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Lucent Technologies Lineage

®

2000 ECS/GPS Battery Plant J85500G-2

Issue 6 May 1999

Installation 4 - 1

4

Installation

General

As mentioned at the beginning of Section 3, Lucent
Technologies offers complete engineering and installation
service that result in “turn-key” plant operation. Contact your
Lucent Technologies Energy Systems Account Executive for
further information on the complete range of installation
services available from Lucent. Customers may, however,
choose to make their own arrangements to fully or partially
install the battery plant based on the information supplied here.

This section outlines an efficient sequence of battery plant
installation steps that minimizes the installer’s exposure to live
circuits. Upgrades, retrofits and replacement 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 must be
plugged into their shelf assemblies during the plant installation
process. The battery subsystem must also be assembled by the
installer. The battery plant installation sequence that follows
refers to the Rectifier, Controller and Battery manuals for details
for those subsystems. Read this section and the referenced
sections in other subsystem manuals completely before starting
any work.

Installation tools

and test

equipment

The following tools and test equipment are required for battery
plant installation and testing.

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Summary of Contents for J85500G-2

Page 1: ...Lineage 2000 600A 48V Battery Plant J85500G 2 Product Manual Select Code 167 790 035 Comcode 106648348 Issue 6 May 1999 1999 Lucent Technologies 1999 ...

Page 2: ......

Page 3: ...hnologies Lineage 2000 600A 48V Battery Plant J85500G 2 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 1999 Lucent Technologies All Rights Reserved Printed in U S A ...

Page 4: ......

Page 5: ...stems 2 3 ECS Battery Plant Physical Description 2 4 Initial Bay 2 5 Supplementary Bays 2 5 ECS Battery Plant Subsystems 2 6 Rectifier 2 6 Batteries 2 7 Controller 2 7 ECS Controller 2 7 Galaxy Controller 2 8 DC Distribution 2 9 ECS DC Distribution Panel 2 9 Circuit Breaker Panel Description 2 12 Fuse panels 2 14 Capacitor Charge 2 24 Plant Bus Bars 2 25 Plant Shunt 2 25 Low Voltage Battery Discon...

Page 6: ...16 Cable and load breaker sizing 3 17 Record Wire And Breaker Fuse Sizes 3 20 Low Voltage Disconnect Reconnect Feature 3 21 Emergency disconnect 3 21 Thermal slope step compensation 3 22 Controller Options 3 22 Alarm System Interface 3 22 Earthquake Bracing 3 22 Planning 3 23 Floor Plan Data 3 23 Cable Rack and Routing 3 24 Grounding 3 24 Growth 3 24 Ordering Reference Material 3 24 Coding and Ter...

Page 7: ...llation procedures for plant growth 4 11 Adding a load circuit 4 12 Installing thermal compensation unit in existing plant 4 13 Test Procedure 4 17 5 Maintenance Controls and Indicators 5 1 CP5 Fuse Board LEDs and fuses 5 1 DC Circuit Breakers Fuses 5 1 Troubleshooting 5 2 Open Distribution Breaker or Fuse 5 2 Red LVD OPEN LED Lit 5 3 Yellow LVD FAIL LED Lit 5 3 Repair and Replacement 5 4 Load Cir...

Page 8: ......

Page 9: ... options 2 12 Figure 2 4 List 20 5 to 600A circuit breaker panel 2 13 Figure 2 5 List 30 1 to 30A fuse panel 2 15 Figure 2 6 List 31 1 to 60A fuse panel 2 15 Figure 2 7 List 32 70 to 100A fuse panel 2 16 Figure 2 8 List 33 110 to 200A fuse panel 2 17 Figure 2 9 List 34 70 to 200A fuse panel 2 18 Figure 2 10 List 35 70 to 600A fuse panel 2 18 Figure 2 11 List 36 3 to 60A fuse panel 2 19 Figure 2 12...

Page 10: ...re 4 3 LVD fuse board CP5 jumper locations 4 8 Figure 4 4 LVD fuse board with thermal compensation circuitry BMD1 switch locations 4 8 Figure 4 5 216A Battery Thermal Compensation Control Unit faceplate 4 18 Figure 4 6 Door assembly 4 19 Figure 4 7 VR Battery stand placement of thermistors 4 19 Figure 4 8 Plant frame work placement of control unit option 1 4 20 Figure 4 9 Door panel placement of c...

