monitored sub distribution 15

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3.5 Connecting the 230 V AC / 400 V AC voltage supply 16
3.6 Installing and connecting the batteries 17
3.6.1 Connecting the batteries of an ONLITE central CPS K system
(compact station) 17
3.6.2 Connecting the batteries of an ONLITE central CPS H system
(main station) 19
3.6.3 Possible set-ups for battery sets 20
4 Connecting external sub distributions 22
4.1 Connecting the system bus 22
4.2 Connecting the voltage supply 24
5 Switching on the system 25
6 Completing the installation 26
Appendix 27
A Technical Data 27
A.1 General 27
A.2 Compact station CPS K 27
A.3 Main station CPS H 28
A.4 Sub station CPS U 29
BFuses 29
C HANDLING INSTRUCTIONS FOR SEALED
VENT-REGULATED LEAD ACID BATTERIES 31
C.1 Safety instructions 31
C.2 Storage instructions 32
C.3 Commissioning 32
C.4 Operating regulations 32
C.5 Charging, discharging 33
C.6 Battery service and maintenance 34
C.7 Warranty 35
C.8 Table of torques for the battery connectors 35

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1 Introduction and safety regulations
1.1 General information
Validity and technical state of this installation instruction
This installation instruction is valid for the following ONLITE central CPS devices:
Hardware version: B
Signs and symbols used in the documentation
The following signs and symbols are used in this documentation:
Type Order number
ONLITE central CPS K (compact station) 22 154 689
ONLITE central CPS H (main station) 22 154 690
ONLITE central CPS U E00 (substation in E0 version) 22 154 691
ONLITE central CPS U E30 (substation in E30 version) 22 154 692
ONLITE central CPS BS (battery cabinet) 22 154 693
ONLITE central CPS BG (battery rack) 22 154 694
ONLITE central CPS Touch PC 22 161 687
ONLITE central CPS Remote Interface 22 154 740
Symbol Description
pOne step text instructions in instructions for action are marked with p. The
individual steps of multiple step instructions for action are numbered.
aIndicates the result for the action step after several action steps. These results
are marked with an asymbol at the beginning of the line.
VRequirements which need to be checked before operation are highlighted with
V.
iNotes are marked with the symbol i.
dWarning notes are marked with the symbol d. Warning notes also contain the
source of the danger as well as the consequence of the danger.
Warning notes are combined with the following signal words:
Danger: Warns of damage to persons (death or severe injury).
Caution: Warns of damage to persons (death or severe injury) which are
dependent on further actions.
Warning: Warns of material damages.

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Who may perform the installation?
The installation may only be performed by suitably qualified professional electrical specialists
who have been briefed on local and operational conditions.
1.2 Safety and danger notes
The central battery system ONLITE central CPS is part of the emergency and general lighting
system and consequently part of a building's safety equipment. Installation and
commissioning of the system must be performed with the appropriate care and precision.
dDanger
Please note that the luminaires are supplied with 216 V DC in case of emergency
operation. Mortal danger by electrical shock!
dDanger
Only qualified electrical specialists may perform work on the 230 V mains. Wiring of
current-carrying lines as well as signal and control lines must be done in accordance
with the relevant guidelines and standards. National guidelines and regulations
applicable in the country in which the system is being installed and operated have to
be observed.
dDanger
Improper use of the batteries or battery-powered parts of the system can cause risk of
injury or mortal danger from high current or arcs that can occur briefly on battery
discharge.
Ensure that the batteries are connected to the correct poles!
dDanger
Non-authorised or non-professional system installation and handling may result in
outages of the safety equipment. This implies immediate danger for people and the
security equipment itself. In addition, damages to machines and plants as well as loss
of productions are possible consequences at production sites.
dCaution
Non-authorised or non-professional system installation and handling may result in
damages of the batteries. The contained electrolyte sulphuric acid is extremely caustic
and can lead to heavy injuries!

