Power 6210 Installation procedure

Manual of Procedures (MOP)

1 Work Process
This section provides an overview of the installation process of Power 6210.

Figure 1 shows the work process for installing Power 6210.

Unpack and Check

Materials

Install a Battery Rack

Mount a Power Rack

Ground a Power Rack

Connect Incoming AC
Power Cables

Install Rectifiers

Install Circuit Breakers

Connect Batteries
to a Power Rack

Connect DC Load Cables

Connect the Power Rack to

Battery Backup Units (optional)

Connect Temperature Sensors

Install ESC or SCU (optional)

Install SAU (optional)

Verify Power System

Installation on Site

Power on the Power System

Configure the Power System

Perform Concluding
Routines
G110801C

Figure 1 Installation Work Process

2 Unpack and Check Materials

This section provides information for unpacking and checking the materials.

Steps

To unpack and check the materials:

1. Examine the packaging for

damage. If it is damaged,
immediately register a complaint
with the transport company. Take
a photo of the damage to improve
Ge9079A the claims process.

2. Unpack the box and verify that the

items delivered correspond to the
packing list.
Examine the items for damage.
For more information, refer to
Handling Faulty Equipment.

Ge7263C
3 Install a Battery Rack
The battery racks are available in two sizes, capacity and compact, as shown in
Figure 4 and Figure 5.

This section describes how to assemble a capacity rack. The compact rack is
assembled in the same way.

For more information about the battery rack, see Battery Rack Description.

G111029B

Figure 4 Capacity Rack Overview

 G111295B

Figure 5 Compact Rack Overview

Steps

Note: To better show the internal details, the side walls of the battery rack are
hidden in the illustrations.

To assemble the battery rack:

1. PH2 Put one of the side frames on the
floor. Install the three battery
1.96 Nm
supporting parts to the side frame
using M5 screws.
Identify the direction of the side
frame and supporting parts.

G109476A

Note: There are only two battery supporting parts for the compact rack.

It is recommended to use protective material on the floor when

assembling the battery rack.
2. Rotate the side frame 90°
counterclockwise.

G109477A

3. PH2 Install the three battery

supporting parts to the other side
1.96 Nm
frame and fasten each supporting
part using two M5 screws.

G109481A

4. PH2
Put a battery shelf in the rack.
Fasten each corner with two M5
screws.
1.96 Nm

G109486C

5. Repeat the step above to install

the remaining battery shelves.

G109493B
6. PH2 Front
Identify the front side of the top
tray and make sure the front side
1.96 Nm faces upwards. Install the top tray
on top of the battery rack using
Back
four M5 screws.

G110973A

7. PH2
Install the cable ladder on the
back top of the battery rack using
1.96 Nm four M5 screws.
Note:
The cable ladder is not available
for the compact rack.

G110974A

8. PH2
Install the cable ladder on the
front top of the battery rack using
1.96 Nm four M5 screws. Raise the battery
rack to the standing position.
Note:
The cable ladder is not available
for the compact rack.

G110975A

9. PH3 Install the back baffle plates from

the bottom to the top using eight
2.45 Nm
M6 screws.

G110976A
10. PH3 Install a pair of rack fixing parts
on the back of the battery rack
2.45 Nm
using M6 screws.

G109499B
4 Anchor the Battery Rack

The battery rack must be fastened to the foundation, using screws and plugs
suitable for the foundation material. It is optional to anchor the battery rack to
the wall.

Anchor the Battery Rack on Concrete Floor

This section describes how to anchor a battery rack onto a concrete floor.

Steps

To anchor the battery rack on a concrete floor:

1. Bottom View
495mm
Place the battery rack on the
foundation and mark the positions
495mm

of four holes for plug bolts.

527mm 327mm

Capacity Rack Compact Rack

G109504B

2. Drill the holes to a depth of 120

mm and a diameter of 16 mm.
Remove the dust and debris.
Insert the plug bolts with sleeves
into each hole.

G109541A
3. 18 mm Position the battery rack over the
plug bolts and install the washers
42 Nm
and nuts. Tighten the nuts.

G109505D

Anchor the Battery Rack to Concrete Wall

This section describes how to anchor the battery rack to a concrete wall.

Steps

To anchor the battery rack to a concrete wall:

1. Mark the positions for two plug bolts on the wall.

2. Drill the holes to a depth of 120

mm and a diameter of 16 mm.
Remove the dust and debris.