Page 11: ...anel 2 19 Table 2 F List 31 Fuse Panel 2 20 Table 2 G List 32 Fuse Panel 2 20 Table 2 H List 33 Fuse Panel 2 20 Table 2 I List 34 Fuse Panel 2 21 Table 2 J List 35 Fuse Panel 2 21 Table 2 K List 36 Fuse Panel 2 22 Table 2 L Initial Bay Feeder Cables for Different Configurations 2 23 Table 3 A Initial Load Drain Information 3 6 Table 3 B Anticipated Future Load Drain Information 3 6 Table 3 C Reser...

Page 12: ...ing Guide J85500G 2 ECS 600 Ampere 48 Volt Battery Plant 3 34 Table 4 A Minimum Torque For All Electrical Connections e g Bus Bars 4 4 Table 4 B Torque For All Non Electrical Connections e g Floor Anchors 4 4 Table 4 C Installation Reference Documents 4 7 Table 4 D SW500 Reference 4 17 Table 5 A Troubleshooting 5 2 ...

Page 13: ...e ECS Battery Plant J85500G 2 is shown in Figure 1 1a This member of the ECS family of battery plants operates from a nominal 208 240 volt ac 50 60 Hz source It offers a 600 ampere total plant capacity with a nominal 48 volt dc output in a totally integrated energy system The basic plant consists of charge and discharge bus bars with optional low voltage disconnect provision for breaker and fuse p...

Page 14: ...installation operation and maintenance The contents of the documentation package are identified for ordering and reference purposes in Section 3 of this manual Customer Training Lucent Technologies offers customer training on many power products For information call 1 972 284 2163 This number is answered from 8 00 a m until 4 30 p m Central Time Zone Zone 6 Monday through Friday Customer Service F...

Page 15: ... problems For other customers worldwide contact your local field support center or your sales representative to discuss your specific needs Product Repair and Return Repair and return service is provided for Lucent Technologies customers around the world For customers in the United States Canada Puerto Rico and the US Virgin Islands call 1 800 255 1402 for information on returning of products for ...

Page 16: ...el List 20 Circuit Breaker Distribution Panel ECS or Galaxy Controller 364A Rectifier List 4 Max 12 between Initial and Supplementary Bay Rectifier Shelf List 10 Plant Charge Discharge Bus Bars Space Available for Distribution Panel or Rectifiers Shown 4th Rectifier Shelf not Available with Galaxy Controller POS 12 POS 11 POS 10 POS 1 POS 4 POS 7 POS 8 POS 9 POS 5 POS 6 POS 2 POS 3 LVD R FAIL OPEN...

Page 17: ...1 1b Lineage 2000 ECS GPS Battery Plant Model J85500G 2 Supplementary Bay List 33 Fuse Panel List 34 Fuse Panel List 30 Fuse Panel List 31 Fuse Panel 364A Rectifier List 4 Rectifier Shelf List 10 Space Available for Rectifiers 7 12 Space Available for Distribution Panels POS 1 POS 4 POS 5 POS 6 POS 2 POS 3 ...

Page 18: ......

Page 19: ...Current Rating 600 amperes Plant Shunt 600 amperes maximum at 50 millivolts LVD R Voltage Settings 40 5 or 42 5 volts dc Controller ECS Basic 113B Microprocessor option circuit pack CP2 Datalogger option circuit pack CP3 or Galaxy basic 48V rectifier control Rectifier Shelf Assembly 4 maximum each mounts 3 rectifiers Rectifiers Type Lineage 2000 SR50 48V Rating 48 volts nominal 50 amperes 12 maxim...

Page 20: ...159 kilograms Battery Supplementary Bay Equipped with 1 string VR batteries 2100 pounds 953 kilograms Equipped with 2 strings VR batteries 4100 pounds 1860 kilograms Earthquake Initial bay Zone 4 upper floors Bays equipped with VR batteries See Earthquake Bracing Section 3 Heat Dissipation Full load 5750 watts 19 602 BTU hr Note 1 Half load 2888 watts 9845 BTU hr Rectifier full load 475 watts 1619...

Page 21: ... three to eight hours of reserve time Battery Plant Subsystems Figure 2 2 illustrates 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 subsyst...

Page 22: ...es state of the art technology to achieve dramatic equipment size and weight reduction and to minimize maintenance These advantages are realized by the application of Switch Mode Rectifier SR and Valve Regulated VR battery technologies and a unique plug in rectifier design The ECS battery plant is designed as a totally integrated energy system package It is a compact and complete system containing...

Page 23: ...nnect feature optional thermal slope step compensation feature and one capacitor charge panel for the circuit breakers When the plant is equipped with a Galaxy Controller the initial bay will accommodate up to nine rectifiers along with the other components listed above Stile strips and end covers are optional appearance kits Supplementary Bays If additional dc output or additional dc distribution...

