PRODUCT MANUAL BATTERY BOX

Knrr - PO# 019250131000001

Knrr AG
Mariakirchener Strae 38
D - 94424 Arnstorf
Tel +49 (0) 8723 27 0
Fax +49 (0) 8723 27 154
www.knuerr.com

Knrr part no. 1_998_119_0 issue b

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PRODUCT MANUAL BATTERY BOX

0.

Revision Status

Issue a
Issua b

2008-12-05 written by Ronny Hengst

2009-02-09 written by Ronny Hengst

created: 2008-12-05, Ronny Hengst

checked:
Contents

Page

0.
1.
2.

Revision Status ................................................................................................ 2

General information ......................................................................................... 3
Technical information...................................................................................... 5
2.1 Overview ......................................................................................................... 5
2.2 Accessories..................................................................................................... 7
2.3 Grounding point locations.............................................................................. 11
2.4 Finish and colour........................................................................................... 11
2.5 Materials List ................................................................................................. 11
2.6 Keys and external screws ............................................................................. 12
2.7 Environmental conditions .............................................................................. 12
2.8 Tools required for installation and service (w/o electrical tools) .................... 12
3.
Installation site requirements ....................................................................... 14
3.1 Packaging and fittings for transportation ....................................................... 14
3.2 Site requirements and pre-requisites. ........................................................... 14
4.
Installation ...................................................................................................... 16
4.1 Plinth installation ........................................................................................... 16
4.3 Stacking ........................................................................................................ 19
4.4 FPRA Flexi Power Rectifiers ......................................................................... 20
4.5 Cable entry.................................................................................................... 23

Appendix
[1] Assembling drawing Battery Box art.no. 01.925.013.1-000001, rev. B
[2] Assembling drawing Plinth art.no. 01.925.013.1-000001, rev. B
[3] Assembling drawing Wall Mounting brackets, art.no. 01.925.013.1-000001,
rev. A
[4] Assembling drawing Mounting brackets FPRA Flexi Power Rectifiers,
art.no. 01.908.460.1

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PRODUCT MANUAL BATTERY BOX

1.

General information

Copyright:
All rights to this manual are owned by Knrr AG, Arnstorf. Reproduction and
reprinting of this manual, in whole or part, are permitted only if the source of the
information is specified.
Knrr AG reserves the right to modify the information contained in this manual
without prior notice.
Liability:
Knrr AG doesn
t accept any liability for damages which result from incorrect use or
operation of the unit.
Safety of operation:
All enclosures are delivered in perfect and safe working order.
Knrr AG can only warrant the safety, reliability and performance of the system if it is
assembled, operated and extended and modified as specified in this manual.
Use the unit only in a technically correct condition. Have any damages or faults
repaired immediately by authorised service persons.
Use only original accessories.
Only the activities described in this manual should be undertaken by authorised
and qualified service persons. No responsibility whatever can be accepted for
unauthorised modifications or repairs.
Transport damage:
Safety is no longer assured if an enclosure has obviously been
damaged during transportation.
Damage suffered during transportation must be reported to
the carrier upon delivery, as well as to the manufacturer.
Warranty:
Knrr AG provides a warranty for 12 months, starting on the date of delivery, on all
mechanical and electrical components.
Further details can be found in the General Business Conditions of Knrr AG.
Service and spare parts order:
Knrr Electronics GmbH
Business Unit Outdoor Systems
Phone:
+49 (0)35 241 56 0
Fax:
+49 (0)35 241 56 252
E-mail:
outdoorsystems@knuerr.com

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PRODUCT MANUAL BATTERY BOX

Standards and regulations:

The Battery Box has been constructed and tested in accordance with the relevant
standards and regulations.
IEC 297
IEC 916
IEC 60529 (IP)
EN 2002/95/EG (ROHS)
ETSI 300 019 class 4.1

Commonality:
Handling and installation must be in accordance with this manual.
Additionally following separate manuals are valid which are supplied together with
this manual if applicable:
[1] Assembly instructions for Battery Box at the plinth art. no. 01.998.120.0
[2] Assembly instructions for Battery Box at the wall art. no. 01.998.121.0
[3] Assembly instructions for the Mounting brackets of FPRA Flexi Power
Rectifiers art. no. 01.998.122.0
Marking and symbols:
Danger!
Requires safety measures to be taken to protect the
health of personnel concerned

Warning!
Emphasises what has to be done or refrained from
being done in order to avoid damaging valuable
property

F
Knrr part no. 1_998_119_0 issue b

Information
Recommends ways of dealing with certain elements
and gives instructions for smooth and quick assembly.

