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Lucent Technologies Lineage

®

2000 ECS Battery Plant H569-403

2 - 8 Product Description

Issue 4 February 1997

Group 8, with the addition of a remote termination panel
allowing external connection to the board from outside the
controller. (See the ECS controller manual for further
information.)

DC-DC Converter

The Lineage

®

2000 KS23832 24-volt to -48-volt dc-dc converter

system utilizes 50KHz technology to provide a reliable and
economical means of obtaining closely regulated and filtered
-48-volt dc power when only one primary source of +24-volt dc
power is available.

The dc-dc converter system consists of KS23832 converter shelf
assemblies equipped with one or two KS23832 10-ampere
+24-volt to -48-volt converters. A maximum of two shelves with
four converters may be equipped per bay. Group 41 provides a
converter shelf equipped with two converters and Group 42
provides a converter shelf equipped with one converter.
Converters should be sized with n+1 redundancy. This extra
reserve not only provides backup to your operating converter but
also provides the necessary energy required to operate fuses.
Distribution to the -48-volt load is provided via a meter and fuse
panel.

The converter shelf assembly has mounting brackets for
standard 26-inch relay rack mounting. Each converter module
contains a blocking diode, low input voltage shutdown, current
limiting, and high voltage shutdown with automatic restart. The
converter shelf assembly is equipped with major and minor
alarms. The converter shelf assembly has two Form C contacts,
one for converter major and one for converter minor. When one
converter fails, the converter minor relay will operate and when
two converters fail, the converter major relay will operate. For
more details, refer to the KS23832 converter product manual.

DC Distribution

The ECS H569-403 distribution includes the plant charge and
discharge bus bars, plant shunt, LVD/R contactor, and
associated circuitry. Space below these items accommodates
circuit breaker panel for 24-volt distribution. A meter and fuse
panel is also available for 48-volt loads when the plant is
equipped with 24-volt to -48-volt converters. A complete
discussion of the ECS dc distribution is presented in the
following section of this manual.

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Summary of Contents for H569-403

Page 1: ...t Technologies Lineage 2000 600 Ampere 24 Volt ECS Battery Plant 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: ...ral and South America 1 3 Europe Middle East and Africa 1 3 Asia Pacific Region 1 3 Customer Service 1 3 2 Product Description Plant Specifications 2 1 Typical Battery Plant Description 2 3 Battery Plant Subsystems 2 3 ECS Battery Plant Physical Description 2 5 Introduction 2 5 Initial Bay 2 6 ECS Battery Plant Subsystems 2 6 Rectifier 2 6 Batteries 2 7 Controller 2 7 DC DC Converter 2 8 DC Distri...

Page 3: ...ture 3 22 Controller Options 3 22 Alarm System Interface 3 23 Planning 3 23 Floor Plan Data 3 23 Grounding 3 24 Growth 3 24 Ordering Reference Material 3 25 Coding and Terminology 3 25 J drawings 3 26 T drawings 3 30 SD drawings 3 31 Documentation References 3 32 Ordering Information 3 34 4 Installation General 4 1 Installation Tools and Test Equipment 4 1 Suggested Installation Sequence 4 2 Gener...

Page 4: ...rs 5 1 Controller LEDs and Switches 5 1 Rectifier LEDs and Switches 5 1 CP5 Fuse Board LEDs and Fuses 5 1 DC Circuit Breakers Fuses 5 2 Troubleshooting 5 2 Open Distribution Breaker 5 4 Red LVD OPEN LED Lit 5 4 Yellow LVD FAIL LED Lit 5 4 Repair and Replacement 5 5 Load Circuit Breaker or Fuse Replacement 5 5 LVD R Contactor Replacement 5 6 LVD Fuse Board CP5 Replacement 5 7 Spare Parts 5 8 6 Prod...

