CBU Assembly Instructions Manual
Contents 1 General... 3 2 Package... 4 2.1 Packing order... 4 2.2 Unpacking... 5 3 Assembly of the body... 6 3.1 General... 6 3.2 Mounting base drilling chart... 8 3.3 Base and side walls.... 9 3.4 Top.... 10 3.5 Corner stiffeners.... 12 4 Insulators... 13 5 Assembly of the back wall... 17 6 Assembly of the battery shelf... 18 7 Assembly of the intermediate door... 19 7.1 Inserting the intermediate door... 19 7.2. Sealing the intermediate door... 19 8 Assembly of the door... 20 9 Cabling and grounding... 21 9.1 Location... 21 9.2 Connecting the groundings... 22 9.3 Connecting the gas tubes of the venting kit.... 23 9.4 Main cables... 24 9.5 Connecting the batteries... 25 9.6 Connecting the terminal... 26 10 Footprint... 27 11 Lifting... 28
12 Assembly of the Cable Duct... 29 13 Cabinet Stacking... 30 14 Plinth Assembly... 31 Appendix 1: Spare Parts
CBU Assembly Instructions Manual 3 (32) 1 General CBU can be assembled in 30 minutes or less. Follow the assembly instructions to ensure that all components are assembled correctly. Needed tools for the assembly: Allen key 3 mm 8 mm wrench Use of drill driver speeds up assembling. When using drill driver do not over tighten the screws. Maximum torque is 6 Nm. Fig. 1. Assembled CBU
CBU Assembly Instructions Manual 4 (32) 2 Package 2.1 Packing order Fig. 2. Packing order of the parts. All of the parts are marked with the corresponding number.
CBU Assembly Instructions Manual 5 (32) 2.2 Unpacking Fig. 3. Remove the lid and place it close. Use it to protect the parts and keep them off from the ground. Pull up the carton around the package and cut it open to be used for protection of the parts. Fig. 4. Unpack the parts and place them on the carton for easy handling since the parts are not in the assembling order in the package.
CBU Assembly Instructions Manual 6 (32) 3 Assembly of the body 3.1 General In case of faulty component check its spare part code from the label on the part or from the table on the right. To order a spare part contact nearest EnerSys sales office or representative. Notice: Lock types used in CBU : Handle with fixed lock chamber Handle with empty/replaceable 40 mm single euro cylinder
CBU Assembly Instructions Manual 7 (32) Fig. 5. Exploded view of the CBU. Names and the spare part ordering codes in the corresponding table.
CBU Assembly Instructions Manual 8 (32) 3.2 Mounting base drilling chart Fig. 6. Mounting base drilling chart. Notice: CBU can be assembled directly on the mounting place by attaching the bottom (part 1) to the fixed surface by washers and bolts. When CBU is installed close to a wall, the body of the cabinet including the insulators must be assembled before mounting the CBU close to the wall. For the assembly of the CBU approximately one meter of space is needed all around the cabinet.
CBU Assembly Instructions Manual 9 (32) 3.3 Base and side walls. Fig. 7. Start the assembly from the bottom panel (part 1). Fig. 8. Fasten the sidewalls (parts 2 and 3) to the bottom (part 1) very loosely to allow the assembly of the insulators. Notice: The cable inlet and the hinges of the right side wall (part 2) align on the front face of the frame.
CBU Assembly Instructions Manual 10 (32) Fig. 9. Fasten the side walls (part numbers 2 and 3) to the bottom (part 1) very loosely to allow the assembly of the insulators. Notice the guiding pins on the side walls that ensure the correct positioning of the walls. 3.4 Top. Fig. 10. Fasten the top (part 4) to the side walls (parts 2 and 3) very loosely to allow the assembly of the insulators.
CBU Assembly Instructions Manual 11 (32) Fig. 11. Fasten the top (part 4) to the side walls (parts 2 and 3) very loosely to allow the assembly of the insulators.
CBU Assembly Instructions Manual 12 (32) 3.5 Corner stiffeners. Fig. 12. Fasten the corner stiffeners to secure the frame very loosely to allow the assembly of the insulators.
CBU Assembly Instructions Manual 13 (32) 4 Insulators Notice that the insulators are precisely shaped, they fit exactly. Reforming or cutting is prohibited. No glue needed Intermediate door insulator is fixed to the door in the factory Use of hammer is forbidden. The insulators are assembled in the following order: Right side wall (part 5) and left side wall (part 6) insulators Bottom insulator (part 7) Top insulator (part 8) Back insulator (part 9) The result is seen in figure 13.
CBU Assembly Instructions Manual 14 (32) Fig. 13. Assembled insulators and the part numbers. Assembly of the insulators The almost hermetical design of CBU cabinet prevents typical condensation water issues. This requires that insulators be correctly installed, that they are free of defects and that seals against inner door are undamaged.
CBU Assembly Instructions Manual 15 (32) Fig. 14. Insert the right side wall insulator (part 5) into the frame. Fig. 15. Insert the left side wall insulator (part 6) into the frame.
CBU Assembly Instructions Manual 16 (32) FRONT Fig. 16. Insert the bottom insulator (part 7). FRONT Fig. 17. Insert the top insulator (part 8). Fig. 18. Insert the back insulator (part 9) from the rear of the frame.
CBU Assembly Instructions Manual 17 (32) 5 Assembly of the back wall Fig. 19. Assembly of the back wall (part 10). Fig. 20. Use the M5x25 (6 pcs) screws to fasten the back wall loosely to the top and to the bottom and the M5x40 (4 pcs) screws to fasten the back wall loosely to the side walls. Next push the back wall insulator against the back wall. Tighten all screws of the frame.