Ge7397A

3. Insert the plug bolts with sleeves

into each hole.

G109542A
4. 18 mm Position the battery rack over the
plug bolts and install the washers
42 Nm
and nuts. Tighten the nuts.

G109509D
5 Ground the Battery Rack

Steps

To connect the grounding cable:

1. Connect one end of the grounding cable to the grounding point on the top of the

battery rack.

2. Connect the other end of the grounding cable to the site grounding terminal.

13 mm

11 Nm

G111010C
6 Mount a Power Rack
A power rack can be mounted on top of a battery rack.

Steps

To mount the power rack on top of a battery rack:

1. PH2
Install the right bracket to the
bottom frame with three M6
3 Nm screws.

G110978A

2. PH2
Install the left bracket to the
bottom frame with three M6
3 Nm screws.

G110977A

3. Locate the installation holes for

the mounting kit on the top of the
battery rack.

G109494B

4. PH3
Fix the mounting kit on top of the
battery rack using four M8 screws.
6 Nm

G110979A

5. PH3 Position the power rack into the

mounting kit and fasten the power
6 Nm rack using M6 screws on the front.

G110694A
 6. PH2
Fix the power rack to the
mounting kit using two M4 screws
1.2 Nm on each side.

G110692A

7 Ground the Power Rack

Steps

To connect the grounding cable:

1. PH2
Remove the top cover by
loosening the screws.

G111014A

2. PH3
Insert the grounding cable into the
grounding connector and tighten
6 Nm the screw.

G111018A

3. Connect the other end of the grounding cable to the site grounding terminal.
8 Connect Incoming AC Power Cables
This section describes how the AC main power is installed. Power Rack 20 kW ST
has dual-route AC Input. Table 3 and Table 4 show the connection between the
rectifiers and AC input interfaces.

Table 3 Power Rack 20 kW ST AC Input (Right)

Rectifier(1) Interfaces Marking
1 1 L
2 L/N
3 PE
2 4 L
5 L/N
6 PE
3 7 L
8 L/N
9 PE
4 10 L
11 L/N
12 PE
(1) The right AC Input supplies power to the upper four rectifiers

Table 4 Power Rack 20 kW ST AC Input (Left)

Rectifier(1) Interface Marking
5 1 L
2 L/N
3 PE
6 4 L
5 L/N
6 PE
7 7 L
8 L/N
9 PE
8 10 L
11 L/N
12 PE
9 13 L
14 L/N
15 PE
(1) The left AC Input supplies power to the lower five rectifiers
Steps

To connect incoming AC power cables:

1. Make sure that the AC power is switched off at the source.

2. Remove the top cover above the AC inputs by loosening the screws.

For Power Rack 20 kW ST, loosen the two M4 screws.

PH2

G110698A
3. D6
Install the L cable into the
interface and tighten the screw.
1.5 Nm

L L/N PE L L/N PE L L/N PE L L/N PE

G110700A

4. D6
Install the N cable into the
interface and tighten the screw.
1.5 Nm

L L/N PE L L/N PE L L/N PE L L/N PE

G110704A

5. D6
Install the grounding cable into
the interface and tighten the
1.5 Nm
screw.

L L/N PE L L/N PE L L/N PE L L/N PE

G110944A

6. Use a cable tie to secure the power

cables to the frame above the AC
input interfaces.

L L/N PE L L/N PE L L/N PE L L/N PE

G110945A
7. PH2
Put the top cover back and tighten
the screws.
3 Nm
Note:
Do not switch on the circuit
breakers before the installation is
completed and the power rack is
ready to be powered on.
G110706A
9 Install Rectifiers

Power Rack 20 kW ST support up to nine rectifiers.

Steps

To install a rectifier:

Note: Illustrations below show positions in Power Rack 20 kW ST.

1. Loosen the fixing screw to extract
the locking handle.

Ge615012

2. Insert a rectifier in the first empty

slot from left. Push it in until it
stops.

Ge615013

3. Push the handle into the socket

and tighten by hand.

Ge615014

4. Install dummies in positions that

do not hold rectifiers.

Ge615014B
10 Install Circuit Breakers
Power 6210 supports circuit breakers from 6 A to 125 A. Battery circuit breakers
are installed on the left, while DC load circuit breakers are installed on the right,
as shown in Figure 3.