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PRODUCT MANUAL BATTERY BOX

2.

Technical information

2.1

Overview

Dimensions:
Externally:
Width x Depth x Height
685mm x 688mm (incl. fastener with depth of 38mm) x 450 mm
Internally:
Width x Depth x Height
625 x 625mm x 390mm
Weight: 17kg (without pallete and packing)
The cabinet consists of:
1 x single skinned selfsupported cabinet, welded
1 x front door with 1 T-Handle, single point interlocking system, hinged left,
1 x bottom panel with vent slots and intergrated battery tray
4 x cable glands M20
provision to stack 2 cabinets on each other
bolts to assemble provision for fixing of FPRA Flexi Power Rectifiers

Fig. 1 External view of the Battery Box (1)

Explanation 1 Corpus
6 Stopping plug
2 Front door
7 Locknut
4 Torx head screw
8-12 Grounding set (Door)
5 Cable gland M20

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Fig. 2

External view of Battery Box (2)

The Batterie Box is designed to contain a maximum

load of 240kg.

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Fig. 3

2.2

External view of Battery Box, with plinth (3)

Accessories

Plinth
Knrr - P/O no. 01.914.300.9-000051

Weight: 7kg (without packing)

U-shaped plinth with removable front panel

plinth trim not removable if door is closed, fixed through door
6 cable grommets DG21 at the rear side of the plinth
incl. material for assembling at the cabinet

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Fig. 4 Plinth for Battery Box with removeable plinth trim (1)
Explanation 1 Plinth frame
4 Flat headed screw
2 Plinth trim
5 Spring washer B8
3 Cable grommet DG21 6 Hexagon nut M8

Fig. 5

Plinth for Battery Box with removeable plinth trim (2)

Wall Mounting Brackets

Knrr - P/O no. 01.925.067.0-000001

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Weight: 6kg (without packing)

triangular brackets for fixing the cabinet to a wall

incl. material for assembling at the cabinet

Fig. 6 Wall Mounting Brackets for Battery Box (1)

Explanation 1 Bracket left
5 Hexagon nut M8
2 Bracket right
6 Washer
4 Spring washer B8

Fig. 7

Wall Mounting Brackets for Battery Box (2)

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Brackets for fixing FPRA Flexi Power Rectifiers

Knrr - P/O no. 01.926.443.1.000003
Weight: 0,6kg (without packing)

brackets for fixing FPRA Flexi Power Rectifiers at the top of the cabinet
incl. material for assembling at the cabinet

Fig. 8 Mounting bracket for FPRA Flexi Power Rectifiers (1)

Explanation 1 Bracket
6 Hexagon nut M6
3 Pan head screw M5
7 Shoulder washer
4 Washer
8 Spring washer B5
5 Spring washer B6

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Fig. 9

2.3

Mouinting bracket for FPRA Flexi Power Rectifiers (2)

Grounding point locations

Near to the front there are two external grounding studs M5x12 at the bottom of the
cabinet equipped with toothed look washer, washer, spring washer and hexagon nut.
2.4

Finish and colour

All aluminium surfaces are colourless chromated.

All steel surfaces are galvanised.
The finish for the external panels is a powder coated RAL 7035 light-grey medium
textured. The door fastener (T-Handle) is of black colour.
2.5

Materials List

Table 3

General materials list outdoor cabinet without equipment

Material
Aluminium sheet metal

Standard
AlMg3 cr, thickness 2mm

Steel sheet metal

DX51D + Z140 M-B-C

2mm (galvanised)
cellular foam

IP gasket
PA, V0 acc. UL94

Knrr part no. 1_998_119_0 issue b

Part
all panels, brackets for
fixing the FPRA Flexi
Power Rectifiers
plinth, wall mounting
brackets
at door
cable glands, Stopping
Plugs
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2.6

Keys and external screws

The door lock is of a T-Handle with a black zinc die-casting housing and is keyed
alike DIRAK 1333. Knrr supplies two keys for this.
The provision for stackability are closed with Torx T25 screws. The cable glands are
removable with a open spanner SW24, the Stopping Plugs at the top of the cabinet
with a screwdriver and the same open spanner.
2.7

Environmental conditions

The enclosure fulfils the requirements of EN 60529/IEC 529 IPX4 Splashing

Water test.