CBU Assembly Instructions Manual 18 (32) 6 Assembly of the battery shelf Fig. 21. Wire frame figure of the battery shelf. Notice the guiding pins on the parts that prevent misassembly. Fig. 22. Start by fastening the bottom piece and the lateral supports together. Use a ball pointed Allen key for more ergonomic fastening. Fasten the top shelf on the lateral supports. Insert the battery shelf into the cabinet. Notice that the cable inlet comes to the front.
CBU Assembly Instructions Manual 19 (32) 7 Assembly of the intermediate door 7.1 Inserting the intermediate door Fig. 23. Lift the intermediate door (part 12) into the cabinet so that the hinges on the right hand side are aligned. Fig. 24. Insert the kingpins to secure the three hinges. 7.2. Sealing the intermediate door Fig. 25. Push the tip of the latch behind the side wall frame. Fig. 26. Fasten the latches by rotating the knobs clockwise.
CBU Assembly Instructions Manual 20 (32) 8 Assembly of the door Fig. 27. Lift the door (part 13) on the hinges on the right side wall of the cabinet. Use your feet to support the door and guide all of the three hinges into place. Fig. 28. Assemble the lower parts of the hinges to secure the door to the cabinet. First mount the lower part of the hinge to its place then insert and fasten the screw.
CBU Assembly Instructions Manual 21 (32) 9 Cabling and grounding 9.1 Location Fig. 29. Groundings and LED wire connection are located in the top right corner of the cabinet. Use the pre-attached cable ties to secure the wires as shown in the fig. 30. Notice: According to low voltage directive no grounding is needed. Available grounding points are placed on the door, intermediate door, mounting base and on the battery shelf
CBU Assembly Instructions Manual 22 (32) 9.2 Connecting the groundings Open the door completely Fig. 30. Fasten the grounding cables (1 and 2) on the intermediate door and on the door. Grounding places are marked with a grounding sign. Connect the LED wire (3) between the intermediate door and the door. Fig. 31. Use the pre-attached cable tie to secure the grounding cable to the door. Use the other pre-attached cable tie to secure the LED wire to the door. Notice: Open the door completely before securing the cable ties to optimize the length of the cables.
CBU Assembly Instructions Manual 23 (32) 9.3 Connecting the gas tubes of the venting kit. Fig. 32. Venting kit assembly for 48 V battery string and for 2 x 48 V battery strings Notice: In order to guide the gas produced by the batteries for longer distances use a tube that has 10 mm outer diameter and 6 mm inner diameter. Use the cable inlet to guide the tube out from the cabinet. This enables to guide the gasses out from a room for example.
CBU Assembly Instructions Manual 24 (32) 9.4 Main cables Fig. 33. Bring the main cables into the cabinet through the cable inlet located in front of the cabinet. The inlets are sealed with removable seal. Remove the seals from the inlets that are used. The maximum cable size recommended is 70 mm 2. Notice: Remove only the sealing s that are necessary for the cabling and use the sealing around the cables if the cables used are less than 70 mm 2. Use the cable inlets to guide all necessary sensors or cables in/out of the cabinet. Seal the inlets properly to avoid temperature transfer.
CBU Assembly Instructions Manual 25 (32) 9.5 Connecting the batteries Fig. 34. Connect the main cables to the battery string. Use the same connection points to connect the power cables for the temperature controlling unit. Fasten the black cable to the positive (+) battery clamp and the blue cable to the negative (-) battery clamp. The cables are labeled with + and signs. Notice: Insert the fuse after connecting the cables. Follow Battery Maintenance & Installation Instructions, provided by EnerSys.
CBU Assembly Instructions Manual 26 (32) 9.6 Connecting the terminal Fig. 35. Attaching the terminal. Use the screws on the bag G to fasten the terminal to the battery shelf. Notice: Alarm wires from the controller box are preinstalled to the terminal.
CBU Assembly Instructions Manual 27 (32) 10 Footprint Fig. 36. Footprint of the CBU. Notice: When cabinets are fixed side by side or by a wall leave at least 10 mm space between the cabinets and the wall.
CBU Assembly Instructions Manual 28 (32) Safety: For safety reasons leave a space in front of the cabinet required by the local law or authorities! 11 Lifting Fig. 37. Use certified lifting rings (M10) in all four corners. Load all lifting rings evenly. Notice: Use certified lifting rings (M10) in all four corners. Follow the weight lifting capacity instructions of the lifting rings provided by the lifting ring manufacturer. The lifting capacity of the lifting rings chances with the angle of the slinging. Lifting rings are not provided with the cabinet.
CBU Assembly Instructions Manual 29 (32) 12 Assembly of the Cable Duct The external Cable Duct (sold separately) can be mounted onto the side walls or onto the back wall of the CBU. Use the M5x40 or the M5x25 screws with the sleeves that belong to the cabinet to fasten the Cable Duct. Fig. 38. Mounting the Cable Duct onto the back wall. Fig. 39. Mounting the Cable Duct onto the side wall.
CBU Assembly Instructions Manual 30 (32) 13 Cabinet Stacking Two CBU s can be stacked and attached by four M10 screws and washers. Use M10x25 screws to fasten the top cabinets from its mounting base to the lower cabinets lifting ring fixtures. In order to fasten DIN912 M10 screw use 8 mm Allen key. Notice: M10x25 screws are not provided with the cabinet. Lifting rings are sold separately. Fig. 40. Stacking of two cabinets.
CBU Assembly Instructions Manual 31 (32) 14 Plinth Assembly Fig. 41. Flexi plinth can be attached on the top of the CBU. Use four M8 screws to secure the plinth to the CBU. The nuts on the top are 12 mm deep. Notice: The M8 screws are not provided with the cabinet. Publication No. EN-AIM-CBU-8190C July 2011 - Subject to revisions without prior notice. E.&O.E.