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dCaution
Only luminaires with an operation voltage of 230 V AC (50 / 60 Hz) and 230 V DC
may be connected to the outputs for the emergency lighting end circuits of the
ONLITE central CPS system. Disregarding the instructions may result in damages to
system and luminaires.
dCaution
Short circuits and incorrect polarity may damage the batteries or parts of the system.
dCaution
Pay attention to the line lengths of the output circuits. The maximum length of 300 m
may not be exceeded. Disregarding the instructions may result in outages of the
emergency lighting, because the proper communication between the system
components is not guaranteed.
dCaution
The batteries may not be stored without maintaining for longer than 3 months.
Disregarding the instructions may result in damages to the batteries. When storing the
batteries without conservation charging, the battery capacity decreases up to the
defect of the battery.
1.3 Designated use
The central battery system ONLITE central CPS is designed for controlling and monitoring an
emergency lighting system. Any use in excess thereof is not allowed.
The adjustment and operation of the system is restricted to authorised technical staff.
Personal dangers may occur in case of
• improper use
• disregarding the safety regulations
The central battery system ONLITE central CPS and connected parts of the system may only
be operated if all system components are in perfect technical condition and in compliance with
• the safety and danger notes contained in this installation instruction,
• the operating and safety instructions stipulated by the system operator,
• the commissioning notes and instruction manual supplied with the central battery system
ONLITE central CPS,
• the technical data listed in the appendix.
Failures which cannot be removed by acknowledging are to be reported to the responsible
service person.
Operating and safety regulations arise from this installation instruction as well as from
organisational instructions and from general as well as technical guidelines and regulations for
accident prevention.

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The manufacturer will not assume warranty or liability for consequential damages that occur
due to:
• improper use
• disregarding the regulations
• unauthorised modifications or modifications made by technically non-competent persons
to device connections and settings of the ONLITE central CPS system
• the use of not allowed or unsuitable system parts
dDanger
Also pay attention to all laws, standards and guidelines applicable in the country in
which the system is being operated.
dCaution
Verify whether electrical installations comply with the application environment. Special
environmental conditions (e.g. areas subject to explosion hazards or areas with an
aggressive atmosphere) require special equipment and installations.
dCaution
Verify whether all used ballasts and luminaires fulfil the requirements of an emergency
lighting system and the operation at an ONLITE central CPS system.
dCaution
If mains, which supplies the ONLITE central CPS system, is interrupted longer than
three days, the battery has to be disconnected to prevent from deep discharge and
thus damage of the battery.
1.4 Notes on illustrations and block diagrams
Illustrations and block diagrams in these installation instruction are partly for demonstration
purposes only. Drawings and plans that were especially created for the emergency lighting
system and are in accordance with local requirements must be observed.

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2 Installing the switch cabinet
iThe ONLITE central CPS systems shown in this installation instruction can differ in
the modular design on delivery.
Special features of customer-specific systems are described in the project
documentation which must be ordered separately.
2.1 System types
2.1.1 Compact station CPS K
The following figure shows an ONLITE central CPS K system with one circuit monitored sub
distribution and one individually monitored sub distribution.
(1) Charging unit LE
(2) Circuit monitored sub distribution S
(3) Individually monitored sub distribution E
(4) Battery compartment
123
4

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2.1.2 Main station CPS H
The following figure shows an ONLITE central CPS H system with two circuit monitored sub
distributions.
(1) Charging unit LE
(2)/(3) Circuit monitored sub distributions S
Flange plate for connection cables
The connection cables are routed into the cabinet through the drillings in the flange plate on
top of the cabinet (see following figure). The flange plate contains rubber bushings for different
cable diameters (8 mm to 44 mm). Each switch cabinet has three flange plates.
123

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2.2 Installation
The switch cabinets of the ONLITE central CPS system must only be installed on flat surfaces
providing enough carrying capacity. Enough space must be provided to the sides and the back
of the cabinets to provide sufficient work space for the installation and future maintenance
work. Ensure that the doors of the switch cabinet can be opened completely.
The connections for the power supply of the ONLITE central CPS system must be provided by
the customer according to the technical data given in appendix A and the wiring diagrams.
iWe recommed to ensure at least 1 m free work space on each side of the switch
cabinet. The switch cabinet dimensions are listed in appendix A of this installation
instruction.

