3. Contents
Contents
1 Introduction 1
1.1 Target Groups 1
2 Prerequisites 3
2.1 Safety Information 3
2.2 Tools 5
2.3 Documentation 6
3 Preventive Maintenance 7
3.1 Maintenance Intervals 7
3.2 Cooling System 8
3.3 Batteries 13
3.4 Gas Ventilation Tubes 13
4 Alarms 21
5 Replacing Spare Parts 25
5.1 Cooling System 25
5.2 Climate System Controller of Direct Air Cooling Unit and
Active Cooling Unit 28
5.3 Air Filter of Direct Air Cooling Unit 31
5.4 External Fan, Direct Air Cooling Unit or Active Cooling Unit 32
5.5 Internal Fan, Active Cooling Unit 35
5.6 Cooling System Fuse - 20 A 37
5.7 Climate Temperature Sensor Cable 38
5.8 Fuses - 150A, 200A, or 250A 41
5.9 Batteries 45
6 Field Upgrades 65
6.1 Upgrading Battery Fuse from 150 A to 200 A 68
6.2 Replacement of Battery Cables 69
6.3 Connecting External Power Supply to CLU 70
7 Concluding Routines 75
7.1 Environment 75
Glossary 77
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5. Introduction
1 Introduction
This document describes how to maintain the BBU 6102, a variant of the
Battery Base Unit (BBU).
1.1 Target Groups
The target groups for these instructions are the personnel involved in
maintenance and repair.
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7. Prerequisites
2 Prerequisites
2.1 Safety Information
Maintenance 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 must be
adhered to.
The Ericsson product information includes the following safety information:
124 46–2885, Personal Health and Safety Information
124 46–2886, System Safety Information
All external circuits to be connected to the power system must comply with
SELV, as defined in EN 60950.
When work is being done in a power cabinet, the power supply system must
be de-energized. The AC power and, if applicable, all batteries must be
disconnected.
Danger!
Explosion risk. Connect lead-acid batteries in enclosed cabinets to
gas-ventilation tubes that lead flammable gas out of the cabinet.
Stop!
Do not install or modify AC or DC powered equipment unless you are a
qualified and authorized electrician. Improper installation work can seriously
damage the equipment.
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8. BBU 6102 Maintenance
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.
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. Before starting the installation, see Chapter Personal Health and
Safety in the installation instruction for the specific RBS.
2.1.1 Approved Disconnector
Note: An adequate disconnection device must be supplied, internally or
externally, in each supply circuit.
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9. Prerequisites
2.2 Tools
Table 1 specifies the tools and equipment required for BBU maintenance:
Table 1 Required Tools
Item Description Product No.
Battery ventilation test
tool
Contains: Pump,
Manometer, short gas
ventilation tube
LTP 177 200/1
Maintenance tool set LTT 601 137/1
Torque set 5–25 Nm LTT 601 140/1
Torque set 20–100 Nm LTT 601 141/1
Torque set Insulated, open-ended
torque wrench
LTT 601 157/1
T-handle SXK 107 2465/1
Soft brush -
Figure 1 T-handle, SXK 107 2465/1
Table 2 is a summary of the torque values specified to fasten vital parts during
installation.
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10. BBU 6102 Maintenance
Table 2 Equipment Torque Values
Description Torque
Intercell connectors 8.0 Nm
Battery cables to batteries 8.0 Nm
Fuse to fuse connecting bar 15.0 Nm
048 V DC cable and 0 V DC cable 15.0 Nm
2.3 Documentation
See Reference List on page 79 for the documents and manuals available.
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11. Preventive Maintenance
3 Preventive Maintenance
This section describes the maintenance routines and procedures for the BBU
6102.
3.1 Maintenance Intervals
Table 3 shows the preventive maintenance actions and how often they must be
performed. The actions must always be performed in the same order as they
appear in the table. The interval between inspections at BBU sites may vary
depending on local environmental conditions.
Table 3 Preventive Maintenance Intervals
Action Interval
Retighten the RBS cabinet to the BBU
cabinet and retighten the BBU cabinet to the
ground
When replacing the batteries,
or every six months after
installation in earthquake
zones and after an
earthquake
Retighten the earth connections When replacing the batteries
Cleaning the Cooling System Once a year
(1)
Control corrosion of the Climate Unit (CLU) Once a year
(2)
Air Filter of Direct Air Cooling Unit Once a year
(1)
Checking batteries Depends on Use inspection
intervals specified by the
battery manufacturer
Checking gas ventilation tubes Once a year or in connection
with other maintenance work
at the equipment
(1)
Retighten the battery cable connectors When replacing the batteries
Replacing batteries
(3)
Use replacement intervals
specified by the battery
manufacturer
Use checklist Concluding Routines before
leaving the site
(4)
Every site visit
(1) Can depend on environmental conditions.
(2) Applies only in aggressive environments.
(3) See Section 5.9 on page 45.
(4) See Section 7 on page 75.
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12. BBU 6102 Maintenance
Ericsson recommends that intervals between preventive maintenance do not
exceed 12 months. Careful inspection is also recommended during preventive
maintenance to determine whether the interval is too long. Preventive
maintenance visits should be planned to occur before and after the hot season.
This ensures best performance during both hot and cold seasons.
3.2 Cooling System
This section describes the procedure for preventive maintenance of the cooling
system in BBU 6102.
The cooling system needs preventive maintenance with specific intervals to
avoid breakdown or inefficient operation. It is important to notice that the
interval between maintenance can vary depending on the specific environment.
3.2.1 Direct Air Cooling Unit Maintenance Procedure
The recommended approach when performing a preventive maintenance visit
is:
Note: It is recommended to do the maintenance procedure in less than one
hour in order not to raise the battery temperature.
1. Open the cabinet door with the T-handle.
2. Lift to remove the door from the BBU opening and set it aside in a safe
location, to avoid scratching.
3. Check the status of the indicators; see Section 4 on page 21.
4. Disconnect the cables from the climate system controller.
5. Disconnect the hoses from the drainage pipes, if attached.
6. Unclasp the latch and remove the Direct Air Cooling Unit.
7. If it is cold outside, close the door of the cabinet to maintain the temperature
inside the cabinet.
8. Unfasten the side cover of the Direct Air Cooling Unit; see Figure 2.
9. Check if the filter needs to be exchanged; see Table 3 for preventive
maintenance intervals. Replace the filter if necessary; see Section 5.3
on page 30 for replacing the filter.
10. Inspect the external mesh screen. Brush the external mesh screens with
a soft brush, if necessary.
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13. Preventive Maintenance
Figure 2 Removal of Side Cover of Direct Air Cooling Unit
11. Clean the surface of the dampers with a soft, dry cloth if necessary; see
Figure 3.