Page 5: ...Breaker Panel 2 11 Figure 2 4 Group 43 Meter and Fuse Panel 3 Inch Cover Removed 2 11 Figure 2 5 Plant Bus Bars with Optional Group 2 Low Voltage Disconnect 2 12 Figure 2 6 ECS DC Distribution Panel Front View 2 12 Figure 3 1 Bay Dimensions and Clearances 3 36 Figure 3 2 Frame Ground Adapter Assembly 3 37 Figure 3 3 Typical J Drawing A Sheet 3 37 Figure 4 1 Typical Floor Mounting Detail 4 5 Figure...

Page 6: ...rmation 3 6 Table 3 B Anticipated Future Load Drain Information 3 7 Table 3 C Reserve Capacity 3 8 Table 3 D Double Hole Terminal Lugs 3 19 Table 3 E Single Hole Terminal Lugs 3 20 Table 3 F Load Feeder Wire and Fuse Breaker Size 3 21 Table 3 G Minimum Wire Gauge Ampacity All Strings 3 22 Table 3 H Ordering Guide H569 403 ECS 600 Ampere 24 Volt Battery Plant 3 35 Table 4 A Minimum Torque for All E...

Page 7: ...x Lineage 2000 SR Series 24 volt 100 ampere rectifiers and space for four 24 volt to 48 volt 10 ampere dc to dc converters and a fuse panel for 48 volt distribution needs The plant s modular front access design facilitates installation and growth Growth in plant output current capacity is achieved by adding Lineage 2000 100 ampere 24 volt rectifiers to rectifier shelf assemblies Adding functionali...

Page 8: ... unless you hold an extended warranty or contractual agreement Central and South America 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 Europe Middle East and Africa If you need product technical support contact your local Field Support Regional Technic...

Page 9: ... to discuss your individual situation Asia Pacific Region If you need to return a product for repair your sales representative will be happy to 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 numbe...

Page 10: ...Lucent Technologies Lineage 2000 ECS Battery Plant H569 403 1 4 Introduction Issue 4 February 1997 Figure 1 1 Lineage 2000 ECS Battery Plant Model H569 403 Lucent ...

Page 11: ... Vdc nominal Float Voltage 24 29 Vdc 24 Vdc nominal Plant Current Rating 600 amperes Plant Shunt 600 amperes maximum at 50 millivolts LVD R Voltage Settings 20 25 or 21 25 Vdc Controller Basic 113B Microprocessor option circuit pack CP2 Datalogger option circuit pack CP3 Rectifier Shelf Assembly 2 maximum each mounts 3 rectifiers Rectifiers Type Lineage 2000 SR100 24 Rating 24 volts nominal 100 am...

Page 12: ... by 0 656 C per 100 meters above 1524 meters Framework Type 7 foot Central Office Framework standard 26 inch width Vertical mounting centers 1 00 inch 25 mm Horizontal mounting centers 24 32 inches 618 mm Dimensions Height 84 inches 2134 mm Width 26 inches 660 mm Depth 18 0 inches 457 mm Weight Includes 6 rectifiers 450 pounds 204 kilograms Earthquake See Note 1 Heat Dissipation Full load 3254 wat...

Page 13: ...ustrates the arrangement and interconnections of the typical ECS dc battery plant subsystems from the ac input to the dc output These subsystems are defined as follows AC Distribution Connects the commercial and or standby ac power sources to the rectifiers within the plant and provides overcurrent protection This subsystem is usually supplied by the customer Rectifiers Convert an ac source voltag...

Page 14: ...d to administer the battery plant Batteries Provide energy storage for an uninterrupted power feed to the using equipment during loss of ac input or rectifier failure DC Distribution Provides overcurrent protection connection points for the using equipment and bus bars used to interconnect the rectifiers batteries plant shunt and dc distribution Figure 2 1 Block Diagram of Typical Battery Plant ...

Page 15: ...recharge capability for the battery reserve The plant operates from a nominal 208 240 Vac 50 60 Hz source It offers a 600 ampere total plant capacity with a nominal 24 Vdc output The ECS battery plant is compatible with virtually all flooded and valve regulated batteries In addition the ECS plant is capable of operating in a batteryless mode making it suitable for those applications where battery ...

