Lucent Technologies ED-83241-30 Product Manual Download Page 6

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Lucent Technologies Lineage

2000 Battery Management System ED-83241-30

Issue 5 March 1997

List of Tables - 1

List of Tables

Table 2-A: Battery Management System (CP5)

Specifications

2 - 1

Table 3-A: P400 Connections to CP3 Datalogger

Option

3 - 11

Table 3-B: SW100 Settings

3 - 20

Table 3-C: SW101 Settings

3 - 23

Table 3-D: SW102 Settings

3 - 23

Table 3-E: Alarm Relay Contacts

3 - 25

Table 4-A: DIP Switch Presets

4 - 2

Summary of Contents for ED-83241-30

Page 1: ... Lucent Technologies Lineage 2000 Battery Management System Notice Every effort was made to ensure that the information in this document was complete and accurate at the time of printing However information is subject to change Lucent Technologies 1997 All Rights Reserved Printed in U S A ...

Page 2: ...urope Middle East and Africa 1 2 Asia Pacific Region 1 3 Customer Service 1 3 2 Product Description Battery Management System CP5 Specifications 2 1 Feature Summary 2 2 Faceplate Feature Summary 2 3 Battery Management System Overview 2 7 Temperature Compensation 2 7 Recharge Current Compensation 2 7 String Voltage Unbalance 2 7 3 Installation Battery Management System Retrofit Installation 3 1 Too...

Page 3: ...tional Kits 3 26 Installing Battery Cable Sets 3 26 Installing CP1 or CP3 Cable Sets 3 27 DIP Switch Configuration 3 28 Verify System Operation 3 28 Alarm Relay Wiring 3 28 4 Setup DIP Switch Settings 4 1 Default DIP Switch Settings 4 2 Other Considerations 4 2 5 Operations Remote Access Signals 5 1 Battery Parameters 5 1 Alarm Signals 5 2 Datalogger Analog Channel Configuration 5 3 Highest Batter...

Page 4: ...3 5 Figure 3 4 Cable Mounting Bracket 3 5 Figure 3 5 Temperature Sensor Assemblies 3 5 Figure 3 6 Hall effect Current Sensor 3 6 Figure 3 7 Label 846919769 3 6 Figure 3 8 Extension Cable 847018314 3 6 Figure 3 9 CP3 Cable 847018280 3 6 Figure 3 10 Cable Bracket Positioning and Cable Routing 3 12 Figure 3 11 Bracket Cable Set Mounting 3 13 Figure 3 12 Sensor Placement and Wire Routing 3 14 Figure 3...

Page 5: ...res Issue 5 March 1997 Figure 3 17 BDW1 Circuit Pack Cover 3 22 Figure 4 1 Battery Management System Temperature Compensation Function 4 4 Figure 4 2 Control Relay Schematics For Closure On Alarm Type System 4 5 Figure 4 3 Control Relay Schematics For Open On Alarm Type System 4 6 ...

Page 6: ... Tables 1 List of Tables Table 2 A Battery Management System CP5 Specifications 2 1 Table 3 A P400 Connections to CP3 Datalogger Option 3 11 Table 3 B SW100 Settings 3 20 Table 3 C SW101 Settings 3 23 Table 3 D SW102 Settings 3 23 Table 3 E Alarm Relay Contacts 3 25 Table 4 A DIP Switch Presets 4 2 ...

Page 7: ...feature adds continuous battery monitoring and control functions to the Lucent Technologies Lineage 2000 J85500D ECS battery plant to maintain valve regulated lead acid batteries at their optimal conditions When combined with the remote access capabilities of the Lineage 2000 ECS Controller the Battery Management System enables the user to have access to important battery parameters without travel...

Page 8: ...l support contact your local Field Support Regional Technical Assistance Center or contact your sales representative who will be happy to discuss your specific needs Asia Pacific Region If you need product technical support contact your local Field Support Regional Technical Assistance Center or contact your sales representative who will be happy to discuss your specific needs Product Repair and R...

Page 9: ...discuss your individual situation Customer Service For customer service any other product or service information or for additional copies of this manual or other Lucent Technologies documents call 1 800 THE 1PWR 1 800 843 1797 Specify the select code number for manuals or drawing number for drawings Contact your regional customer service organization or sales representative for information regardi...