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2.3 Preliminaries
Before installing the ONLITE central CPS system, open the following fuses:
• Main fuses: -2F1, -2F2, -2F10.2 and -2F10.2
• Battery fuses: -2F4, -2F5, -2F6 and -2F7
• Outgoing fuses in the individual sub distributions: F1 to F20, both for phase L (red labelled
fuses) and for the neutral wire N (blue labelled fuse).
If the battery case (ONLITE central CPS K) or the battery cabinets (ONLITE central CPS H)
contain any batteries, you have to remove them prior to installation. In this case, also note the
instructions described in chapter "Handling instructions for sealed vent-regulated lead acid
batteries" (see chap. C on page 31).
iAlready installed and connected batteries must be removed taking into account the
battery installation order.

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3Installation
3.1 Connecting the relay outputs
Connection of the relay outputs has to be performed in accordance with the schematic
drawing shown below and the plans and drawings valid for the conditions at the installation
site. The charging unit of the ONLITE central CPS system provides five potential-free relay
outputs which can be used either as normally closed or normally open contact each.
1. Route the connection cables into the cabinet through the flange plate at the top side of the
switch cabinet (see chap. 2.1.2 on page 8).
2. Connect the relay outputs to the terminal block -2X4 of the charging unit relay module (see
following figure).
iThe relay outputs are implemented potential-free. If a signal voltage is required, the
internal 24 V DC voltage supply is provided at terminal block -2X5. The 24 V DC
voltage must be wired to the middle contact (Common) of the corresponding relay.
dDanger
Leave no connection cables temporarily loose and unsecured.
24VDC
0V
-2x5
12345678910 11 12 13 14 15
-2x4
Ö4 C4 S4 Ö5 C5 S5 Ö6 C6 S6 Ö7 C7 S7 Ö8 C8 S8
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Relay output 4 Relay output 5 Relay output 6 Relay output 7 Relay output 8 Internal signal voltage supply

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3.2 Connecting the ONLITE central CPS Remote Interface
Connection of the ONLITE central CPS Remote Interface (Art. No. 22 154 740) has to be
performed in accordance with the schematic drawing shown below and the plans and
drawings valid for the conditions at the installation site.
dDanger
Comply with the national regulations and guidelines for indicating and signalling when
using a remote switch or remote indicator for emergency lighting systems.
The ONLITE central CPS Remote Interface is powered by the internal 24 V DC voltage supply
of the ONLITE central CPS system.
dCaution
Do not use an external 24 V DC voltage supply. Disregarding the instructions may
result in outages of the emergency lighting because the proper communication
between the system components may not be guaranteed.
Connect the ONLITE central CPS Remote Interface as follows:
24V
0V
2x5
12345678910 11 12 13 14 15
-2x4
S2 S3 S4
S5 S6
S7
ONLITE central CPS
Remote Interface
Mains
operation
Battery
operation
Failure
OFF
S5+ S5- Rel5 Rel6 Rel7
Ö4 C4 S4 Ö5 C5 S5 Ö6 C6 S6 Ö7 C7 S7 Ö8 C8 S8
Fan error message Maintained light On/Off Free
Block system
Free Free

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3.3 Connecting the line monitors
3.3.1 Connecting the line monitors in a circuit monitored sub distribution
Connect the line monitors to the input terminals S1 to Sx of the circuit monitored sub
distribution (depending on the configuration of the ONLITE central CPS system).
The terminal block is labelled -4X1 (see following figure).
3.3.2 Connecting the line monitors in a single monitored sub distribution
Connect the line monitors to the input terminals S1 to Sx of the single monitored sub
distribution (depending on the configuration of the ONLITE central CPS system).
The terminal block is labelled -5X1 (see following figure).

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3.4 Connecting the emergency circuits
dCaution
Note the line length limitation of the output circuits. The maximum length of 300 m
may not be exceeded. Disregarding the instructions may result in outages of the
emergency lighting because the proper communication between the system
components is not guaranteed.
dCaution
Connect the luminaires to the emergency circuits according to the specifications of the
luminaires manufacturer. Disregarding the instructions may result in damages to the
system and luminaires.
3.4.1 Connecting the emergency ciruits in a circuit monitored sub
distribution
A maximum of 20 emergency circuits can be connected to each sub distribution. Each circuit
is fused by two outgoing fuses.
1. Route the connection cables into the cabinet through the flange plate at the top side of the
switch cabinet.
2. Connect each emergency circuit to the terminal blocks -4X2 and the PE terminal block in
the switch cabinet of the ONLITE central CPS system or the external sub distribution (as
shown in the following figure).
PE
(yellow/green)
N (blue)
L (red)