Page 24: ...ficant reduction in size and weight over conventional ferroresonant rectifiers The plug in connectorized design of the rectifiers reduces installation time to minutes permitting easy growth and maintenance without service interruption The Lineage 2000 SR Series 50 ampere rectifiers operate over 208 220 240 Vac 50 60 Hz nominal single phase input range without any necessary tap changes A power fact...

Page 25: ...ry product manual for additional information For systems requiring higher capacities and or longer reserve times the Lineage 2000 Round Cell Series of batteries is appropriate Controller The ECS or Galaxy controller performs the centralized monitoring control and reporting functions for the ECS battery plant ECS Controller The basic ECS controller can monitor and control up to twelve rectifiers It...

Page 26: ...t alarms and histories load statistics auto boost Rectifier features including sequencing energy efficiency algorithm remote rectifier on standby rectifier event histories Battery prediction an option that predicts reserve time for batteries made by Lucent Technologies Data Switch an optional interface with RS 232 devices such as Lucent Technologies XCS ECS RAS and OMNIpulse units Data Switch perm...

Page 27: ...ngs of 5 600 amperes and 1 200 amperes respectively A supplementary bay is also orderable and can accommodate these panels A complete discussion of the ECS dc distribution is presented in the following section of this manual ECS DC Distribution Panel Both circuit breaker and fuse protected distribution panels are available with the ECS Battery Plant They are orderable via list numbers from J85500G...

Page 28: ... Amps Ordering Information 20 30 31 32 33 34 35 36 Breaker Fuse Fuse Fuse Fuse Fuse Fuse Fuse 17 or 21 1 to 4 24 8 4 2 3 2 19 5 100 125 600 1 30 1 60 70 100 110 200 70 200 70 600 3 60 Table 2 D Table 2 E Tab e 2 F Table 2 G Table 2 H Table 2 J Table 2 K Table 2 L An optional capacitor charge feature panel is available with List 20 and occupies 4 slots on the breaker panel Table 2 C Load Lead Termi...

Page 29: ...R 36 OR SEE NOTE 1 BELOW LIST 20 OR 36 OR SEE NOTE 1 BELOW LIST 20 OR 36 OR SEE NOTE 1 BELOW LIST 20 OR 36 OR SEE NOTE 1 BELOW DESIGNATES AREA UNAVAILABLE FOR GROWTH USED FOR FRONT ACCESS AND LOAD LEADS AVAILABLE FOR LIST 10 4th RECTIFIER SHELF FUTURE NON X DISTRIBUTION PANELS OR EQUIPPED WITH ITEMS SEE MANUFACTURING NOTE 7 A SECOND LIST 20 CAN BE MOUNTED BUT ONLY KS22010 BREAKERS LIST AA AJ ALLOW...

Page 30: ...eaker s alarm contacts Figure 2 3b Supplementary Bay options 6 Typ Bay Position 76 71 65 59 53 47 70 64 58 52 46 41 UNAVAILABLE BLANK PANEL SPACE FOR RECTIFIER SHELF LIST 11 DISTRIBUTION PANEL OPTIONS MOUNTING AREA REQUIRED LIST 20 or 36 BREAKER PANEL LIST 30 FUSE PANEL LIST 31 THRU 35 FUSE PANEL DESIGNATES AREA REQUIRED FOR LOAD LEAD ROUTING LIST K1 BLANK PANEL KIT LOWER BAY LIST K2 BLANK PANEL K...

Page 31: ...List 20 5 to 600A circuit breaker panel SLOT 1 SLOT 2 SLOT 3 SLOT 4 SLOT 5 SLOT 6 SLOT 7 SLOT 8 SLOT 9 SLOT 10 SLOT 11 CHG 10A CHG ALM CHG CAP SLOT 12 CHARGE SWITCH 1 2 3 4 5 6 7 8 9 14 15 16 17 18 A B C D O F F 21 20 19 SLOT 13 SLOT 14 SLOT 15 SLOT 16 SLOT 17 SLOT 18 SLOT 19 SLOT 20 SLOT 21 SLOT A SLOT B SLOT C SLOT D ...

Page 32: ...dering information is available from Tables W and Z on J85500G 2 drawing Table 2 D List 20 Circuit Breaker Panel With Optional Capacitor Charge Feature Panel Circuit breakers operate and provide an alarm during electrical trip The List 20 panel contains 21 slots for circuit breakers and an optional capacitor charge feature The panel bus bar is sized for 600 ampere capacity Circuit Breaker Specific...