Page 16: ...ECS Battery Plant subsystems from the ac input to the dc output These subsystems are described below Rectifier The Lineage 2000 SR Series rectifiers are designed specifically for applications where small size low weight and ease of installation are of overriding importance The rectifiers utilize a combination of switchmode technology and forced air cooling to achieve a significant reduction in siz...

Page 17: ...pere hour configuration for use in the ECS plant The compact physical dimensions of the VR battery permit the installation of up to 1500 ampere hours of 24 volt battery reserve in a single framework space See the battery product manual for additional information Controller The ECS controller performs the centralized monitoring control and reporting functions for the ECS battery plant In the H569 4...

Page 18: ...perating converter but also provides the necessary energy required to operate fuses Distribution to the 48 volt load is provided via a meter and fuse panel The converter shelf assembly has mounting brackets for standard 26 inch relay rack mounting Each converter module contains a blocking diode low input voltage shutdown current limiting and high voltage shutdown with automatic restart The convert...

Page 19: ...ront cover panel allows easy access to the breakers for connecting load leads or adding circuit breakers When dc dc converters are required the first four mounting positions should be reserved for 45 ampere circuit breakers one for each converter Figure 2 3 shows the circuit breaker panel and Table 2 B describes the circuit breaker options and ordering information Table 2 B H569 403 Group 20 Linea...

Page 20: ...monitor the total current and voltage delivered by the converters Load lead connections to the fuse block and discharge return are front accessible via a removable 3 inch cover panel Figure 2 4 shows the meter and fuse panel and Table 2 C describes the load fuse options Table 2 C H569 403 Group 43 Fuse Options The Group 43 panel contains a fuse block which accommodates 8 load fuses Refer below for...

Page 21: ...es Lineage 2000 ECS Battery Plant H569 403 Issue 4 February 1997 Product Description 2 11 Figure 2 3 Group 20 10 to 100A Circuit Breaker Panel Figure 2 4 Group 43 Meter and Fuse Panel 3 Inch Cover Removed SHUNT A 50 50 ...

Page 22: ...gies Lineage 2000 ECS Battery Plant H569 403 2 12 Product Description Issue 4 February 1997 Figure 2 5 Plant Bus Bars with Optional Group 2 Low Voltage Disconnect Figure 2 6 ECS DC Distribution Panel Front View Lucent ...

Page 23: ...ce of the shunt in milliohms which is thermally stable and accurately known The current shunt in the ECS Battery Plant is connected between the Charge Return Bus and the Discharge Return Bus see Figure 2 6 It is used to measure the total current supplied to the load from the rectifiers and or batteries The shunt has a full scale rating of 50 millivolts at the maximum plant current of 600 amperes T...

Page 24: ...rious alarms are issued to the alarm reporting center See the Lineage 2000 Controller manual for further details The red LVD OPEN and yellow LVD FAIL LEDs are located on the dc distribution panel as shown in Figure 2 6 The red LVD OPEN LED on the CP5 Fuse Board is lit whenever the contactor is open during a normal disconnect or in the unlikely event of a contactor failure The LVD sensing circuitry...

Page 25: ...ess of engineering a battery plant is described as it progresses through four stages This process is essentially the same for the field modification of an existing battery plant as it is for a new installation The four stages are 1 characterizing the basic power requirements 2 determining the power equipment that satisfies those needs 3 determining the impact on the various building systems and 4 ...

Page 26: ...tion in the following sections a Recommended operating voltage ______ volts b Minimum steady state voltage ______ volts c Maximum steady state voltage _____ volts d Maximum high voltage transient ______ volts e Can the load be damaged by low input voltage ___ yes or no If the answer to e is yes low voltage LOAD disconnect provisions may be necessary It is important to distinguish between low volta...