Page 10: ...3962 m For altitudes of 5000 to 13 000 ft 1524 to 3962 m reduce the maximum ambient temperature 3 6 F 2 C for every 1000 ft Humidity 10 95 noncondensing Electrostatic Discharge IEC 801 2 Levels 2 4 14 kV 15 kV at 40 relative humidity Radiated Emission FCC Level A Electromagnetic Immunity 10 V m over a range of 20 to 1000 MHz Alarm Contacts Four sets of Form C contacts one for each system alarm 500...

Page 11: ...F 20 55 C Temperature Measurement Accuracy 3 6 F 2 C from 68 131 F 20 55 C 5 4 F 3 C from 32 158 F 0 70 C Voltage Sensors One set per battery string that measures the voltage in two groups Voltage Measurement Accuracy 0 5 Current Sensors One per battery string Hall effect device with a gain of 33 3 mV A RechargeCurrentCompensation Settings 12 5A 100A in 12 5A increments Current Measurement Accurac...

Page 12: ... operation of the system All external cables meet or exceed the requirements of UL NEC and Bellcore for control signal wiring Connectorized sensor package provides maximum flexibility in cable routing and minimizes installation time Faceplate Feature Summary The faceplate of the Battery Management System provides a visual indication of basic system operation see Figure 2 1 The green visual indicat...

Page 13: ... batteries exceeds the user selectable threshold causing the plant voltage to decrease below its nominal value A group of four yellow visual indicators labeled BATTERY STATUS lights under the following conditions TEMP BAT 1 lights when the temperature of battery string one is the highest and has exceeded the lower temperature threshold TEMP BAT 2 lights when the temperature of battery string two i...

Page 14: ...gies Lineage 2000 Battery Management System ED 83241 30 Issue 5 March 1997 Product Description 2 5 Figure 2 1 Battery Management System Faceplate Figure 2 2 Battery Management System Temperature Compensation Function ...

Page 15: ...Lucent Technologies Lineage 2000 Battery Management System ED 83241 30 2 6 Product Description Issue 5 March 1997 Figure 2 3 Battery Management System Recharge Current Compensation Function ...

Page 16: ...nd T2 MJT Major Temperature Alarm at T2 T1 MNT and T2 MJT are user selectable levels set via DIP switches on the back of the Battery Management System circuit pack see Section 3 Recharge Current Compensation The recharge current compensation function adjusts battery float voltage as a function of the highest monitored recharge current This reduces peak charge currents and heat and gas evolution in...

Page 17: ... 30 2 8 Product Description Issue 5 March 1997 per cell voltage in each half string thus accommodating 23 or 24 cell plants The Battery Management System alerts the user with a Minor Voltage Alarm when the difference between the two halves of the string exceeds 0 25 V ...

Page 18: ...illips screwdriver Socket set Inspect Contents Open the shipping container and inspect the contents for damage Contents ED 83241 30 GK1 Battery Management System distribution door circuit pack and cover Figure 3 1 Battery Cable Sets 4 Figure 3 2 CP1 Cable Set Figure 3 3 Cable Ties 7 Cable Mounting Bracket Figure 3 4 Temperature Sensor Assemblies 2 Figure 3 5 Hall effect Current Sensor Figure 3 6 T...

Page 19: ... 83241 30 GK2 Battery Cable Sets 4 Figure 3 2 Cable Ties 6 Cable Mounting Bracket Figure 3 4 Temperature Sensor Assemblies 2 Figure 3 5 Hall effect Current Sensor Figure 3 6 Tape Velcro 4 Contents ED 83241 30 GK3 Extension Cable Figure 3 8 Contents ED 83241 30 GK4 CP3 Cable Figure 3 9 Cable Ties 6 Terminals for connection to remote termination unit ...

Page 20: ...Lucent Technologies Lineage 2000 Battery Management System ED 83241 30 Issue 5 March 1997 Installation 3 3 Figure 3 1 Battery Management System Lucent ...

Page 21: ...Lucent Technologies Lineage 2000 Battery Management System ED 83241 30 3 4 Installation Issue 5 March 1997 Figure 3 2 Battery Cable Sets ...

Page 22: ...cent Technologies Lineage 2000 Battery Management System ED 83241 30 Issue 5 March 1997 Installation 3 5 Figure 3 3 CP1 Cable Set Figure 3 4 Cable Mounting Bracket Figure 3 5 Temperature Sensor Assemblies ...