Figure 3 Dampers
12. Inspect the status of the external temperature sensor cable; see Figure 4.
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14. BBU 6102 Maintenance
13. Fasten the side cover; see Figure 2.
14. Open the door of the cabinet, if closed, and slide in the Direct Air Cooling
Unit.
15. Connect the cables to the climate system controller.
16. Fasten the latch.
17. Reconnect the hoses to the drainage pipes, if previously disconnected.
Figure 4 External Temperature Sensor Cable
3.2.2 Active Cooling Unit Maintenance Procedure
The recommended approach when performing a preventive maintenance visit
is:
Note: It is recommended to do the maintenance procedure in less than one
hour in order not to raise the battery temperature.
1. Open the cabinet door with the T-handle.
2. Lift to remove the door from the BBU opening and set it aside in a safe
location, to avoid scratching.
3. Check the status of the indicators; see Section 4 on page 21.
4. Disconnect the cables from the climate system controller.
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15. Preventive Maintenance
5. Disconnect the hoses from the drainage pipes, if attached.
6. Unclasp the latch and remove the Active Cooling Unit.
7. If it is cold outside, close the door of the cabinet to maintain the temperature
inside of the cabinet.
8. Unfasten the side cover of the Active Cooling Unit; see Figure 5.
9. Remove the screws from the frame holding the heat sink in the cassette
and remove the heat sink.
10. Inspect the internal and the external heat sink for trapped debris and other
matter inside the fin channels.
Figure 5 Removal of Side Cover of Active Cooling Unit
11. If the heat sink looks clogged or heavily soiled, cleaning may be necessary.
Brush off any loose debris from the fins of the internal and the external heat
sink with a soft brush; see Figure 6.
12. Inspect the drainage pipes for trapped dirt and debris. Clean the drainage
pipes with a brush if necessary.
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16. BBU 6102 Maintenance
Figure 6 Brushing Fins of Internal and External Heat Sink
13. Inspect the status of the external temperature sensor cable.
14. Fasten the side cover.
15. Open the door of the cabinet, if closed, and slide in the Active Cooling Unit.
16. Refer to Section 3.2.1 on page 8 and follow the steps 15 - 17.
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17. Preventive Maintenance
Figure 7 External Temperature Sensor Cable
3.3 Batteries
For a list of approved battery types, battery dimensions, and battery weights,
refer to Spare Parts Catalog, Reference [4].
To avoid improper handling of batteries, and possible accidents, it is necessary
to refer to Battery Guidelines, Reference [3].
For more information on batteries, see Section 5.9 on page 45.
3.4 Gas Ventilation Tubes
All battery blocks must be connected to each other with gas ventilation tubes to
form a chain with just one outflow. Check the gas ventilation system as follows:
1. Check that the gas ventilation tube is routed from the rightmost battery
block and out of the cabinet through the gas ventilation nipple, as shown
in Figure 8.
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18. BBU 6102 Maintenance
P023319A
B1
B2
B3
B4
B5
B6
B7
B8
View from inside
Out of cabinet
Figure 8 Gas Ventilation Tube System - Example with Two Battery Strings
2. Check that the end cap is attached to the leftmost battery block.
3. Check that all batteries are connected to each other with gas ventilation
tubes.
4. Check that all gas ventilation tubes are in good condition and that they are
not in anyway pinched or squeezed, so that gas can flow freely through
the tubes. Replace when in doubt.
The gas ventilation tubes must be changed when replacing batteries. Refer to
Section 5.9.1 on page 47 for instructions.
3.4.1 Testing Gas Ventilation Tubes
The procedure for testing the gas ventilation system is given below. Test only
the NorthStar batteries.
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19. Preventive Maintenance
Do not test the EnerSys batteries because they are not designed to withstand
external over-pressure and can get damaged during test.
Note: Never re-install old gas ventilation tubes. The old tubes have hardened
and must be replaced with new ones if removed.
1. Remove the protective cap from the left ventilation hole in battery block 1, if
it was placed there.
2. Connect the gas tube included in the Battery Ventilation Test Tool (LTP
177200/1) to the left ventilation hole on battery block 1.
Ge4004A
3. Connect the pump to the gas tube.
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20. BBU 6102 Maintenance
Ge4004B
4. Connect the manometer to the long gas ventilation tube.
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21. Preventive Maintenance
Ge3476E
5. Pump up the pressure to maximum 160 mmHg and wait 1 minute.
P023355B
6. If the pressure has decreased significantly, there is a leak in the gas
ventilation system. Proceed to the next step to find the leak.
If the pressure has not decreased, go to Step 9.
7. Find the leaking unit by testing each battery block in the battery string and
its connected gas ventilation tube one at a time, as shown in the illustration
below.
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22. BBU 6102 Maintenance
Ge4005
8. Replace the faulty gas ventilation tube(s).
If one or more battery blocks are faulty, replace all battery blocks. Refer to
Battery Guidelines for more information.
9. Remove the pump and the manometer, and install the protective cap on the
left ventilation hole of battery block 1 in the chain, as shown in Figure 9.
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23. Preventive Maintenance
P023320A
B1
B2
B3
B4
View from inside
Out of cabinet
Figure 9 Installing Protective Cap on Battery B1
10. Connect the other end of the long gas ventilation tube from the last battery
block in the chain to the gas ventilation nipple, as shown in Figure 10.
P023182A
Figure 10 Connecting the Long Gas Ventilation Tube
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25. Alarms
4 Alarms
Indicators of the Climate System Controller
There are two Cooling Systems available for the BBU 6102: Direct Air Cooling
Unit and Active Cooling Unit. Both units are equipped with indicators; see Figure
11 for Direct Air Cooling Unit climate system controller with a cover and Figure
12 for Active Cooling Unit climate system controller with a cover, to indicate the
operational state of the Direct Air Cooling Unit and the Active Cooling Unit.
The indicators are specified in Table 4.
Table 4 Operational State as Defined By Indicators
Indicator Operational Mode
Green - On Power On
Yellow - On Cooling Unit in operation (blinking if
an alarm)
Red - On Cooling Unit Failure
All Off No power available to the Cooling
Unit
Figure 11 Direct Air Cooling Unit Climate System Controller with Cover
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26. BBU 6102 Maintenance
Figure 12 Active Cooling Unit Climate System Controller with Cover
Alarm Indications of Direct Air Cooling Unit
The following alarms (Alarm = Open Circuit) are issued by the Direct Air
Cooling Unit.
The climate system controller monitors the alarm conditions specified in Table 5.