Page 27: ...ies differs slightly among vendors and varies with chemistry The most common float voltages are 2 17 2 27 and 2 35 volts per cell Nominal 24 volt systems typically use 12 cell battery strings for float voltages that range from 26 04 to 28 20 volts per string Lucent KS type flooded lead acid batteries float at 2 17 volts per cell 26 04 volts per string Customers should select a battery type and ven...

Page 28: ...stant During an ac power outage however as the batteries deliver power the voltage drops steadily Most types of load equipment do not draw a constant current over their input voltage range Therefore the current drain on the plant may change as the batteries discharge Some types of load equipment are purely resistive in that their current drain decreases as the plant voltage decreases Other types o...

Page 29: ... be added relatively easily to operating plants To determine the initial rectifier and battery needs fill in the current drain information for all load circuits in the initial installation in Table 3 A Use additional sheets as needed As the customer s power needs evolve however load circuits may need to be added and traffic on existing circuits may increase Ultimate List 2 drain should be used to ...

Page 30: ...chnologies Lineage 2000 ECS Battery Plant H569 403 3 6 Engineering Planning and Ordering Issue 4 February 1997 Table 3 A Initial Load Drain Information Load Circuit List 1 Amps List 2 Amps 1 Battery Plant Total ...

Page 31: ...S Battery Plant H569 403 Issue 4 February 1997 Engineering Planning and Ordering 3 7 Table 3 B Anticipated Future Load Drain Information Load Circuit List 1 Amps List 2 Amps NC C or A 1 Battery Plant Total NC No Change C Changed A Added ...

Page 32: ...electing the minimum battery capacity Many using systems specify the maximum allowable input noise Applications such as UPS supplied ac power which do not require batteries for dc reserve purposes may require batteries or some other means for noise filtering Compare the input noise requirements of the using system to the ECS Battery Plant specifications in Table 2 A Fill in the minimum reserve tim...

Page 33: ...time and voltage For example increasing the plant voltage will within limitations decrease the necessary recharge time but this calls for more current Increasing the plant voltage after a discharge is also recommended by some battery vendors to assure that all cells charge equally for maximum life Although these two charging methods are essentially the same they are usually called by different nam...

Page 34: ...p and Balancing The rectifiers while recharging or floating the batteries maintain a constant voltage at the battery plant bus bars When batteries are accepting recharge current after a discharge there is a finite voltage drop from the charge bus bars inside the ECS bay to the battery string terminals This voltage drop is of course proportional to the magnitude of the recharge current Any voltage ...

Page 35: ...calculation methods are described in the paragraph Calculating Voltage Drop For the calculation use the plant List 2 drain divided by the number of parallel battery strings For extraordinarily long runs between batteries and dc distribution wire gauges may be called for that cannot be conveniently terminated at the equipment at either end In such cases the necessary larger cables may usually be ta...

Page 36: ...tems Account Executive for details on this service Alternatively various rules of thumb are used to specify maximum voltage drops During discharge the critical voltage drop is the total drop from the battery terminals to the load equipment Increasing the voltage drop from dc distribution to load can potentially be compensated by decreasing the voltage drop from batteries to dc distribution The vol...

Page 37: ...L VD where VD allowable voltage drop in volts CM conductor size in circular mils K 11 1 for copper at 78 F 25 5 C I appropriate current drain in amperes L conductor length in feet The formula may be applied to one way conductors or to loop circuits i e paired power and return conductors The value of K in the above expression increases with increasing conductor temperature Conductor Ampacity Two cr...

Page 38: ...ed or side by side Overcurrent Protection The rating of an overcurrent protection device fuse or circuit breaker should not exceed the AMPACITY of the conductor it is intended to protect The absolute maximum rating permitted by the NEC for an overcurrent protector is the next larger standard rating above the ampacity Overcurrent protectors may be sized smaller than this maximum rating In general h...

Page 39: ...the specific types and quantities of equipment available with the Lineage 2000 ECS battery plant The following topics are covered in this section Rectifier sizing Battery sizing Cable and load breaker sizing Low voltage disconnect reconnect Controller options Alarm system interface Rectifier Sizing The H569 403 Battery Plant uses the Lineage 2000 SR 100 ampere 24 volt switched mode rectifier A max...