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3.4.2 Connecting the emergency ciruits in a single monitored sub
distribution
A maximum of 20 emergency circuits can be connected to each sub distribution. Each circuit
is fused by two outgoing fuses.
1. Route the connection cables into the cabinet through the flange plate at the top side of the
switch cabinet.
2. Connect each emergency circuit to the terminal blocks -5X1 (DALI terminals and PE
terminal block) and -5X2 in the switch cabinet of the ONLITE central CPS system or the
external sub distribution (as shown in the figure below).
iFor connecting the emergency circuits of a single monitored sub distribution a 5-pin
cable is used because two DALI connections D1 and D2 must be wired additionally to
the voltage supply.
PE
(yellow/green
)
N (blue)
L (red)
DALI connection D1 and D2
(brown/grey)

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3.5 Connecting the 230 V AC / 400 V AC voltage supply
The ONLITE central CPS system is powered by the general 230 V AC / 400 V AC mains or in
emergency operation by the batteries (battery cabinet or battery rack) or an emergency
generator.
Before connecting the voltage supply, ensure that
• the system and the supply lines are switched dead,
• the fuses 2F1, 2F2, 2F10.1 and 2F10.2 are opened (removed).
dDanger
When disregarding the preliminaries there is a risk of mortal danger due to live parts!
Proceed as follows to connect the ONLITE central CPS system to 230 V AC / 400 V AC
mains:
1. Switch the system dead by opening the external main switch and protect the system
against re-engagement.
2. Route the connection cables into the cabinet through the flange plate at the top side of the
switch cabinet.
3. Connect the 230 V AC / 400 V AC mains and the earth wire to the screw terminals L1, L2,
L3, N and PE of the terminal block -2X1 of the ONLITE central CPS switch cabinet.
iWhen connecting the 400 V AC voltage supply, please note that the phasing (L1-L3)
corresponds to a clockwise rotating field. For this purpose a phase sequence indicator
must be used.
L1 L2 L3 NPE

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3.6 Installing and connecting the batteries
Before connecting the batteries, ensure that
• no persons work on the installation,
• all mounting and installation works are completed,
• the battery fuses -2F4, -2F5, -2F6 and -2F7 have been removed. Two fuses for each sub
distribution are installed.
dDanger
When disregarding the preliminaries there is a risk of mortal danger by electrical
shock!
dDanger
Comply with the valid accidental regulations and wear protective clothes and
protective goggles.
dCaution
Also note the maximum admissible torques for battery connectors (see chap. C.8 on
page 35).
3.6.1 Connecting the batteries of an ONLITE central CPS K system
(compact station)
The battery set for an ONLITE central CPS K (compact station) consists of 18 batteries
connected in series (see chap. A.2 on page 27). The voltage of the battery set (system
voltage) is 216 V DC.
iWe recommend the following battery set-up in the compact cabinet switch:
When arranging the batteries, the first battery has to be installed in the rear row and
the last battery in the first row. This way, access to the battery connectors is easier
and additionally the risk of danger is reduced.
The batteries of the battery sets from 24 Ah to 75 Ah are installed on two levels. The
first nine batteries have to be installed on the floor board, the other nine batteries on
the grating supplied with the system (see chap. 3.6.3 on page 20).
iIn the switch cabinet of the compact station CPS K, the battery cabling is already
connected to the fuses -2F4 and -2F5. The other two cable ends are ready for
connection and can be found in the battery compartment.
Proceed as follows to connect the batteries of a compact station CPS K:
VPrepare the bridges, pole covers and numbering stickers supplied with the system.

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1. Connect the blue labelled cable to the negative pole (-) of battery 1.
2. Install one of the supplied bridges between the positive pole (+) of battery 1 and the
negative pole (-) of battery 2 and fix it accordingly.
3. Repeat step 2. for the other batteries until all batteries are connected in series.
4. Connect the red labelled cable to the positive pole (+) of battery 18. The second end of the
cable is already connected to fuse -2F5.
aThe batteries are connected.
Rear side of the ONLITE central CPS switch cabinet
Floor board