Table 5 Alarm Table
Operating
State
Cooling /
Heating
Cooling
Unit Failu
re
Red Indica
tor
In Operatio
n
Yellow
Indicator
Power On
Green
Indicator
Alarm
Output
Alarm
Reset
Low Supply
Voltage
Off Off Off On Closed
Circuit
Automat
ic Reset
High Suppl
y Voltage
Off Off Off On Closed
Circuit
Automat
ic Reset
Internal
Fan Low
RPM
Off On 2 Quick
Flashes and
a Pause
On Open
Circuit
Manual
Reset
(1)
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27. Alarms
Table 5 Alarm Table
Operating
State
Cooling /
Heating
Cooling
Unit Failu
re
Red Indica
tor
In Operatio
n
Yellow
Indicator
Power On
Green
Indicator
Alarm
Output
Alarm
Reset
Unit Failure Off On 3 Quick
Flashes and
a Pause
On Open
Circuit
Manual
Reset
(1)
Heater
Current Out
of Range (if
installed)
Off On 4 Quick
Flashes and
a Pause
On Open
Circuit
Manual
Reset
(1)
(1) Turn off, wait, and then turn on the power.
Alarm Indications of Active Cooling Unit
The following alarms (Alarm = Open Circuit) are issued by the Active Cooling
Unit.
The climate system controller monitors the alarm conditions specified in Table 6.
Table 6 Alarm Table
Operating
State
Cooling /
Heating
Cooling
Unit Failure
Red Indica
tor
In Operatio
n
Yellow
Indicator
Power On
Green
Indicator
Alarm
Output
Alarm
Reset
Low Supply
Voltage
Off Off Off On Closed
Circuit
Automat
ic Reset
High Suppl
y Voltage
Off Off Off On Closed
Circuit
Automat
ic Reset
External
Fan Low
RPM
Off On 1 Quick
Flash and
a Pause
On Open
Circuit
Manual
Reset
(1)
Internal
Fan Low
RPM
Off On 2 Quick
Flashes and
a Pause
On Open
Circuit
Manual
Reset
(1)
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28. BBU 6102 Maintenance
Table 6 Alarm Table
Operating
State
Cooling /
Heating
Cooling
Unit Failure
Red Indica
tor
In Operatio
n
Yellow
Indicator
Power On
Green
Indicator
Alarm
Output
Alarm
Reset
Unit Failure Off On 3 Quick
Flashes and
a Pause
On Open
Circuit
Manual
Reset
(1)
Heater
Current
Out of
Range (if
installed)
Off On 4 Quick
Flashes and
a Pause
On Open
Circuit
Manual
Reset
(1)
(1) Turn off, wait, and then turn on the power.
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29. Replacing Spare Parts
5 Replacing Spare Parts
This section describes how to replace the spare parts.
For information on spare parts, refer to Spare Parts Catalog.
5.1 Cooling System
Replacing Direct Air Cooling Unit and Active Cooling Unit
Figure 13 Direct Air Cooling Unit, BPD 104 1006/2
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30. BBU 6102 Maintenance
Figure 14 Active Cooling Unit, BPD 104 1005/2
Note: It is recommended to do the maintenance procedure in less than one
hour in order not to raise the battery temperature.
Remove the air bubble film from the dampers in the Direct Air Cooling
Unit, before installation of the Direct Air Cooling Unit. Check if the
dumpers work correctly.
1. Open the door with the T-handle.
2. Lift to remove the door from the BBU opening and set aside in a safe
location, to avoid scratching.
3. Disconnect the cables from the climate system controller.
4. Disconnect the hoses from the drainage pipes, if attached.
5. Unclasp the latch and remove the Direct Air Cooling Unit or the Active
Cooling Unit.
6. Slide in the Direct Air Cooling Unit or the Active Cooling Unit; see Figure 15.
7. Connect the cables to the climate system controller.
8. Fasten the latch.
9. Reconnect the hoses to the drainage pipes, if previously disconnected.
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31. Replacing Spare Parts
Figure 15 Replacing Direct Air Cooling Unit or Active Cooling Unit
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32. BBU 6102 Maintenance
5.2 Climate System Controller of Direct Air Cooling Unit
and Active Cooling Unit
Figure 16 Climate System Controller of Direct Air Cooling Unit and Active
Cooling Unit, 3/BPD 104 1005/1
Replace the Climate System Controller as follows:
1. Open the door with the T-handle.
2. Lift to remove the door from the BBU opening and set aside in a safe
location, to avoid scratching.
3. Disconnect the cables from the climate system controller.
4. Disconnect the hoses from the drainage pipes, if attached.
5. Unclasp the latch and remove the Cooling Unit.
6. If it is cold outside, then close the door of the cabinet to maintain the
temperature inside the cabinet.
7. Push out the plastic rivets to release the cover of climate system controller;
see Figure 17.
8. Release the screws of the climate system controller; see Figure 17.
9. Replace the climate system controller.
Note: Make sure to use the correct antistatic protection when handling the
climate system controller.
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33. Replacing Spare Parts
Figure 17 Replacing Cooling System Climate System Controller
Note: Make sure that the jumper on the climate system controller in the Direct
Air Cooling Unit or the Active Cooling Unit is correctly configured; see
Figure 18 and Figure 19.
10. Tighten the screws of the climate system controller.
11. Put back the plastic rivets on the cover of the climate system controller;
see Figure 17.
12. Open the door of the cabinet, if there was a need to close the door and
slide in the Direct Air Cooling Unit or the Active Cooling Unit.
13. Reinstall the Cooling Unit according to Section 5.1 on page 25.
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34. BBU 6102 Maintenance
Figure 18 Jumper on Climate System Controller in Direct Air Cooling Unit
Figure 19 Jumper on Climate System Controller in Active Cooling Unit
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35. Replacing Spare Parts
5.3 Air Filter of Direct Air Cooling Unit
Figure 20 Air Filter of Direct Air Cooling Unit, 1/BPD 104 1006/2
Replace the air filter as follows:
1. Disconnect and pull out the Direct Air Cooling Unit according to Section
5.1 on page 25.
2. If it is cold outside, close the door of the cabinet to maintain the temperature
inside of the cabinet.
3. Unfasten the side cover of the Direct Air Cooling Unit.
4. Replace the air filter of Direct Air Cooling Unit; see Figure 21.
Note: The air filter is protected by removable sliding profiles, which must be
put back with the new filter.
5. Fasten the side cover of the Direct Air Cooling Unit.
6. Open the door of the cabinet, if there was a need to close the door and
slide in the Direct Air Cooling Unit.
7. Connect the cables to the climate system controller.
8. Fasten the latch.
9. Reconnect the hoses to the drainage pipes, if previously disconnected.
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36. BBU 6102 Maintenance
Figure 21 Replacing Air Filter of Direct Air Cooling Unit
5.4 External Fan, Direct Air Cooling Unit or Active Cooling
Unit
Figure 22 External Fan, Direct Air Cooling Unit or Active Cooling Unit, 1/BPD
104 1005/1
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37. Replacing Spare Parts
Replace the external fan as follows:
1. Disconnect and pull out the Direct Air Cooling Unit or the Active Cooling
Unit according to Section 5.1 on page 25.
2. If it is cold outside, close the door of the cabinet to maintain the temperature
inside of the cabinet.