Page 40: ...tial material cost therefore the number of strings should be minimized Weight and Space Efficiency Weight density and space efficiency increase in general as battery capacity increases There can be significant differences in space efficiency however between different vendors of the same capacity battery Floor loading restrictions may limit the potential compactness of the battery arrangement Such ...

Page 41: ...good practice to select battery size such that at least two strings are required Multiple strings allow for easier maintenance on the battery system without jeopardizing service to the load equipment Cable and Load Breaker Sizing In this section power cabling for the dc distribution and battery subsystems is covered including the following subtopics Maximum and minimum wire gauges Wire type Crimp ...

Page 42: ...of the fuses are from 1 30 amperes The breaker or fuse rating for a given circuit is selected by the criteria covered in paragraph Overcurrent Protection The lengths of all load and battery conductors must be known before proceeding with this section Use the following steps to record the wire and breaker fuse sizes for each load feeder in Table 3 F Use additional sheets as needed Step A Copy List ...

Page 43: ...nd Calculating Voltage Drop Step L List the sizes based on voltage drop in Table 3 G Step M Indicate the larger size for each load feeder in the final column Selected Wire Gauge Table 3 D Double Hole Terminal Lugs KS 5482 Wire KS 20921 Wire WP 91412 List Comcode Bolt Size Centers Die 10 8 8 6 4 2 1 0 2 0 4 0 350MCM 10 8 8 6 4 2 1 0 2 0 4 0 350MCM 73 52 75 3 5 54 8 56 57 57 77 59 27 61 56 405356171...

Page 44: ...12 List Comcode Bolt Size Die 10 8 8 6 4 2 1 0 2 0 4 0 10 8 8 6 4 2 1 0 2 0 4 0 93 1 74 2 4 53 7 55 10 10 17 58 78 406338145 405474402 405356189 405474436 405347543 40 5348186 405347659 405348210 405477717 405477717 4053 47790 405348244 406021741 10 10 0 250 0 250 0 250 0 250 0 250 0 375 0 375 0 375 0 375 0 375 0 375 R5473 Red Red Blue Grey Brown Green Pink Black Black Orange Purple Yellow ...

Page 45: ...Battery Plant H569 403 Issue 4 February 1997 Engineering Planning and Ordering 3 21 Table 3 F Load Feeder Wire and Fuse Breaker Size CIRCUIT NUMBER LIST 2 DRAIN MINIMUM WIRE GAUGE SELECTED WIRE GAUGE BREAKER RATING AMPACITY VOLTAGE DROP 1 ...

Page 46: ...ed _____ yes or no If yes specify the disconnect level _____ 20 25 or 21 25 Controller Options The engineering of the ECS controller features involves orderable circuit packs and DIP switch settings Circuit Packs Circuit pack options for the ECS controller are presented on the H569 403 battery plant drawing Refer to that drawing and to the Controller manual for more information on the availability...

Page 47: ...just the battery plant Some of these common systems are ac distribution cabling air conditioning and ventilation and the building structure itself For example the ac distribution system for a building or room is not completely defined by the power equipment needs alone but clearly the number and type of rectifiers have a direct impact The following topics are covered in this section Floor Plan Dat...

Page 48: ...unted in the overhead cable rack When the discharge return bus is in the initial bay a connection point is provided on it specifically for grounding This point may be used to tie the battery plant to the building grounding electrode Two holes for 250 20 self tap screws are provided at the rear of the top crossmember of the bay uniframe to accommodate a two hole cable lug on 62 centers If the frame...

Page 49: ...apparatus is controlled by a SERIES NUMBER The series number may be appended to the apparatus code for a complete description of the product but is not necessary because only the latest vintage is orderable at any given time Apparatus coded components for a battery plant are typically replacement parts and spares See Spare Parts in Section 5 Equipment coded hardware is available in different confi...