Page 23: ... Lineage 2000 Battery Management System ED 83241 30 3 6 Installation Issue 5 March 1997 Figure 3 6 Hall effect Current Sensor Figure 3 7 Label 846919769 Figure 3 8 Extension Cable 847018314 Figure 3 9 CP3 Cable 847018280 ...

Page 24: ...en on continuous uninterrupted float for at least one month 6 Repeat steps 1 5 for all battery strings 7 If controller is equipped with a CP2 Microprocessor Circuit pack verify the integrity of the lithium battery Measure voltage across the battery New cells should be approximately 3 1 to 3 2 volts Low cell conditions are 2 6 volts 0 25 volts Low battery conditions may result in the loss of CP2 s ...

Page 25: ...e corresponding circuit breaker positions Or the old circuit breaker panels can be removed from the original distribution door and installed in place of the panels in the new door 3 Verify that the ENABLE DISABLE switch is disabled 4 Install the Battery Management System assembly on the three studs the original door assembly was installed on using the original nuts and washers 5 Reconnect LVD cabl...

Page 26: ...t bracket cable set in appropriate cutouts on cable bracket Figure 3 11 3 Attach board cable set to bracket cable set Figure 3 11 and route up towards cable tray Figure 3 10 down through the top of the plant and towards P200 P201 if installing second battery string 4 If extension cable is necessary insert between bracket and board cable sets 5 Repeat Steps 1 through 5 for second battery string if ...

Page 27: ... to RMJ TB101 4 on CP1 See ECS 6 Controller Product Manual 167 790 031 Section 3 3 1 for proper connection technique Installing CP3 Cable Set 1 If CP3 is present do not install the CP1 cable set 2 Place CP3 cable set near P400 on CP5 but do not connect to CP5 at this time Route as shown in Figure 3 10 3 Connect the opposite end to unused analog channels on CP3 See Section 3 of ECS Controller Optio...

Page 28: ...3 TB301 4 TB101 3 TB101 4 3 Battery String One Current Return Red White Green White TB301 5 TB301 6 TB101 5 TB101 6 4 Battery String Two Current Return Blue White Black Red TB301 7 TB301 8 TB101 7 TB101 8 5 Battery Management Fail Alarm Return Orange Blue TB302 1 TB302 2 TB101 9 TB101 10 6 Minor Voltage Alarm Return White Black Red Black TB302 3 TB302 4 TB101 11 TB101 12 7 Minor Temperature Alarm ...

Page 29: ...12 Installation Issue 5 March 1997 Figure 3 10 Cable Bracket Positioning and Cable Routing Lucent Lucent Cable Tray General Path of Battery Cables Path of CP1 Cable General Path of Battery Cable Cable Bracket Mounting Position One String VR Series Batteries Path of CP3 Cable ...

Page 30: ...Lucent Technologies Lineage 2000 Battery Management System ED 83241 30 Issue 5 March 1997 Installation 3 13 Figure 3 11 Bracket Cable Set Mounting ...

Page 31: ...Lucent Technologies Lineage 2000 Battery Management System ED 83241 30 3 14 Installation Issue 5 March 1997 Figure 3 12 Sensor Placement and Wire Routing ...

Page 32: ... Battery Bus Plant Battery Bus Terminal Plate 6 7 18 19 5 8 17 20 4 9 16 21 3 10 15 22 2 11 14 23 1 12 13 24 Shelf 1 Shelf 2 Shelf 3 Shelf 4 V2 V3 V4 V5 V1 V1 Voltage Probe Attached to Cell 24 V2 Voltage Probe Attached to Cell 18 V3 Voltage Probe Attached to Cell 12 V4 Voltage Probe Attached to Cell 6 V5 Voltage Probe Attached to Cell 1 Current Sensor 2GA 2GA 4 0 4 0 ...

Page 33: ...ogies Lineage 2000 Battery Management System ED 83241 30 3 16 Installation Issue 5 March 1997 Figure 3 14 Battery Post Connection for Voltage Probe Figure 3 15 Battery Post Connection Vertical Inter Cell Strap Lucent ...