The gray-marked circuit breakers are pre-installed in the power racks. Table 6
describes the circuit breaker ratings for each position.

Table 6 Circuit Breakers Rating

(1) The battery circuit breaker consists of two 125A circuit breakers mechanically fixed together
and electrically connected in parallel. The electrical rating for this combined CB will be 200 A.
This CB will be described as “125A 2-poles” in CPI.
 G110987A

ML25 can be equipped with

a 125 A CB

ML ML ML ML ML ML ML ML ML ML ML ML ML ML ML ML ML ML ML ML ML
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

B1 B2 B3 B4
ML ML ML ML PL PL PL PL PL PL PL
1 2 3 4 1 2 3 4 5 6 7

G110674A

Figure 3 DC Output Distribution for Power Rack 20 kW ST

10.1 Install Battery Circuit Breakers

To install a battery circuit breaker:

1. Make sure all screws are completely open on the circuit breaker.

2. Loosen the top two fixing screws

to open the front cover plate of the
power rack.

G110707A

3. PH2
Remove the stopper.

G111019A

4. Slide the circuit breaker in place,

making sure the connector "peg"
at the bottom are correctly
inserted in the slots.

Ge160927B

5. PH2
Tighten the two screws at the
bottom of the circuit breaker.
0V

2.8 Nm

G111024A
10.2 Install DC Load Circuit Breakers

To install a DC load circuit breaker:

1. Make sure all screws are completely open on the circuit breaker.

2. Loosen the top two fixing screws

to open the front cover plate of the
power rack.

G110707A

3. Slide the circuit breaker in place,

making sure the connector "peg"
at the bottom are correctly
inserted in the slots.

Ge160927B

4. Tighten the screw at the bottom of

the circuit breaker.
PH2

2.8 Nm

Ge613003G
11 Connect Batteries to the Power Rack
This section describes how to connect batteries to a power rack.

11.1 Install Battery Blocks

To connect cables to the battery block, do the following:

Steps

1. Make sure that the battery cable is not yet connected to the power system.

2. For Leoch batteries, attach the end terminal covers to the battery cables and
bend them back to expose the end of the cable. Match the color of the end
terminal cover with the color of the terminal.

Ge14632A

3. Connect the battery cable to the battery block poles. Do the following:

a. Connect the black or blue end of the battery cable to the negative (-)
pole of the leftmost battery block.
b. Connect the red end of the battery cable to the positive (+) pole of
rightmost battery block.
 c. Tighten the bolts to the torque given on the battery front label.

13 mm

-48 V

0V

Ge14625A

4. For Leoch batteries, secure the end terminal covers on the terminals.

Ge14633A

5. Check polarity and voltage with a digital multimeter at the connector.

6. Connect the battery cable to the power system.

7. Attach cables to the handles of the battery blocks using cable ties.
 11.2 Finish battery installation

To finish battery installation, do the following:

1. Attach the pole protection caps over the battery block poles.

For Northstar Black and Northstar HT Red 100 Ah, use the same pole
protection caps on all battery blocks.

Ge14626A

Figure 8 Northstar Black

Ge14639A

Figure 9 Northstar HT Red 100 Ah

For Northstar HT Red 190-210 Ah, adapt the two pole protection caps on the
ends to use extension caps.
 Ge14627A

Figure 10 Northstar HT Red 190-210 Ah

For Leoch, adapt the two pole protection caps at the ends to fit the front-end
adapters.

Ge14634A

2. Switch on the power system connected to the batteries.

3. Verify Battery Block Installation on Site.

4. Perform concluding routines.

11.3 Connect Battery Cables to the Power Rack

This section describes how to connect battery cables to the power racks.

Steps

To connect a pair of battery cables:

1. Install a circuit breaker according to steps below
2. Wire Stripper
Strip 20 mm of the conductor
insulation of the battery cables.

20 mm

Ge9485B

3. PH2
Loosen the screws to remove the
top cover plates above the battery
connectors.

G111016A

4. PH2 +0V Connect the 0 V cable to the 0 V

connector at the back from above.
Tighten the screw.
2.8 Nm

0V

G110712A

5. D8 PH2
Connect the −48 V cable to the
1 -48V

+0V
2
battery circuit breaker from above.
Insert the alarm cable and tighten
4.0 Nm 2.8 Nm the screw.
0V
Alarm Cable
1

G110713A

6. PH2
Re-install the top cover plates
above the battery connectors.
3 Nm

G111092A
12 Connect DC Load Cables
Power 6210 can supply −48 V DC power to various DC-operated indoor site
equipment. This section describes how to install these power feeds.