The enclosure fulfils the requirements of EN 60529/IEC 529 IP4X protected

against Object size >1mm.

2.8

Tools required for installation and service (w/o electrical tools)

Table 4

Tools for installation and maintenance

Item Tool
1
Screw driver
2
3
4
5
6

Part number
Standard
tool
Screw driver with hexagon
Standard
head 8
tool
Screw driver with hexagon
Standard
head 13
tool
Screw driver with Torx head Standard
T25
tool
Screw driver with Torx head Standard
T30
tool
Open Spanner SW24
Standard
tool
Open Spanner SW8
Standard
tool

Knrr part no. 1_998_119_0 issue b

Used for
loosen the Stopping Plugs at the
top for stacking
fixing the bracket for FPRA Flexi
Power Rectifiers
fixing the cabinet at the plinth and
wall mounting brackets
fixing the FPRA Flexi Power
Rectifiers
fixing the stacked cabinet
loosen and fixing the cable glands
at the bottom for stacking
loosen and fixing the grounding
connection

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1
2
3
4
5

6
Fig. 10

Tools required for installation and service

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3.

Installation site requirements

3.1

Packaging and fittings for transportation

The battery box is to be suitably protected during transportation using a cardboard

box. Ten boxes are fixed onto a wooden pallet with an additional cardboard box
overall and PE straps.
This is the standard packing material for all transportation within Europe.
3.2

Site requirements and pre-requisites.

The Battery Box has two holes at the right and left side of the bottom with diamm. of
10mm for installation at the wall mounting brackets or plinth using the M8 bolts.
The preparation of the installation sites is depending on
local laws, rules and guidelines.
The preparation of the installation sites, the installation
of the batteries and the installation of the Battery Box
itself is not part of the delivery scope of Knrr. Also
Knrr is not responsible for a correct installation of the
Battery Box.
Please contact the responsible authorities to get the
installation conditions.
Plinth installation
The prepared base should be flat and level.
Adequate clearance should be available to the front so that the door may be fully
opened.
The minimum clearance required to the front is 700 mm. Only front access is
required.
A minimum clearance of 15mm is required to the rear side to avoid air flow
restrictions.
The recommended floor space, and to allow the door to open to its maximum angle
of 120, is wide 1,000 mm by deep 1,500 mm.
The installation can be done both on metal frames and concrete pedestals.

F
Knrr part no. 1_998_119_0 issue b

It is recommended to install a sun shade if the battery box is

placed at direct sun shine.

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Wall installation
The prepared wall should be perpendicular and level.
Adequate clearance should be available to the front so that the door may be fully
opened.
The minimum clearance required to the front is 700 mm. Only front access is
required.
The recommended floor space, and to allow the door to open to its maximum angle
of 120, is wide 1,000 mm by high 0,500 mm.
The mounting material, the way of mounting the brackets and the wall itself must be
suitable to bear the weight of the battery box plus batteries and additional equipment.

Knrr part no. 1_998_119_0 issue b

It is recommended to install a sun shade if the battery box is

placed at direct sun shine.

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4.

Installation

Before starting remove the cardboard boxes of the cabinet and the brackets or plinth.
4.1

Plinth installation

Footprint
The footprint is externally wide 685 mm by deep 632 mm.
Four holes with diameter 8 mm for anchor studs up to M8 are available for the fixing
of the plinth to the base, e.g. concrete pad or metal frame.
The installation fixing position is wide 635 mm by deep 300 mm.

Fig. 11 Plinth with footprint and base fixing dimensions

Be sure that the removable plinth trim is in front direction.