Page 50: ...andard drawing of the same number This drawing contains the descriptions of the optional configurations manufacturing assembly information and any additional details for engineering or field installation An equipment option is identified by a number or letter called a LIST or a GROUP J and H coded equipment use Lists while ED coded products are equipped with Groups For simplicity the discussion th...

Page 51: ...ays followed by at least one List number when describing an orderable piece of equipment On its own the J code refers to either the drawing itself or in generic terms only the product 3 Issue number Each sheet of a drawing has its own issue number which changes whenever anything is changed on that sheet The issue number of the first cover sheet changes whenever any sheet in the J drawing is change...

Page 52: ... Main List describes a set of features which is a lowest common denominator or a typical arrangement There may be several Main Lists on a given J drawing that share perhaps common components or Supplementary Lists see below Only one Main List number is specified for one equipment assembly and the quantity specified for that List is one 5A 2 Supplementary Lists Features are added to or omitted from...

Page 53: ...iffer from one List to another these differences are indicated by Apparatus Options on the T drawing 6 Table C This table cross references the schematic SD and wiring diagram T 7 Table D This table provides a list of all associated drawings such as other J ED or H coded equipment that must be ordered separately Drawings which are required for engineering or manufacturing but are not necessary for ...

Page 54: ...iring details such as wire colors gauges and routing which cannot be conveniently shown in assembly views of the J drawing T drawings are similar in format to J drawings with cover sheets and assembly sheets There is no stocklist or Table A however on a T drawing The following T drawing cover sheet features are essentially the same as those for J drawings Title Block Issue number Sheet Index Manuf...

Page 55: ...ing options are derived directly from those defined on the SD drawing using the same lettering scheme see below Options which are found on the T drawing but not on the SD always include the prefix H Optional wiring and hardware is provided only when the associated options are specifically called for by Table A of the J drawing SD drawings The SD drawing is the source for the circuit information th...

Page 56: ...er connections This information is duplicated in the Installer Figures of the T drawing H sheets are included in some SD drawings to provide Block Diagrams BDs that are helpful in understanding complex circuits J sheets are used for Circuit Pack Schematics CPSs if any are included in the SD Most circuit packs however are documented on separate schematic drawings some of which are proprietary and a...

Page 57: ...669 02 Product Manual 167 790 033 Optional Circuit Pack Product Manual 167 790 109 SR Series Rectifiers and RSA Assembly and Ordering Drawing J85702C 1 Wiring Diagram T 82668 30 Schematic Diagram SD 82668 01 Product Manual 169 790 115 VR Series Battery Assembly and Ordering Drawing ED83242 31 Wiring Diagram T 82671 30 Schematic Diagram SD 82671 01 Product Manual 157 622 010 KS23832 Converter Produ...

Page 58: ...ample order for an H569 403 plant containing a low voltage disconnect 3 100 ampere rectifiers a CP2 microprocessor pack 7 100 ampere breakers 4 45 ampere breakers 3 24 to 48 volt converters and 1 48 volt meter and fuse distribution panel would look like the following Item Qty Description 1 1 H569 403 G 2 24V 600A ECS Plant E W 3 G 4 1 G 5 1 G 41 1 G 42 1 G 43 Fuse Panel 1 G 20 Circuit Breaker Pane...

Page 59: ...ta acquisition pack that always requires a CP2 circuit pack 9 Same as Group 8 with remote termination panel The remote termination panel allows external connection to the CP3 circuit pack from outside the controller 20 Circuit breaker panel for 10A to 100A breakers Items AA AF Provide Circuit Breakers For Group 20 With These Ampere Capacities AA 10 ampere breaker AB 20 ampere breaker AC 30 ampere ...

Page 60: ...it to add a Group 42 converter shelf equipped with one converter in the field K3 Upgrade kit to add a 100 ampere circuit breaker in the field K10 Upgrade kit to add voice response feature to a plant controller in the field Table 3 H Ordering Guide H569 403 ECS 600 Ampere 24 Volt Battery Plant Figure 3 1 Bay Dimensions and Clearances ...