Page 34: ...tationary battery string making the following connections Automotive battery string to plant battery bus Automotive battery string to plant battery bus 3 Follow the instructions in paragraph Installing Battery Management System Sensors on a Two Battery String Plant One Battery Available If only one 12 volt automotive battery is available use it to bypass each shelf of the stationary battery string...

Page 35: ... is located see Figure 3 15 6 Slide the Hall effect current sensor CS onto the 2 AWG wire coming off the negative battery post of cell 23 or 24 depending on the configuration Be sure the arrow marked on the Hall effect sensor is pointing away from the negative post Figure 3 16 7 Connect the automotive battery across Shelf 2 as follows Automotive battery to Cell 19 Automotive battery to Cell 13 8 P...

Page 36: ...n lb insert the two temperature sensors between battery cells 15 16 and 9 10 Thermal grease may be used to ease insertion 14 Attach both the temperature sensors and Hall effect sensor to their appropriate connectors on the volt temp sensor cable set and the current sensor cable set respectively Installing Battery Management System Sensors on a Two Battery String Plant When at least two battery str...

Page 37: ...ertion 6 Attach both the temperature sensors and Hall effect sensor to their appropriate connectors on the volt temp sensor cable set and the current sensor cable set respectively 7 Repeat for second battery string DIP Switch Configuration 1 Refer to Section 4 for help in determining proper DIP switch settings for your particular application 2 Use DIP switch SW100 1 2 to select T1 Use DIP switch S...

Page 38: ...Lucent Technologies Lineage 2000 Battery Management System ED 83241 30 Issue 5 March 1997 Installation 3 21 Figure 3 16 Installing Hall effect Current Sensor ...

Page 39: ...Lucent Technologies Lineage 2000 Battery Management System ED 83241 30 3 22 Installation Issue 5 March 1997 Figure 3 17 BDW1 Circuit Pack Cover ...

Page 40: ...d Disabled Verify System Operation 1 Connect board cable set s to P200 and P201 if two strings present on CP5 2 Connect CP3 cable set to P400 on CP5 3 Activate Battery Management System by moving switch SW700 to the enable position 4 Confirm that the green system on LED is illuminated and no alarm conditions exist Table 3 C SW101 Settings MNT Setpoint 23 24 Cell Select F C Display Select C F 1 2 3...

Page 41: ... The terminal block is a separable connector that accepts the stripped end of a wire in a screw clamp type connection Maximum wire size should be 18 AWG wire Strip ends 3 8 inch To ease connection remove the terminal block from the circuit board by pulling down After making connections simply plug back onto the board This is only to ease connections connections may also be made with the terminal b...

Page 42: ...blade screwdriver Small Phillips screwdriver Socket set Check List The Battery Management System circuit pack and cover reside on the distribution door which is factory mounted at the top of the battery plant The following is a list of additional cabling and hardware that should have been shipped with the battery plant in order to properly install the Battery Management System Table 3 E Alarm Rela...

Page 43: ...beginning of Section 3 Open the packaging carefully to verify that the contents are complete and undamaged Installing Battery Cable Sets 1 While mounting the batteries in the battery stand be aware that the battery temperature sensors are to be installed between batteries 9 10 and 15 16 as shown in Figure 3 12 Try to leave a small gap between these battery cells in order to ease temperature sensor...

Page 44: ...wire coming off the negative battery post of cell 23 or 24 depending on the configuration see Figure 3 15 Be sure the arrow marked on the Hall effect sensor is pointing away from the negative battery post see Figure 3 16 10 After torquing the battery post nuts to 60 in lb insert the two temperature sensors between battery cells 9 10 and 15 16 Thermal grease may be used to ease insertion see Figure...

Page 45: ...ue 5 March 1997 DIP Switch Configuration Follow procedure in previous paragraph DIP Switch Configuration Verify System Operation Follow procedure in previous paragraph Verify System Operation Alarm Relay Wiring Follow procedure in previous paragraph Battery Management System Alarm Relay Wiring ...

Page 46: ... each switch is defined below SW100 Positions 1 and 2 select the T1 setpoint The values range from 20 C to 35 C in 5 C increments Positions 3 and 4 select the T2 and MJT setpoint The values range from 40 C to 55 C in 5 C increments SW101 Positions 1 and 2 select the MNT Minor Temperature Alarm setpoint The values range from 30 C to 45 C in 5 C increments Position 3 provides compatibility with eith...