Page 33: ...Lucent Technologies Lineage 2000 ECS GPS Battery Plant J85500G 2 Issue 6 May 1999 Product Description 2 15 Figure 2 5 List 30 1 to 30A fuse panel Figure 2 6 List 31 1 to 60A fuse panel ...

Page 34: ...Lucent Technologies Lineage 2000 ECS GPS Battery Plant J85500G 2 2 16 Product Description Issue 6 May 1999 Figure 2 7 List 32 70 to 100A fuse panel 70 100A FUSE BLOCK 4 PLACES INDICATING FUSE ...

Page 35: ...Lucent Technologies Lineage 2000 ECS GPS Battery Plant J85500G 2 Issue 6 May 1999 Product Description 2 17 Figure 2 8 List 33 110 to 200A fuse panel 110 200A FUSE BLOCK 2 PLACES INDICATING FUSE ...

Page 36: ... 2000 ECS GPS Battery Plant J85500G 2 2 18 Product Description Issue 6 May 1999 Figure 2 9 List 34 70 to 200A fuse panel 70 100A FUSE BLOCK 2 PLACES 100 200A FUSE BLOCK Figure 2 10 List 35 70 to 600A fuse panel 70 600A Fuse Block ...

Page 37: ...Yellow White White Blue Pink Table 2 E List 30 Fuse Panel The List 30 panel contains 3 individual fuse blocks each of which can accommodate up to 8 load fuses for a total of up to 24 per panel Refer below for fuse specifications Load fuses are ordered on a job basis separately from the battery plant order Load Fuse Size Type Range Amps OrderInformation for a Fuse Panel 9 32x1 1 4 inch 74 KS 19870 ...

Page 38: ...L 21 1 8 L H 1 8 L J Specify positions from left to right numbered 1 8 Table 2 G List 32 Fuse Panel The List 32 panel contains 4 individual fuse blocks 70 100A each accommodating a single fuse Refer below for fuse specifications Load fuses are ordered on a job basis separately from the battery plant order Type Range Amps Order Informationfor a Fuse Panel NON 70 100 J85500G 2 L 32 Table 2 H List 33...

Page 39: ...B L BB L BC Table 2 J List 35 Fuse Panel The List 35 fuse panel contains 2 individual fuse blocks each accommodating a single fuse 70 600A arranged for load monitoring shunts and head assemblies ordered by number and list from this table Load fuses are ordered on a job basis separately from the battery plant order Type Capacity Amps Ordering Information Fuse Blocks NON 70 250 300 600 L BP L BQ Loa...

Page 40: ... single load fuse and an alarm fuse This table lists fuse specifications Load fuses are ordered on a job basis separately from the battery plant order Fuse Blocks and Load Fuses Type WP 92461 List Capacity Amps Ordering Information 100 101 102 103 104 105 106 107 108 109 110 3 5 6 10 15 20 25 30 40 50 60 406700567 406700583 406700591 406700609 406700617 406700625 406700633 406700641 406700658 4067...

Page 41: ...0 K40 H285 226 L 40 2 2 601286279 601326218 List 31 thriugh 35 List 20 or 36 Figure E 53 58 41 52 K38 H285 226 L 38 K41 H285 226 L 41 2 2 601326192 601337645 List 30 List 31 through 35 List 20 or 36 Figure F 62 64 53 58 41 52 K37 H285 226 L 37 K38 H285 226 L 38 K41 H285 226 L 41 1 2 2 601326184 601326192 601337645 List 31 through 35 List 31 through 35 Figure G 53 58 41 46 K38 H285 226 L 38 K40 H28...

Page 42: ...ad is as follows 1 Verify that the affected equipment is ready to accept dc power 2 Locate the rotary slot selector and charge switch in the middle of the circuit breaker distribution panel L AA through AH KS22010 circuit breakers are numbered from left to right and L AM through AX KS22012 circuit breakers are lettered from left to right and correspond to the rotary selector 3 Select the circuit b...

Page 43: ...Charge RTN Bus which is connected via the plant shunt to the uppermost Discharge RTN Bus Bar Refer to Figure 2 10 A hinged panel covers the front of the bus bars and includes a mounting space for a LVD Fuse Power Board see Figure 2 11 The LVD Fuse Board CP5 provides circuitry for the LVD sensing see Section 2 and regulation fuses to protect the ECS controller from overcurrent in the sense leads Pl...