Page 61: ... F F G G H H INFORMATION FURNISHED PER THIS DRAWING IS IN ACCORDANCE WITH LUCENT COMPANY STANDARD XXX XXX XXX LINE LINE LINE NAME NAME NUMBER UGII V4 1 02 22 88 NUMBER 1 1 8 2 2 9 3 3 10 4 4 11 5 5 12 6 13 7 14 CIRCUIT NAME SCHEMATIC WIRING DIAGRAM FIGURE OPT WIRING WIRED REMARKS WIRING PROVIDE IN THE LOCAL CABLE TABLE C WIRING PROVIDED INFORMATION DENOTES NOT REQUIRED BY INSTALLER TABLE D LIST OF...

Page 62: ...ent of equipment in the controller rectifier and battery subsystems are covered in their respective manuals The framework rectifier controller and dc distribution subsystems described in Section 2 are factory tested as a system The controller and distribution subsystems are shipped assembled to the framework ready for use To improve shipping and handling the rectifiers are packaged separately and ...

Page 63: ...ds each capable of carrying 3 amperes Suggested Installation Sequence General Information 1 The plant is wired with ac from the right side Typical routing of ac dc and control cabling is shown on the plant assembly drawing H569 403 Connection points and wire types are indicated on the plant wiring diagram T 83118 30 2 When running dc cable ensure that all non protected leads are run in a separate ...

Page 64: ...uipment during handling of crates and uncrated equipment Use the equipment weights and dimensions given in Section 2 1 as a guideline for choosing material handling tools Move crated equipment to an area with adequate space and tools for unpacking and handling Carefully open the packaging to verify that the contents are complete and undamaged If the equipment must be returned repack it in the orig...

Page 65: ...ubject to vibration Belleville type washers or jam nuts are the preferred means 7 For less than 1 4 inch thick tapped copper bars use No 8 No 10 or 1 4 inch machine screws to minimize applicable torque When larger size screws are required provide captive type steel nuts or reduce torque 8 Torque recommendations are also suitable for all non ferrous fasteners except aluminum 9 Where application per...

Page 66: ...4 February 1997 Installation 4 5 Table 4 B Torque for All Non Electrical Connections e g Floor Anchors Cap Screw Diameter Torque Ft Lb UNRC 1 4 3 16 3 8 7 16 1 2 9 16 5 8 3 4 1 1 1 4 1 1 2 6 12 22 35 54 77 107 190 290 580 1010 Figure 4 1 Typical Floor Mounting Detail ...

Page 67: ...rge Batteries may undergo initial charging at this time according to the manufacturer s recommendations One of the rectifiers may be used for initial charging Refer to the procedure given in the Rectifier manual Cable Support and Ground System Hang all cable support systems as well as any auxiliary ground bus bars as dictated by the job application drawings Figure 4 2 Floor Mounting Template All D...

Page 68: ...al circuit packs Check and set the low voltage disconnect reconnect if provided at the desired voltage level See Figure 4 3 for the location of the disconnect voltage select jumpers J505 1 and J505 2 on CP5 Fuse Board Plug these jumpers across pins 1 and 2 of their respective connectors to provide a disconnect voltage of 21 25 0 5 volts To provide a disconnect voltage of 20 25 0 5 volts plug the j...

Page 69: ...ttery plant end on the discharge return bus located at the top front of the bus bar arrangement Recommendations for routing and dressing of load leads as they leave the battery plant and enter the cable rack system are shown on the plant assembly drawing H569 403 or in Figure 3 4 Consult the job application drawings for the routing of these leads to the load equipment Before proceeding verify that...

Page 70: ... string according to the manufacturer s documentation Measure the resistance between the two ends of any battery string to verify that the circuit is open Close the last remaining part of the battery circuit on each string either intercell connector or disconnect breaker Reinsert all fuses in CP5 Fuse Board Match the fuse ratings and positions as indicated on the distribution cover panel Controlle...