3. Unfasten the side cover of the Direct Air Cooling Unit or the Active Cooling
Unit.
4. Disconnect the fan from the climate system controller.
5. Pull the fan cable through the grommet. The sealing mastic in the grommet
must be reused.
6. Disconnect the fan from the choke.
7. Unscrew and remove the ring plate; see Figure 23 for the Direct Air Cooling
Unit and Figure 24 for the Active Cooling Unit.
8. Unfasten and remove the fan; see Figure 23 for the Direct Air Cooling Unit
and Figure 24 for the Active Cooling Unit.
Note: Check the status of the anti-vibration gasket. Replace it if necessary.
9. Replace the fan.
10. Put back the ring plate.
11. Connect the fan to the choke.
12. Pull back the fan cable through the grommet.
13. Connect the fan to the climate system controller.
14. Fasten the side cover of the Direct Air Cooling Unit or the Active Cooling
Unit.
15. Slide in the Direct Air Cooling Unit or the Active Cooling Unit.
16. Connect the cables to the climate system controller.
17. Fasten the latch.
18. Reconnect the hoses to the drainage pipes, if previously disconnected.
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38. BBU 6102 Maintenance
Figure 23 Replacing External Fan, Direct Air Cooling Unit
Figure 24 Replacing External Fan, Active Cooling Unit
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39. Replacing Spare Parts
5.5 Internal Fan, Active Cooling Unit
Figure 25 Internal Fan, Active Cooling Unit, 2/BPD 104 1005/1
Replace the Internal Fan as follows:
1. Disconnect and pull out the Active Cooling Unit according to Section 5.1
on page 25.
2. If it is cold outside, close the door of the cabinet to maintain the temperature
inside of the cabinet.
3. Unfasten the side cover of the Active Cooling Unit.
4. Disconnect the fan from the climate system controller.
5. Pull the fan cable through the grommet. The sealing mastic in the grommet
should be reused.
6. Disconnect the fan from the choke.
7. Unfasten and remove the fan.
8. Replace the fan.
Note: Pay attention to the airflow direction indicated by arrows; see Figure 26.
9. Connect the fan to the choke.
10. Pull back the fan cable through the grommet.
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40. BBU 6102 Maintenance
11. Connect the fan to the climate system controller.
12. Fasten the side cover of the Active Cooling Unit.
13. Slide in the Active Cooling Unit.
14. Connect the cables to the climate system controller.
15. Fasten the latch.
16. Reconnect the hoses to the drainage pipes, if previously disconnected.
Figure 26 Replacing the Internal Axial Fan
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41. Replacing Spare Parts
5.6 Cooling System Fuse - 20 A
Figure 27 20 A Fuse, 4/BPD 104 1005/1 (Valid for Direct Air Cooling Unit
and Active Cooling Unit)
To replace the cooling system fuse, do as follows.
1. Open the door with the T-handle.
2. Lift to remove the door out of the BBU opening and set aside in a safe
location, to avoid scratching.
3. Press the fuse holder cap inwards and turn the fuse holder cap counter
clockwise a quarter turn; see Figure 28.
4. Remove the fuse holder cap.
5. Replace the fuse.
6. Press the fuse holder cap inwards and turn the fuse holder cap clockwise a
quarter turn; see Figure 28.
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42. BBU 6102 Maintenance
Figure 28 Replacing Fuse 20 A
5.7 Climate Temperature Sensor Cable
Figure 29 Climate Temperature Sensor Cable, 5/BPD 104 1005/1
Replace the Climate Temperature Sensor Cable as follows:
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43. Replacing Spare Parts
1. Inform the OMC operator and get approval for temporarily taking the
backup battery system out of service.
Note: Make sure that the BFU circuit breaker(s) in the RBS is (are) off. The
battery cables are then not connected to the RBS power.
2. Open the door with the T-handle.
3. Lift to remove the door from the BBU opening and set it aside in a safe
location, to avoid damage.
4. Remove the upper insulation plate and set the insulation plate aside in a
safe location, to avoid damaging.
5. Unfasten the battery straps from battery clamp.
6. Remove the three screws of the battery clamp from the top and remove
the battery clamp.
7. Remove the pole protection caps from battery blocks B1 - B5; see Figure
35.
Danger!
Explosion risk. Connect lead-acid batteries in enclosed cabinets to
gas-ventilation tubes that lead flammable gas out of 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.
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44. BBU 6102 Maintenance
8. Remove all the intercell connectors between the battery blocks; see Figure
38.
9. Disconnect the 048 V DC battery cable from battery B1; see Figure 45.
10. Protect the cable against short circuits by using insulation tape on the cable
lug.
11. Disconnect the 048 V DC battery cable from battery B5; see Figure 45.
12. Protect the cable against short circuit by using insulation tape on the cable
lug.
13. Put the pole protecting caps back on battery blocks B1 and B5 to protect
the batteries against short circuit.
14. Remove the intercell connectors from battery blocks B2 - B4; see Figure 38.
15. Remove the gas ventilation tubes from battery blocks B2 - B4; see Figure
44.
16. Slide out the battery B3.
17. Replace the climate temperature sensor cable.
18. Slide in the battery B3.
19. Attach new gas ventilation tubes to the battery blocks B2 - B4; see Figure
44.
Note: Battery ventilation tubes must always be connected to the batteries as
specified in this document to ensure safe gas ventilation.
20. Remove the pole protection caps from battery blocks B1 and B5.
21. Remove the insulation tape from the cable lug.
22. Connect the 048 V DC battery cable to battery B1; see Figure 45. Tighten
the cables; see Table 2 for the proper torque.
23. Remove the insulation tape from the cable lug.
24. Connect the 048 V DC battery cable to battery B5; see Figure 45. Tighten
the cables; see Table 2 for the proper torque.
25. Attach the intercell connectors to battery blocks B2 - B4; see Figure 38.
Tighten the batteries; see Table 2 for the proper torque.
26. Attach the pole protection caps to battery blocks B1 - B5; see Figure 35.
27. Fasten the battery clamp back.
28. Fasten the battery straps, by routing the front battery strap half through the
strap holder in the battery clamp.
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45. Replacing Spare Parts
Note: Make sure to strap the battery straps in a proper way.
Do not tighten the straps too firmly; otherwise the caps can be
damaged.
29. Strap the cables to the battery shelf.
30. Check that the gas ventilation tubes are correctly connected and routed
out of the cabinet.
31. Turn on the BFU circuit breakers.
32. Inform the OMC operator that maintenance is completed.
5.8 Fuses - 150A, 200A, or 250A
The BBU 6102 can have three different types of fuses, which all have identical
form as shown in Figure 30. The correct part number must be identified.
• The 150 A fuse is the original factory delivery. It should be replaced with a
200 A fuse as part of the field upgrade described in Section 6 on page 65.
Note: Do not replace the 150 a fuse with a 200A fuse without replacing
battery cables which are part of the field upgrade kit,
• The 200 A fuse is delivered with systems with revision R2A, which provide
higher power.