Steps

To connect a pair of DC load cables:

1. Install a DC load circuit breaker according to steps below

2. Wire Stripper
Strip 20 mm of the insulation of
the conductor of the power cables.

20 mm

Ge9485B

3. PH2
Loosen the screws to remove the
top cover above the DC load
connectors.

G111016A

4. PH2
+0V Connect the 0 V cable to the
ground connector at the back from
above. Tighten the screw.
2.8 Nm

G110714A
5. -48V
Connect the −48 V cable to the
PH3
circuit breaker from above. Insert
the alarm cable and tighten the
screw.
Alarm Cable
+0V
3 Nm

G109549A

6. PH2
Re-install the top cover plates
above the DC load connectors.
3 Nm

G111092A
13 Connect the Power Rack to Battery Backup
Units
The Power 6210 system can be connected to battery backup units. When
expanding a Power 6210 system with additional battery racks, the power rack is
connected to the PCU DC 09 on top of each additional battery rack.

This section describes how to connect a power rack to a PCU DC 09. For more
information about power rack and PCU DC 09 connections

Steps

To connect a power rack to a PCU DC 09:

1. Connect battery cables to the power rack following the steps below
2. Strip 15 mm of the conductor
Wire Stripper
insulation of the battery cables.

15 mm

Ge14905A

3. PH3
Connect the −48 V power cable to
the screw in the negative (−)
connection field and tighten the
3 Nm screw.

G111037B

4. PH3
Connect the 0 V power cable to
the screw in the positive (+)
connection field and tighten the
3 Nm screw.

G111038B
14 Connect Temperature Sensors

This section describes how to connect the temperature sensors to the battery
temperature sensors.

Steps

To connect the temperature sensors:

1. Cut cable ties to release the cables

and route the cables through the
outlet on top of the power rack.

G110799A

2. Connect battery temperature

sensors to the temperature sensor
interfaces.
Note:
Two temperature sensors are
configured by default. If the third
temperature sensor is installed, set
G110818A

"Temp 3" parameter in controller.

15 Install SCU

This section describes how to install a Control Unit (SCU) for Power 6210.

SCU 09 01 can be used for Power Rack 20 kW ST.

Note: The illustrations in this section show the SCU installed on the front left
side of the power rack. If an SAU is used, install the SCU on the front
right side of the power rack.

Steps

To install the SCU:

PH3 Install a SCU holder using two

1. M6 screws.
6 Nm

G111020A

2. Snap the SCU into the

holder.

G111021A
 3. Route the communication cable
out of the power rack through the
outlet on the top. Connect the
cable to the serial port on the
SCU.

G111022A

4. Install a 6 A circuit breaker in the

power rack for the SCU
For Power Rack 20 kW MT, the 6 A
circuit breaker is pre-installed in
the PL 1 of User 4.

Ge160927B

5. Insert the power cable to −48 V

DC port on the SCU. Connect
the other end of the power
cable to the 6 A circuit
breaker in the power rack.
Black = –48 V

White = 0 V

G111023A

16 Install SAU

This section describes how to install SAU 02 01 for Power 6210.

 3.
2.
Steps

PH3

6 Nm

1 9 17 25 SAU 02 01
4 12 20 28

EXTERNAL
ALARMS

5 13 21 29 SAU
8 16 24 32

1 9 17 25 SAU 02 01
4 12 20 28
EXTER 1 9 17
ALAR
25 SAU 02 01
5 13 21 29 SAU
8 16 24 32 4 12 20
28
EXTE
RNAL
ALAR
MS

5 13 21
29 SAU
8 16 24
32
To install an SAU: 1.

1 9 17 25 SAU 02 01
4 12 20 28

EXTE
RNAL
ALAR
MS

5 13 21 29 SAU
8 16 24 32

SCU 09 01
SAU
2 1
EXT ALARM EC SERIAL

-48V

Ge14900A

Ge14902A
G111020A

the SAU port on the SCU

References

Snap the SAU into the holder.

Connect an alarm cable to the

SAU port on the SAU. Route the
cable rightwards and connect it to
Install SAU holder using M6 Screws