Page 71: ...may be readily added to the battery plant to provide any of the following Expanded controller features Additional rectifier capacity Increased battery capacity associated with additional rectifier capacity Additional load circuits Procedures for adding controller features rectifiers and batteries to an operating plant are described in the installation sections of the associated subsystem manuals T...

Page 72: ...ding to the next step 7 Turn on the load circuit breaker or install the fuses If the circuit breaker trips or the fuse blows immediately when turned on this may be due to inrush current and does not necessarily indicate a fault condition Attempt to close the circuit breaker a second time or add another fuse If the breaker trips or the fuse blows again check the wiring to the load circuit 8 When al...

Page 73: ...es that the disconnect reconnect contactor is open and therefore that batteries are disconnected from the rest of the battery plant The yellow LVD FAIL LED indicates that only one of the two redundant low voltage detectors has directed the contactor to open and that the disconnect circuit may have failed Fuses F1 through F21 are also located on the CP5 LVD Fuse Board and provide power for controll...

Page 74: ...fuse blocks in the battery plant have indicating fuses that allow a red element to pop out when a fuse blows opens If a breaker has tripped off or a fuse blows the overcurrent problem should be cleared before restoring power to the load by resetting the breaker or replacing the fuse See Troubleshooting below for information on tripped breakers or blown fuses Troubleshooting Table 5 A provides a li...

Page 75: ...leshooting in Controller Manual Rectifier Red or yellow LEDs lit No LEDs or Display lit No output low output Oscillation Open output breaker See Troubleshooting in Rectifier Manual DC Distribution Subsystem Open distribution breaker or fuse a manually turned off b overcurrent trip c breaker failure Open Distribution Breaker or Fuse LVD OPEN LED lit a failed LVD contactor b low voltage c faulty wir...

Page 76: ...eaker as described in paragraph Load Circuit Breaker or Fuse Replacement below Red LVD OPEN LED Lit A lit red LVD OPEN LED indicates that the LVD Contactor is de energized i e open The contactor may be open due to one of the following reasons Plant voltage is below the disconnect threshold The contactor has failed and must be replaced See procedure LVD R Contactor Replacement below There is an ope...

Page 77: ... bar should be approximately the float voltage of the plant With a blown fuse the indicating fuse can be replaced to verify that the fuse is truly open If the faulty breaker or fuse is in fact still closed the load equipment which it powers must be shut down so that no current flows through the breaker fuse arrangement during the following replacement steps 5 Disassemble the faulty breaker from th...

Page 78: ...rs are carrying the load off battery with excess capacity available for charging the batteries Battery string s are at a voltage below the rectifier voltage in a state of partial or complete discharge LVD OPEN LED is lit on the distribution front panel The following equipment is required Socket wrench with insulated handle 1 2 inch socket Procedure Refer to Figure 2 5 and T 83118 30 drawing 1 Remo...

Page 79: ...ng equipment is required Standard screwdriver Procedure Refer to Figure 4 3 and T 83118 30 drawing 1 Open distribution panel 2 Unplug the following connectors from the LVD Fuse Board CP5 Leave the cables dressed J502 from P502 J508 from P508 J506 from P506 J501 from P501 J504 from P504 Wires from TB501 3 Remove the 6 mounting screws 4 Set jumpers J505 1 and J505 2 on replacement LVD Fuse Board CP5...

Page 80: ...ecommended spares information on Table T of the H569 403 drawing Rectifiers and fans Circuit Breakers 10 100 ampere Fuses 1 30 ampere LVD Fuse Board CP5 Fuses F1 to F21 Controller Circuit Packs Refer to the Controller manual In addition to these items any piece part may be ordered that is identified in the assembly views and stocklist on the H569 403 drawing When ordering please specify the Descri...

Page 81: ...rranties 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 shippe...

Page 82: ...to repair but which are not 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 an...

Page 83: ...other than Seller or its 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 addit...

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