• The optional 250 A fuse is used for optional expansion to additional battery
backup systems.
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46. BBU 6102 Maintenance
Figure 30 Fuse
Replace the fuse as follows:
1. Inform the OMC operator and get approval for temporarily taking the
backup battery system out of service.
2. Open the door with the T-handle.
3. Lift to remove the door out of the BBU opening and set aside in a safe
location, to avoid damage.
4. Remove the upper insulation plate and set the insulation plate aside in a
safe location, to avoid damaging.
5. Unfasten the battery straps from battery clamp.
6. Remove the pole protection caps from battery blocks B1 and B5.
Danger!
Explosion risk. Connect lead-acid batteries in enclosed cabinets to
gas-ventilation tubes that lead flammable gas out of the cabinet.
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47. Replacing Spare Parts
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.
7. Remove all the intercell connectors between the battery blocks; see Figure
38.
8. Disconnect the 048 V DC battery cable from battery B1; see Figure 45.
Note: If this work is part of fuse upgrade kit, the battery cable must be
replaced with the AWG 1/0 cable provided in the kit. Discard the
existing cable.
9. Protect the cable against short circuits by using insulation tape on the cable
lug.
10. Disconnect the 048 V DC battery cable from battery B5; see Figure 45.
Note: If this work is part of fuse upgrade kit, the battery cable must be
replaced with the AWG 1/0 cable provided in the kit. Discard the
existing cable.
11. Protect the cable against short circuits by using insulation tape on the cable
lug.
12. Put the pole protection caps back on battery blocks B1 and B5 to protect
the batteries against short circuits.
13. Unfasten the cover plate of the fuse connecting bar; see Figure 31.
14. Unfasten the150 A, 200 A, or 250 A fuse; see Figure 31 with details given
in Figure 32.
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48. BBU 6102 Maintenance
Figure 31 Removing the Cover Plate of the Fuse Connecting Bar and
Replacing Fuse
P022877A
200 A 170 V
200 A 170 V
250 A 170 V
A
G
G
F
F
B
C
D
E
Figure 32 BBU Fuse Box
Table 7 Fuse Box Description
Legend Description
A Factory installed fuse, connection to RBS
B Optional second fuse to RBS
C Optional expansion to additional battery backup systems
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49. Replacing Spare Parts
Legend Description
D Battery cable connection for 048 V
E Optional connections for 048 V
F Studs for fastening the fuse box cover plate
G Screws for fastening the fuse plate.
15. Replace the150 A, 200 A, or 250 A fuse. Tighten the screws; see Table 2
for the correct torque.
16. Remove the pole protection caps from battery blocks B1 and B5.
17. Remove the insulation tape from the cable lug.
18. Connect the 048 V DC battery cable to the battery B1. Tighten the screws;
see Table 2 for the proper torque.
19. Remove the insulation tape from the cable lug.
20. Connect the 048 V DC battery cable to the battery B5. Tighten the screws;
see Table 2 for the proper torque.
21. Attach the intercell connectors to battery blocks; see Figure 38. Tighten
the batteries; see Table 2 for the proper torque.
22. Put the pole protection caps back on the battery blocks.
23. Fasten back the cover plate of the fuse connecting bar.
24. Fasten the battery straps, by routing the front battery strap half through the
strap holder in the battery clamp.
Note: Make sure to strap the battery straps in a proper way.
Do not tighten the straps too firmly; otherwise the caps can be
damaged.
25. Inform the OMC operator that operation is completed.
5.9 Batteries
This section describes how to replace battery blocks in the BBU. Refer to
Reference [3] for instructions regarding handling and connecting batteries.
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50. BBU 6102 Maintenance
Figure 33 048 V DC 170 Ah AGM Battery Set, BKC 901 62/1, and 48 V DC
140 Ah AGM Battery Set, BKC 901 06 /122
Figure 34 048 V DC 110 Ah AGM Battery Set, BKC 901 06/141
Prerequisites
Before replacing battery blocks, ensure the following:
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51. Replacing Spare Parts
• All power is disconnected from the battery blocks
• The safety instructions regarding handling and connecting batteries have
been read
• All tools are insulated
Danger!
Explosion risk. Connect lead-acid batteries in enclosed cabinets to
gas-ventilation tubes that lead flammable gas out of 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.
Note: Always replace all battery blocks.
If the new batteries are a different type than the batteries being replaced,
update the battery parameters in the RBS parameter set; see Reference [3].
5.9.1 Replacing One Battery String
Replace one battery string as follows:
1. Make sure that the BFU circuit breaker(s) in the RBS is (are) off. The
battery cables are then not connected to the RBS power.
2. Inform the OMC operator and get approval for temporarily taking the
backup battery system out of service.
3. Open the door with the T-handle.
4. Lift to remove the door from the BBU opening and set aside in a safe
location, to avoid scratching.
5. Remove the upper insulation plate and set the insulation plate aside in a
safe location, to avoid damaging.
Removing One Battery String
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52. BBU 6102 Maintenance
6. Unfasten the battery straps from battery clamp.
7. Remove the three screws of the battery clamp from the top and remove
the battery clamp.
8. Remove the pole protection caps from battery blocks B1 - B4; see Figure
35.
Figure 35 Removing Pole Protection Caps
9. Remove the intercell connectors from battery blocks B1 - B4; see Figure 38.
10. Disconnect the 0 V DC battery cable from battery B4 as is shown for the
150 A fuse in Figure 36, or for the 200 A fuse in Figure 37.
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53. Replacing Spare Parts
P023180A
B1
–48 V cable 0 V cable
B2 B3 B4
gas ventilation tube
Figure 36 Battery Cables - One Battery String
P022965B
B1
–48 V cable 0 V cable
B2 B3 B4
gas ventilation tube
Figure 37 Battery Cables - One String - AWG 1/0
11. Protect the cable against short circuits by using insulation tape on the cable
lug.
12. Disconnect the 048 V DC battery cable from battery B1 as is shown for the
150 A fuse in Figure 36, or for the 200 A fuse in Figure 37.
13. Protect the cable against short circuits by using insulation tape on the cable
lug.
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54. BBU 6102 Maintenance
P022954A
Figure 38 Intercell Connectors - Example with Front-End Adaptors
14. Remove the end cap from battery block B1, gas ventilation tubes, and the
tube from the gas ventilation nipple from battery B4; see Figure 39.
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55. Replacing Spare Parts
P023320A
B1
B2
B3
B4
View from inside
Out of cabinet
Figure 39 Gas Ventilation Tube System - One Battery String
15. Remove battery block B4 from the shelf.
16. Remove the climate temperature sensor cable from battery block B3.
17. Remove the RBS temperature sensor cable from battery block B3.
18. Remove battery blocks 1–3 from the shelf.
Preparing Gas Ventilation Tubes
This section describes how to prepare the gas ventilation tubes.