Page 47: ...be issued Figure 4 1 This control algorithm is shown by the curve labeled PRESET in Figure 4 1 The temperature displayed on the LCD meter will read in degrees Fahrenheit This temperature control function is recommended for the Lucent Technologies VR Series battery to maximize the battery s life and performance when used in a controlled environment If the battery plant is being used in a different ...

Page 48: ...by raising the preset T1 setpoint T1b and lowering the preset T2 setpoint T2b as shown in Figure 4 1 If the battery plant is located in an environment where the ambient temperature will exceed the preset T1a setpoint for long periods of time it may be necessary to raise the T1 setpoint T1b to ensure that the battery is maintained in a fully charged state In order to reduce the probability of nuisa...

Page 49: ...Lucent Technologies Lineage 2000 Battery Management System ED 83241 30 4 4 Setup Issue 5 March 1997 Figure 4 1 Battery Management System Temperature Compensation Function ...

Page 50: ...Lucent Technologies Lineage 2000 Battery Management System ED 83241 30 Issue 5 March 1997 Setup 4 5 Figure 4 2 Control Relay Schematics For Closure On Alarm Type System ...

Page 51: ...Lucent Technologies Lineage 2000 Battery Management System ED 83241 30 4 6 Setup Issue 5 March 1997 Figure 4 3 Control Relay Schematics For Open On Alarm Type System ...

Page 52: ...ent out through a 31 6 kΩ resistor The signal is 0 volts at 0 F and changes at a rate of 10 mV F The front panel Battery Temp Status LEDs indicate which string is the hottest if temperature is above T1 see Figure 2 1 Ambient Temperature Signal This signal is the ambient temperature as measured by a thermistor mounted on the Battery Management System circuit pack The signal is buffered and sent out...

Page 53: ... but there are no temperature probes plugged in 3 The system is enabled and both temperature probes on the same battery string have failed or are reading an out of range temperature Also the Battery Temp status LED corresponding to the battery string with the failed temperature probes will blink at a rate of twice per second 4 The current compensation function is enabled but there are no Hall effe...

Page 54: ...annel must be configured as follows Channel Description Highest Battery Temp Input Type DC Range 6V Scale Factor 100 Transducer Offset None Alarm Threshold An upper or lower user defined threshold may be set to warn the user if the maximum battery temperature is greater less than expected This threshold could be set to a different temperature than the Minor Temperature Alarm Also this threshold co...

Page 55: ... Transducer Offset 0 32 Alarm Threshold An upper or lower user defined threshold may be set to warn the user if the maximum battery temperature is greater less than expected This threshold could be set to a different temperature than the Minor Temperature Alarm Also this threshold could be set to the same temperature as T1 to let the user know when the Battery Management System is actively control...

Page 56: ...one Alarm Threshold An upper or lower user defined threshold may be set to warn the user if the ambient temperature near the battery plant is greater less than expected by taking advantage of the dial out on alarm capability of the ECS Controller The number entered is in degrees Fahrenheit Units Degrees Fahrenheit Channel Description Ambient Temp Input Type DC Range 6V Scale Factor 55 556 Transduc...

Page 57: ...fect sensor to the current sensor cable set and make sure the board cable set is connected to P200 or P201 on CP5 then measure the voltage between pins 2 and 5 Figure 3 16 on the current sensor connector while it is plugged into the Hall effect sensor The voltage and polarity measured will be the number entered in this field For example if the voltage measured is 15 mV the number entered will be 0...

Page 58: ...lay Program Line with the following Assume the following alarms are hard wired into the following analog channels on CP3 any available analog channel may be used BMF A5 MNV A6 MNT A7 MJT A8 If control relay one CR1 is to be used to trigger a Plant Minor Alarm the following information should be in its Program Line Program Line A5 or A6 or A7 Description Minor Battery Alarm into PMN If control rela...

Page 59: ... threshold is commonly set 1 volt below float voltage However the Battery Management System has a control range in the temperature compensation mode of 0 to 2 4 volts This could cause a nuisance BD alarm To alleviate this set the BD alarm threshold below the nominal control range of the Battery Management System For a 24 cell battery string floating at 54 48 volts set the BD alarm at 52 00 volts F...

