1. Pre-Installation Preparation Phase

1.1 Technical Preparation

• Technical Disclosure: Organize construction teams, supervisors, and technical personnel to conduct technical disclosure, clarify installation drawings, process requirements, safety norms, and acceptance standards. Focus on key links such as power distribution topology, battery connection, and grounding system design, and answer questions from construction personnel.

• Standard Familiarization: All construction personnel must be proficient in relevant national and industry standards, including environmental requirements for equipment installation, wiring specifications, insulation performance indicators, and grounding resistance standards.

• Scheme Formulation: Formulate a detailed construction plan and emergency plan, including construction schedule, personnel allocation, tool preparation, and accident handling measures (such as power outage, short circuit, and battery leakage).

1.2 On-Site Preparation

• On-Site Survey: Confirm the installation location, space size, and environmental conditions (temperature, humidity, dust, and vibration) of the power supply system. The indoor installation environment shall meet: temperature 15-30℃, relative humidity 40%-70%, no corrosive gas, and vibration acceleration ≤0.5g; outdoor power cabinets shall be installed in well-drained, wind-shielded, and lightning-protected areas.

• Infrastructure Inspection: Check the installation foundation (concrete platform, steel bracket) for flatness, load-bearing capacity, and corrosion resistance. The flatness error of the foundation shall not exceed 2mm/m, and the load-bearing capacity shall be ≥1.2 times the total weight of the equipment.

• Power and Auxiliary Preparation: Confirm the availability of temporary construction power (consistent with the rated voltage of construction tools) and prepare auxiliary facilities such as ventilation, lighting, and fire-fighting equipment. For outdoor installations, prepare waterproof, dustproof, and anti-theft accessories in advance.

1.3 Equipment and Material Preparation

• Equipment Inspection: Check the appearance of rectifier modules, storage batteries, power distribution cabinets, and monitoring devices for damage, deformation, or missing parts. Verify that the model, specification, and technical parameters of the equipment are consistent with the design requirements. Conduct pre-installation power-on testing for key components (such as rectifier modules) to ensure normal operation.

• Material Inspection: Check the quality of wires, cables, connectors, fuses, and grounding materials. Wires and cables shall have 3C certification, and their cross-sectional area shall meet the current-carrying capacity requirements; connectors shall be corrosion-resistant and have reliable contact performance; grounding materials shall be made of hot-dip galvanized steel or copper to ensure conductivity.

• Tool Preparation: Prepare professional tools, including torque wrenches, wire strippers, crimping tools, multimeter, insulation resistance tester, grounding resistance tester, and hoisting equipment. All tools must be calibrated and meet measurement accuracy requirements.

2. Core On-Site Installation Process

2.1 Foundation Fixing and Equipment Installation

1. Foundation Fixing: Install expansion bolts or anchor bolts on the prefabricated foundation according to the installation holes of the equipment. The bolt specification shall match the equipment weight, and the tightening torque shall comply with the manufacturer's requirements (generally 40-60N·m for M12 bolts). After fixing, check the equipment levelness and verticality with a level meter, and adjust if necessary.

2. Power Distribution Cabinet Installation: Hoist or move the power distribution cabinet to the fixed position, align with the foundation bolts, and fasten with nuts. The verticality error of the cabinet shall not exceed 1.5mm/m, and the distance between multiple cabinets shall be 50-100mm to facilitate heat dissipation and maintenance. Install waterproof covers and dustproof gaskets for outdoor cabinets to ensure IP54 or higher protection level.

3. Rectifier Module Installation: Insert the rectifier module into the slot of the power distribution cabinet in sequence, ensuring that the module is tightly connected to the backplane connector. The installation gap between modules shall be ≥5mm to avoid overheating due to poor heat dissipation. After installation, manually push and pull the module to confirm that it is firmly fixed without loosening.

4. Battery Installation: Install the battery pack in the battery cabinet or dedicated area, with the positive and negative poles arranged in accordance with the design drawing. The spacing between battery cells shall be 10-15mm to facilitate heat dissipation and inspection. Connect the battery strings with copper bars or cables, and apply anti-corrosion grease to the connection points to prevent oxidation. The battery cabinet shall be grounded reliably, and the installation location shall be away from heat sources and direct sunlight.

5. Monitoring System Installation: Install the monitoring host, sensors (temperature, voltage, current), and communication modules in the designated position. Ensure that the monitoring host is placed in a well-ventilated area with easy operation, and the sensors are installed at key positions (such as battery compartment, rectifier area) to ensure accurate data collection.

2.2 Wiring Construction

1. AC Wiring: Connect the input AC power (three-phase four-wire or single-phase two-wire) to the AC distribution unit of the power cabinet. The wire cross-sectional area shall be selected according to the rated current (e.g., 16mm² copper wire for 50A current). The wiring shall be neat, with no tension on the wires, and the bending radius of cables shall be ≥10 times the cable diameter. Install fuses or circuit breakers at the input end, with the rated current 1.2-1.5 times the maximum operating current.

2. DC Wiring: Connect the output of the rectifier module to the DC distribution unit, and then connect the DC distribution unit to the battery pack and load. The positive and negative wires shall be distinguished by color (red for positive, black for negative) and marked clearly. The connection points shall be crimped or bolted firmly, and the torque shall be controlled within the range specified by the manufacturer (generally 15-25N·m for copper bar connections). Avoid parallel connection of multiple small cross-sectional area wires; instead, use a single wire with sufficient cross-sectional area.