Note: When replacing batteries, all gas ventilation tubes must also be
replaced.
Each battery block must be ventilated from gas which otherwise can cause an
explosion inside the cabinet. All battery blocks must be connected to each
other through gas ventilation tubes. One connection from the battery string
transports the gas out from the cabinet.
The gas ventilation tube kit contains one tube that has to be cut up in pieces.
Do the following to prepare the gas ventilation tubes:
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56. BBU 6102 Maintenance
1. Cut the gas ventilation tube into the number of pieces and lengths as
shown in Table 8.
• The short tubes are used for connection between the battery blocks.
• The long tube is used for connection between a battery block and the gas
ventilation nipple in the cabinet.
Table 8 Gas Ventilation Tube Lengths
Number of
Battery Strings
Battery Type Long Tube, y Short Tubes, x
NorthStar NSB
110 FT
1
NorthStar NSB
170 FT
NorthStar NSB
170 Blue
NorthStar NSB
180 Red
EnerSys SBS PS
170
1 × X mm
(1)
3 × 105 mm
NorthStar NSB
110 FT
2
NorthStar NSB
170 FT
NorthStar NSB
170 Blue
NorthStar NSB
180 Red
EnerSys SBS PS
170
1 × X mm
(1)
7 × 105 mm
(1) The length depends on the configuration.
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57. Replacing Spare Parts
P021909A
y mm
x mm
Figure 40 Gas Ventilation Tube
Installing New Battery Blocks for One Battery String
Installing Battery Temperature Sensors
1. Attach two spacers on battery blocks B1 - B3 as shown in Figure 41.
Figure 41 Attaching Spacers
Before the battery blocks are installed in the cabinet, it is recommended that
the gas ventilation tubes are attached to the battery blocks. Do the following:
2. Attach a gas ventilation tube to each of the battery block 1, 2, and 3 as
shown in Figure 42.
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58. BBU 6102 Maintenance
P021923B
Figure 42 Gas Ventilation Tubes
3. Attach the climate temperature sensor cable to battery block B3, as shown
in the detailed part of Figure 43. See Table 9.
4. Attach the RBS temperature sensor cable to battery block B3, as shown
in the detailed part of Figure 43. See Table 9.
5. If applicable, install a second RBS temperature sensor cable, as close as
possible to the first RBS temperature sensor cable. See Table 9.
P023027A
1
2 3
Figure 43 The Climate and RBS Temperature Sensor Cables
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59. Replacing Spare Parts
Table 9 Key to the Climate and RBS Temperature Sensor Cables
Position Description
1 Climate temperature sensor cable
position
2 First RBS or BFU temperature sensor
cable position
3 Second RBS or BFU temperature
sensor cable position
6. Put battery blocks B1 - B3 on the shelf, and route the temperature sensor
cables as shown in Figure 43.
7. Put battery block B4 on the shelf.
Installing Gas Ventilation Tubes
8. Attach an end cap to the battery B1 according to Figure 44.
P023320A
B1
B2
B3
B4
View from inside
Out of cabinet
Figure 44 Gas Ventilation Tube System - One Battery String
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60. BBU 6102 Maintenance
Danger!
Explosion risk. Connect lead-acid batteries in enclosed cabinets to
gas-ventilation tubes that lead flammable gas out of the cabinet.
9. Attach the gas ventilation tubes to the battery blocks B1 - B4 according
to Figure 44.
Installing Power Cables
10. Remove the insulation tape from the 048 V DC battery cable lug.
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.
11. Attach the 048 V DC battery cable to battery block B1. Route the cable as
shown in Figure 36 for the 150 A version and as shown in Figure 37 for the
200 A version. Tighten the cable; see Table 2 for the proper torque.
12. Remove the insulation tape from the 0 V DC battery cable lug.
13. Attach the 0 V DC battery cable to battery B4. Route the cable as shown in
Figure 36 for the 150 A version and as shown in Figure 37 for the 200 A
version. Tighten the cable; see Table 2 for the correct torque.
Attaching Intercell Connectors
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61. Replacing Spare Parts
14. Attach the intercell connectors to the battery blocks B1 - B4; see Figure 38.
Tighten the batteries; see Table 2 for the proper torque.
Attaching Pole Protection Caps
15. Attach the pole protection caps on battery blocks B1 - B4; see Figure 35.
Fastening the Batteries
16. Fasten the battery clamp by fastening the three screws from the top.
17. Fasten the battery straps, by routing the front battery strap half through the
strap holder in the battery clamp.
Note: Make sure to strap the battery straps in a proper way.
Do not tighten the straps too firmly; otherwise the caps can be
damaged.
18. Strap the 048 V DC cable and 0 V DC cable to the battery shelf.
19. Inform the OMC operator that maintenance is completed.
5.9.2 Replacing Two Battery Strings
Replace two battery strings as follows:
1. Make sure that the BFU circuit breaker(s) in the RBS is (are) off. The
battery cables are then not connected to the RBS power.
2. Inform the OMC operator and get approval for temporarily taking the
backup battery system out of service.
3. Open the door with the T-handle.
4. Lift to remove the door from the BBU opening and set aside in a safe
location, to avoid scratching.
5. Remove the upper insulation plate and set the insulation plate aside in a
safe location, to avoid damaging.
Removing Two Battery Strings
6. Unfasten the battery straps from battery clamp.
7. Remove the three screws of the battery clamp from the top and remove
the battery clamp.
8. Remove the pole protection caps from battery blocks B1 - B8; see Figure
35.
9. Remove the intercell connectors from all battery blocks; see Figure 38.
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62. BBU 6102 Maintenance
10. Disconnect the 0 V DC battery cable from battery block B4, shown in Figure
45 for the 150 A version, or in Figure 46 for the 200 A version.
P023181A
B1
–48 V cable 0 V cable
B2 B3 B4 B5 B6 B7 B8
Figure 45 Battery Cables - Two Battery Strings
P022966C
B1
–48 V cable
0 V cable
B2 B3 B4 B5 B6 B7 B8
Figure 46 Battery Cables - Two Battery Strings - AWG 1/0
11. Protect the cable against short circuits by using insulation tape on the cable
lug.
12. Disconnect the 048 V DC battery cable from battery block B5, shown in
Figure 45 for the 150 A version, or in Figure 46 for the 200 A version.
13. Protect the cable against short circuits by using insulation tape on the cable
lug.
14. Disconnect the 048 V DC battery cable from battery block B1, shown in
Figure 45 for the 150 A version, or in Figure 46 for the 200 A version.
15. Protect the cable against short circuits by using insulation tape on the cable
lug.