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Installation
A Fit and tighten the plinth onto the base using the defined mounting hardware
e.g. nuts, bolts (mounting hardware are not in the scope of supply by Knrr)
B Install the cable grommets acc. Fig. 12.
C Adjust the cabinet onto the plinth (Fig. 12).

Fig. 12 Adjusting the Batterie Box

D Use the four M8 nuts and spring washers (part of delivery scope) to fix the
cabinet onto the plinth (Fig. 13, torque max. 7Nm).

Fig. 13 Fixing the cabinet at the plinth

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4.2

Wall Installation

Footprint
The footprint is externally wide 685 mm by high 452 mm.
Four holes with diameter 8,4 mm for anchor studs up to M8 are available for the
fixing of the brackets to the wall.
The installation fixing position is wide 635 mm by high 400 mm.

Fig. 14 Wall mounting brackets with footprint and fixing dimensions

Installation
A Fit the brackets onto the wall using the defined mounting hardware e.g. nuts,
bolts (mounting hardware are not in the scope of supply by Knrr)
B Install the cable grommets acc. Fig. 15.
C Adjust the cabinet onto the brackets (Fig. 15).

Fig. 15

Adjusting the Batterie Box

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D Use the four M8 nuts and spring washers (part of delivery scope) to fix the
cabinet onto the Wall mounting bracket (Fig. 13, torque max. 7Nm).
4.3

Stacking

Just in case of floor installation it is possible to stack 2

cabinets on each other using one plinth. Don
t stack
cabinets in case of wall mounting. Be sure that no bracket
for fixing the FPRA Flexi Power Rectifiers is installed.

A Install the plinth and first cabinet acc. to chapter 4.1

B Remove the Stopping Plugs at the top and the M8 Torx screws at the top of the
plinth mounted cabinet.

Fig. 16 Removed stopping plug and Torx screws

C Remove the cable glands at the bottom of the cabinet which has to be stacked
(Fig. 17)

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Fig. 17 Removed cable glands at the bottom

D Adjust both cabinets on each other.

E Use the M8 screws from the lower box to fix both cabinets (torque max. 7Nm)
F Stuck the cable glands through the stacked cabinets with head to the top and
screw them with the locknut from down below together.

4.4

FPRA Flexi Power Rectifiers

The mechenical and electrical installation of the FPRA Flexi
Power Rectifiers is not part of the delivery scope of Knrr.
Also Knrr is not responsible for a correct mechenical and
electrical installation of the FPRA Flexi Power Rectifiers .
Please contact the responsible authorities to get the
installation conditions.

The Battery Box is prepared for mounting FPRA Flexi Power Rectifiers at the top of
the cabinet. Acc. to the following please assemble the mounting brackets and the
FPRA Flexi Power Rectifiers.

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A Adjust the bracket at the top of the cabinets acc. Fig. 18.

Fig. 18 Mounted bracket fot FPRA Flexi Power Rectifiers

B Fix the brackets with 4 hexogon nuts, spring washer and washer (torque max.
7Nm, Fig. 19)

Fig. 19 Fix the hexagon nuts

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C Locate the FPRA Flexi Power Rectifiers at the top of the battery box by using
the rear case slots of the FPRA Flexi Power Rectifiers and the shoulder washers
(Fig. 20).

Fig. 20 Use the rear case slots and shoulder washers for pre-positioning

D Acc. Fig. 21 push the front of the FPRA Flexi Power Rectifiers down (1) and all
together to the rear (2)

Fig. 21 Positioning the FPRA Flexi Power Rectifiers

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E Fix the FPRA Flexi Power Rectifiers with 2 Torx head screws and spring washer

Fig. 22 Fixing the FPRA Flexi Power Rectifiers

Independent of wall or plinth installation of the Battery Box

please do not install more then 4 FPRA Flexi Power
Rectifiers on each other at the top of the Battery Box.

4.5

Cable entry

The cable entry on the bottom at the left and right hand side is prepared with cable
glands for the penetration of cables with diameters between 6 and 12mm.
A Loosen the plug of the cable gland

B Pull out the inlet in the cable gland. Push the plug over the cable through the
cable gland and fit the cable into the inlet
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