Page 60: ...e warranties given to Seller by its Vendor of such Vendor Items such assignment to be effective upon Customer s acceptance of such Vendor Items With respect to Vendor items recommended by Seller in its specifications for which the Vendor s warranty cannot be assigned to Customer or if assigned less than Sixty 60 days remain of the Vendor s warranty or warranty period when the Vendor s items are sh...

Page 61: ...ot readily returnable for repair whether or not installed by Seller Seller at its option may repair the cable and Wire Products at Customer s site D If Seller has elected to repair or replace a defective Product Customer shall have the option of removing and reinstalling or having Seller remove and reinstall the defective or nonconforming Product The cost of the removal and the reinstallation shal...

Page 62: ...subcontractors caused by any of the following modifications misuse neglect accident or abuse improper wiring repairing splicing alteration installation storage or maintenance use in a manner not in accordance with Seller s or Vendor s specifications or operating instructions or failure of Customer to apply previously applicable Seller modifications and corrections In addition Seller makes no warra...

Page 63: ...es Lineage 2000 Battery Management System ED 83241 30 Issue 5 March 1997 Appendix A 1 Appendix A Connector Pin Assignments Pin assignments on the Battery Management System circuit pack are given in the following tables ...

Page 64: ...1 Terminal 12V Cell 6 through 31 6K to VRU through P400 17 20 P200 9 Battery String 1 Terminal 0V Cell 1 through 31 6K to VRU through P400 19 P200 10 Temperature Probe Present TPP1 connected to P200 1 when temperature probe plugged in P200 11 Hall Effect Present HPP1 connected to P200 14 12V1 when Hall Effect plugged in P200 12 Battery String 1 Terminal 24V A through 31 6K Cell 12 P200 13 12V1 bia...

Page 65: ...ttery String 2 Terminal 12V Cell 6 through 31 6K to VRU through P400 27 30 P201 9 Battery String 2 Terminal 0V Cell 1 through 31 6K to VRU through P400 29 P201 10 Temperature Probe Present TPP2 connected to P201 1 when temperature probe plugged in P201 11 Hall Effect Present HPP2 connected to P200 14 12V2 when Hall Effect plugged in P201 12 Battery String 2 Terminal 24V A through 31 6K Cell 12 P20...

Page 66: ...1 6K P400 10 Battery Management System Return through 31 6K P400 11 Major Temperature Alarm signal to CP3 VRU Closure to RG through 31 6K P400 12 Battery Management System Return through 31 6K P400 13 Battery String 1 Terminal Voltage to VRU 36V Cell 18 from P200 6 P400 14 Battery String 1 Terminal Voltage to VRU 48V Cell 23 24 from P200 17 P400 15 Battery String 1 Terminal Voltage to VRU 24V Cell...

Page 67: ...26 Battery String 2 Terminal Voltage to VRU 36V Cell 18 from P201 6 P400 27 Battery String 2 Terminal Voltage to VRU 12V Cell 6 from P201 6 P400 28 Battery String 2 Terminal Voltage to VRU 24V Cell 12 from P201 6 P400 29 Battery String 2 Terminal Voltage to VRU 0V Cell 1 from P201 6 P400 30 Battery String 2 Terminal Voltage to VRU 12V Cell 6 from P201 6 P400 31 Battery String 2 Current to CP3 VRU ...

Page 68: ... Minor Temperature Alarm Normally Open Contact TB100 7 Battery Management Failed Minor Alarm Center TB100 8 Battery Management Failed Minor Alarm Normally Closed Contact TB100 9 Battery Management Failed Minor Alarm Normally Open Contact TB100 10 Major Temperature Alarm Center TB100 11 Major Temperature Alarm Normally Closed Contact TB100 12 Major Temperature Alarm Normally Open Contact Major Mino...

Page 69: ...ellow Battery String 1 Voltage Unbalance Indicator BAT 1 VOLT DS201 Yellow Battery String 2 Voltage Unbalance Indicator BAT 2 VOLT DS202 Yellow Minor Voltage Alarm Indicator MNV DS300 Yellow Recharge Current Control Indicator RECHG CUR CONT DS450 Yellow Battery String 1 High Temp Indicator BAT 1 TEMP DS451 Yellow Battery String 2 High Temp Indicator BAT 2 TEMP DS501 Yellow LVD Circuit Failure Indi...

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