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63. Replacing Spare Parts
16. Remove the gas ventilation tubes from battery blocks B1 - B8; Figure 47.
P023319A
B1
B2
B3
B4
B5
B6
B7
B8
View from inside
Out of cabinet
Figure 47 Gas Ventilation Tube System - Two Battery Strings
17. Remove the end cap from battery B1.
18. Remove the battery blocks B4 - B7 from the battery shelf.
19. Remove the climate temperature sensor cable from battery block B3.
20. Remove the RBS temperature sensor cable from battery block B3.
21. Remove battery blocks B1–B3 from the battery shelf.
22. Pull out battery block B8 far enough so that the 0V DC battery cable
connection can be reached.
23. Disconnect the 0 V DC battery cable from battery block B8, shown in Figure
45 for the 150 A version, or in Figure 46 for the 200 A version.
24. Protect the cable against short circuits by using insulation tape on the cable
lug.
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64. BBU 6102 Maintenance
25. Remove battery block B8 from the shelf.
Installing New Batteries for Two Battery Strings
26. Install battery blocks B1 - B4 according to Step 1 to in Step 13. Then follow
the steps below.
27. Attach two spacers on battery blocks B5–B7 as shown in Figure 41.
Installing Gas Ventilation Tubes
Note: Gas ventilation tubes must always be connected to the batteries as
specified in this document to secure safe gas ventilation.
Before the battery blocks are installed in the cabinet, it is recommended that
the gas ventilation tubes are attached to the battery blocks. Do the following:
28. Attach a gas ventilation tube to each of the battery block B4–B7 as shown
in Figure 47.
Installing Power Cable
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.
29. Remove the protecting shrink tube that covers the lug of battery cable 0
V DC for the second battery string.
30. Attach battery cable 0 V DC for the second battery string to battery B8.
Route the cable as shown in Figure 45 for the 150 A version, and as shown
in Figure 46 for the 200 A version. Tighten the cable; see Table 2 for the
proper torque.
31. Put battery blocks B8 and B7 on the shelf as shown in Figure 48.
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65. Replacing Spare Parts
Figure 48 Installing Batteries B7 and B8
32. Put battery blocks B5 and B6 on the shelf.
33. Attach the long gas ventilation tube to battery block B8 according to Figure
49.
Note: Do not connect the gas ventilation tube to the gas ventilation nipple
in the cabinet until the gas ventilation system has been checked,
as described in Section 3.4.1 on page 14.
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66. BBU 6102 Maintenance
P023319A
B1
B2
B3
B4
B5
B6
B7
B8
View from inside
Out of cabinet
Figure 49 Gas Ventilation Tube System - Two Battery Strings
Installing Power Cable - Second Battery String
34. Remove the insulation tape from the cable lug of the 048 V DC battery
cable for second battery string.
35. Attach the 048 V DC battery cable to battery block B5. Route the cable as
shown in Figure 45 for the 150 A version, and as shown in Figure 46 for the
200 A version. Tighten the cable; see Table 2 for the correct torque.
Attaching Intercell Connectors - Second Battery String
36. Attach the intercell connector to battery blocks B1 - B8; see Figure 38.
Tighten the screws; see Table 2 for the correct torque.
Attaching Pole Protection Caps
37. Attach the pole protection caps on batteries B1 - B8; see Figure 35.
Fastening the Batteries
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67. Replacing Spare Parts
38. Fasten back the battery clamp by fastening the three screws from the top.
39. Fasten the battery straps, by routing the front battery strap half through the
strap holder in the battery clamp.
Note: Make sure to strap the battery straps in a proper way.
Do not tighten the straps too firmly; or the caps may be damaged.
40. Strap the 048 V DC cables and 0 V DC cables to the battery shelf.
41. Turn on the BFU circuit breakers.
42. Inform the OMC operator that maintenance activity is completed.
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69. Field Upgrades
6 Field Upgrades
The field upgrade is recommended to all customers who want to take advantage
of increased battery backup power. The field upgrade kit consists of five parts.
Note: Before any field upgrade work is begun, make sure that the circuit
breaker on the BFU is off, and the battery cable is disconnected from
the BFU.
Make sure that all intercell connectors are removed from the battery
blocks when battery cables are removed, and reattached when the
battery cables are reconnected.
• Replacement of 048 V bar and fuse holder.
• Replacement of 0 V bar.
• Upgrade of battery fuse from the original 150–200 A which is described
in Section 6.1 on page 68.
• Replacement of battery cables to support higher capacity batteries as
described in Section 6.2 on page 69.
• External 048 V power from the RBS to the CLU as described in Section
6.3 on page 70.
Figure 50 is a view from below. In the upper front part, the different power
connections can be seen. The fuse box on the right is normally protected with a
cover plate. Figure 51 shows a detail of the fuse box which holds one factory
installed 150 A or 200 A fuse.
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70. BBU 6102 Maintenance
P022880A
Bottom
A B C
D
E
Figure 50 Power Connection Points
Table 10 Power Connection Description
Legend Description
A 0 V and earth bar
B Fuse for CLU, 20 A
C Fuse bar with up to three fuses for battery power
connections
D Power terminal to CLU.
(1)
E Power terminal for incoming power to CLU.
(2)
(1) Terminal only installed in systems with revision R2A
(2) Terminal only installed in systems with revision R2A
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71. Field Upgrades
P022877A
200 A 170 V
200 A 170 V
250 A 170 V
A
G
G
F
F
B
C
D
E
Figure 51 Power Connection Fuses
Table 11 Power Connection Fuses Description
Legend Description
A Fuse connection point to
B Fuse connection point to
C Fuse connection point to for optional additional battery
backup systems
D 048 V battery string connection points
E 048 V connection points
F Studs for fuse box cover plate
G Screws for fuse box installation.
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72. BBU 6102 Maintenance
P022967A
A
B
C
D
Figure 52 BBU 6102 0V Bar
Table 12 0 V Bar
Legend Description
A 0 V bar fastening in original installation with isolating washers
to chassis
B Updated 0 V bar fastening with conducting washers to
underlying bracket
C Connection bar between chassis and 0V bar.
D New bracket for fastening 0 V bar with improved connectivity
to the chassis.
6.1 Upgrading Battery Fuse from 150 A to 200 A
One portion of the upgrade kit is to replace the main battery fuse, connecting
the two battery strings to the Battery Fuse Unit (BFU) of the RBS. The operation
in replacing or upgrading the fuse to a 200 A version is described in detail in
Section 5.8 on page 41.
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73. Field Upgrades
To replace fuses and power bars, the following procedure is performed.
1. Follow step 1-13 as described in Section 5.8 on page 41.
Note: Remove all fuses and battery cables
2. Remove the 048 V bar, by unscrewing the four screws shown as G in
Figure 51.
3. Insert the new 048 V bar from the upgrade kit, and tighten the screws.
4. Remove the 0 V bar by unscrewing the nuts shown as A in Figure 52.
5. Insert the new 0 V bar from the upgrade kit.
Note: The removed bar had isolation plates, separating the 0 V bar from
the chassis. The bar to be installed has connection washers to
ensure a good connection between the chassis and the 0 V bar.