3. Grounding Wiring: Construct a unified grounding system, including working ground, protective ground, and lightning protection ground. The grounding wire shall be made of copper wire with cross-sectional area ≥16mm² (indoor) or ≥25mm² (outdoor). The grounding resistance of the communication power supply system shall not exceed 4Ω (base stations) or 1Ω (data centers). The grounding connection points shall be clean and free of rust, and the connection shall be reliable without virtual connection.

4. Communication Wiring: Connect the monitoring host to the rectifier module, battery management system (BMS), and upper monitoring platform using shielded cables. The shielding layer shall be grounded at one end to avoid interference. The wiring shall be separated from AC/DC power cables by ≥30cm to prevent electromagnetic interference, and cross-connection shall be avoided; if unavoidable, cross at 90°.

5. Marking: Attach clear marks to all wires, connectors, and equipment, indicating the source, destination, and specification. The marks shall be wear-resistant, waterproof, and easy to identify, facilitating subsequent maintenance and troubleshooting.

2.3 System Debugging

1. Insulation Performance Test: Use an insulation resistance tester (500V) to test the insulation resistance between AC input, DC output, and ground. The insulation resistance shall be ≥2MΩ; if it is lower than the standard, check for wire insulation damage or water ingress and eliminate faults.

2. Power-On Debugging: First connect the AC input power, start the rectifier module, and check whether the output voltage, current, and frequency of the module are within the rated range (DC output voltage deviation ≤±1%). Then connect the battery pack, check the charging current and voltage of the battery, and ensure that the rectifier module can automatically switch between constant current and constant voltage charging modes.

3. Protection Function Test: Test the overvoltage, undervoltage, overcurrent, short circuit, and overtemperature protection functions of the system. For example, simulate a DC output short circuit to check whether the system can quickly cut off the power supply; adjust the AC input voltage to test the overvoltage/undervoltage protection response. All protection functions shall be sensitive and reliable.

4. Monitoring System Debugging: Test the data collection accuracy of the monitoring system, including battery voltage, current, temperature, rectifier module operating status, and load power. Check whether the remote monitoring, fault alarm, and parameter adjustment functions are normal. Ensure that the monitoring data is consistent with the actual value, and the fault alarm is timely and accurate.

5. Load Test: Connect the actual communication load or simulated load, and test the system's load-bearing capacity and stability under rated load and 110% overload conditions. The system shall operate stably, with no abnormal heating, noise, or voltage fluctuation.

3. Key Technical Standards and Quality Control

3.1 Equipment Installation Standards

• The levelness error of power distribution cabinets, battery cabinets, and other equipment shall not exceed 1.5mm/m, and the verticality error shall not exceed 2mm/m.

• The installation of rectifier modules shall be tight and firm, with no loose or virtual connection; the heat dissipation vents shall be unobstructed, and the ambient temperature around the module shall not exceed 40℃.

• Battery installation shall comply with the manufacturer's requirements, with consistent polarity, reliable connection, and no electrolyte leakage; the battery surface shall be clean and dry.

• Outdoor power supply cabinets shall be installed with a slope of 3°-5° to the outside to prevent rainwater accumulation, and the waterproof seal shall be intact.

3.2 Wiring Technical Standards

• The cross-sectional area of wires and cables shall meet the current-carrying capacity and voltage drop requirements: the voltage drop of DC cables shall not exceed 3% of the rated voltage, and the voltage drop of AC cables shall not exceed 5%.

• All connection points shall be crimped or bolted firmly, with the torque meeting the specification requirements; after crimping, the wire shall not be pulled out easily.

• The grounding system shall be unified and reliable, with no series connection of grounding wires; the grounding resistance shall meet the industry specification requirements, and regular inspection shall be conducted.

• Shielded cables shall be used for communication wiring, and the shielding layer shall be grounded at one end to avoid ground loop interference.

3.3 Performance Index Standards

• The output voltage accuracy of the rectifier module shall be ±1%, the current stability shall be ±5%, and the ripple coefficient shall be ≤0.5%.

• The battery charging and discharging parameters shall comply with the manufacturer's requirements, and the floating charge voltage of lead-acid batteries shall be 2.25-2.30V per cell.

• The system protection functions (overvoltage, undervoltage, overcurrent, etc.) shall be sensitive and reliable, with the response time ≤10ms for short circuit protection.

• The monitoring system shall have a data collection accuracy of ±1% for voltage and current, and the fault alarm rate shall be 100%.

4. Acceptance and Trial Operation

4.1 On-Site Acceptance

4.2 Trial Operation

5. Safety Precautions

• During construction, strictly implement power outage operation procedures, hang "No Power On" warning signs, and send special personnel to supervise to avoid electric shock accidents.

• When installing and connecting batteries, wear insulating gloves and goggles to prevent electrolyte leakage and corrosion; avoid short circuit of battery poles.

• Hoisting equipment shall be operated by professionals, and the hoisting process shall be stable to avoid equipment collision and damage.

• Fire-fighting equipment shall be prepared on-site, and smoking and open flames are prohibited to prevent fire accidents caused by electrical short circuits.

• After the construction is completed, clean the on-site environment, remove construction waste, and ensure that the equipment and surrounding area are clean and tidy.

Conclusion