6. Ensure that the correct battery cables are in place before connecting cable
to the power bars. Thicker battery cables are supplied in the upgrade kit
and are installed as described in Section 6.2 on page 69.
7. Follow step 14-24 as described in Section 5.8 on page 41.
6.2 Replacement of Battery Cables
One portion of the upgrade kit is to replace the battery cables to thicker AWG
1/0 cables. Depending on system configuration, one or two battery strings
may be installed as shown in Figure 45. Both the 0 V cables and the 048
V cables must be replaced.
On the left side of Figure 31, the 0 V busbar is shown. On the right-hand side
the 048 bar is shown, with details in Figure 32.
To replace battery cables, perform the following procedure.
1. Remove the -48 V battery cables from the batteries as described in Section
5.8 on page 41.
2. Remove the -48 V battery cables, connected to position D in Figure 32,
and discard the cables.
3. Remove the 0 V cables from the batteries.
4. Remove the 0 V battery cables from the busbar, and discard the cables.
5. Install new AWG 1/0 battery cables as shown in Figure 45 .
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74. BBU 6102 Maintenance
P022975A
Bottom
Figure 53 BBU Cable Connections for Upgrade
6.3 Connecting External Power Supply to CLU
This section describes how to upgrade the BBU making the CLU to be supplied
by 048 V DC power from the RBS. Depending on product R-state, the BBU has
different factory installed CLU power connections. The product R-state Rxx is
the last part of the BBU product number COH 109 397/29 Rxx.
A BBU with R-state R2A has power connected to the CLU directly from the
RBS, as shown in Figure 54.
P022940A
+ –
B A
E
F3
+ –
D
F1
C
F4
CLU
Heater
Figure 54 BBU 6102 with External Supply to CLU
A BBU with R-state R1A to R1C has power connected to the CLU from the
internal batteries, as shown in Figure 55.
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75. Field Upgrades
P022939A
+ –
B A
E
F3
+ –
D
F1
C
F2
F4
CLU
Heater
Figure 55 BBU 6102 with Internal Supply to CLU
A BBU with R-state R1A to R1C can be upgraded making the CLU receive
power from the RBS, using upgrade cable kit NTM 101 2577/1.
Or, if upgrading to R2A status, using upgrade cable kit NTM 101 2572/1.
To install the power cable from the Power Distribution Unit (PDU) in the RBS
directly to the climate system controller in the BBU, do the following:
1. Connect the power cable to the PDU in the RBS, and route the cable to the
CLU into the BBU, as shown in Figure 56.
SK
PDU
CLU
Figure 56 Connection of the Power Cable between the RBS and the BBU
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76. BBU 6102 Maintenance
2. Remove the plastic cover that protects the fuses.
3. Loosen the black cable going to the -48 V busbar from the fuse, as shown
in Figure 57.
P022522A
Ground –48 V
Figure 57 0 V Busbar and -48 V Busbar
4. Cut the black cable close to the eyelet.
5. Strip 8 mm of insulation from the cable.
6. Cut the terminal of the power cable (black) from the RBS and strip 8 mm
of the insulation.
7. Connect the -48 V DC (black) cable to the black cable from the RBS with
a terminal block.
8. Loosen the screw holding the 0 V DC (red) cable on the 0 V busbar, as
shown in Figure 57.
9. Cut the 0 V DC (red) cable close to the eyelet.
10. Cut the terminal of the power cable (gray) from the RBS and strip 8 mm
of the insulation.
11. Connect the 0 V DC (red) cable to the gray cable from the RBS with a
terminal block.
6.3.1 Connecting Additional Earth Cable to CLU
To connect the additional earth cable, do the following:
1. Remove the cable strap (if not already done).
2. Place the unstripped 0 V DC (red) cable to the climate system controller in
the run channel of the ScotchlokTM 562, shown in Figure 58.
Note: Place the ScotchlokTM 150 mm from the power connection.
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77. Field Upgrades
P022358A
Figure 58 Scotchlok TM 562
3. Insert the unstripped earth cable into the ScotchlokTM 562 up to the stop.
4. Use snipe nose pliers to drive down the u-connector until it is in line with
the top of the plastic insulator.
5. Close the hinged top cover. Ensure that the cover latches, as shown
in Figure 59.
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78. BBU 6102 Maintenance
P022357B
Figure 59 Scotchlok TM 562 with Closed and Latched Top Cover
6. Remove the M4 screw, holding the cover of the CLU. Place the star washer
under the eyelet and fasten the earth cable with the screw, as shown
in Figure 60.
Figure 60 Climate System Control with the Extra Earth Cable Installed
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79. Concluding Routines
7 Concluding Routines
1. Check that all cables are correctly routed and connected and, where
applicable, the cables are fastened to the top or sides of the cabinet.
2. Follow the instructions in Section 3.4.1 on page 14 to test the gas ventilation
system.
3. Check that all covers are in place.
4. Check that the site is clear of waste materials and the cabinet is clear of
the tools listed in Table 1.
5. Insert the upper insulation plate (if removed).
6. Make sure that the cooling system is functioning; see Section 4 on page 21.
7. Put back the door into the BBU opening.
8. Close and lock the BBU door.
9. At site commissioning and start of operation, switch on the power from
the RBS.
7.1 Environment
Note: Ericsson strongly recommends paying careful attention to the
environment when cleaning a site after installation. In particular,
recycle all waste that can be recycled and sort the rest so that it can be
disposed of in accordance with local regulations.
Table 13 shows the recommended methods to take care of waste material
after maintenance.
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80. BBU 6102 Maintenance
Table 13 Waste Sorting and Recycling
Item Recycle or Sort
Bubble plastic
Cable insulation from
crimping, brazing, or
welding
Cable pieces, low metallic
content
Cable tie clippings
Foam
Packing chips
Polystyrene
Recycle or sort as plastic
Paper and wood Recycle or sort as paper
Cable pieces, high metallic
content
Metal from cable ladders
Nuts, bolts, washers, and
screws
Recycle or sort as metal
Batteries
Refrigeration fluids
Dispose of in accordance with local regulations
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83. Reference List
Reference List
Safety
[1] Personal Health and Safety Information, 124 46-2885
[2] System Safety Information, 124 46-2886
Site
[3] Battery Guidelines, 1/154 43-LZA 701 6009
[4] Spare Parts Catalog, 1/154 11-LZA 701 6011
[5] Grounding Guidelines for RBS Sites, 190 08-EN/LZT 735 0018
[6] Installation Team Products Overview, EN/LZT 751 0065
[7] Site Installation Documentation (SID), Specific to the Site
[8] Site Material Installation Instructions, EN/LZT 751 0049
RBS
[9] Installing BBU 6102, 10/1531-LZA 701 6009
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