Page 44: ...preset level a comparator circuit on the CP5 Fuse Board senses the low voltage condition and removes power to the contactor This opens the connection between Charge Bus and Battery Bus disconnecting the batteries from the rectifiers and the load The user has a choice of disconnect threshold voltages 40 5 and 42 5 volts When the contactor is open and the rectifiers are not delivering power the cont...

Page 45: ...ised 4 0 VDC when the temperature returns to 65 C 149 F A green indicator is illuminated to reflect an active module A yellow indicator illuminates to reflect temperatures above 53 C and blinks to reflect temperatures above 75 C The 216A Control Unit also has the ability to increase the plant voltage for sensor temperatures below 25 C The plant voltage is increased 72 mV per degree Celsius to a ma...

Page 46: ... retrofit kit contains two paddle thermistors to monitor one string of batteries If more than one string of batteries is to be monitored order a thermistor kit for each additional battery string Figure 2 12 Plant Bus Bars With Optional List 2 Low Voltage Disconnect Optional Low Voltage Disconnect Reconnect LVD R Contactor Charge Bus Charge Bus Charge Return Bus Charge Return Bus Section A A Plant ...

Page 47: ... CAUTION F 13 F 1 F 14 F 2 F 15 F 3 1 1 3 A LVD R FAIL OPEN 1 1 3 A 1 1 3 A 2A 0 5 A F 16 F 4 F 17 F 5 F 18 F 6 F 19 F 7 F 20 F 8 F 21 F 9 F 10 F 11 F 12 SPARE FUSES LINEAGE 2000 Hazardous Voltage Risk of Electrical Shock FOR CONTINUED PROTECTION AGAINST RISK OF FIRE AND SHOCK REPLACE ONLY WITH SAME TYPE AND RATING OF FUSE Door should be opened only by service personnel ...

Page 48: ......

Page 49: ...ecutive This section of the manual is intended to provide guidance for those customers who wish to engineer their battery plant completely or partially The detailed process 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...

Page 50: ...recommended operating voltage range of the using equipment If the battery plant is used to power different types of equipment it must meet the requirements of each Fill in the load voltage information below The answers to these questions will be used in engineering calculations and equipment selection in the following sections 1 Recommended operating voltage ______ volts 2 Minimum steady state vol...

Page 51: ...usually defined as 2 volts The actual recommended float voltage of lead acid batteries 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 48 volt systems typically use 23 or 24 cell battery strings for float voltages that range from 49 91 to 56 40 volts per string Standard arrangements are more commonly available fo...

Page 52: ... and 3 If 12 is a higher voltage than 2 it may be desirable to provide the low voltage battery disconnect reconnect feature to prevent battery damage from deep discharge A more complete comparison of battery and load voltage ranges involving dc voltage drops in the cabling system is provided in the following sections Load drain and growth Under normal conditions with a constant load battery plant ...

Page 53: ...rotectors The summations of List 1 and List 2 drains for all the individual load circuits provide the List 1 and List 2 drains respectively for the entire battery plant Initial List 1 drains are used to size initial rectifiers and batteries since these components may be added relatively easily to operating plants To determine the initial rectifier and battery needs fill in the current drain inform...

Page 54: ...s of service is another factor which will vary from application to application Table 3 C lists reserve time practices which have been used in some telecommunications applications where maintaining power to the load is critical The figures are not intended to be guidelines except in the absence of any specified customer practices Table 3 A Initial Load Drain Information Load Circuit List 1 Amps Lis...

Page 55: ...harged battery to a specified end voltage For comparison purposes most vendors of telecommunications batteries specify ampere hour ratings at the 8 hour rate of discharge to an end voltage of 1 75 volts per cell Many battery vendors also supply ratings at other discharge rates such as 3 5 and 24 hour rates Although ampere hour ratings are useful for rough estimates of battery size actual battery s...

Page 56: ... to the battery manufacturer s recommendations on equalize charging The recharging requirement is determined by customer practices and is usually specified as a maximum time to reach a minimum percent of full capacity for example at least 90 capacity in no more than 24 hours 15 Maximum recharge time ____ hours 16 Percent of full capacity after recharge time 15 ____ Refer to the Battery manual or o...

Page 57: ...ate of battery recharge and delay their readiness for future discharges The same cable resistance responsible for voltage during recharge creates a voltage drop during discharge as well Voltage drop during discharge can limit the effectiveness of the batteries in supplying the necessary reserve For these reasons the engineer should minimize the voltage drop between bus bars and batteries by interc...

Page 58: ...quipment remain within the proper operating range for the prescribed reserve time Constants imposed by the typical 48 volt battery system are the normal battery float voltage and the minimum battery end voltage Note Engineering of plants with end cell or counter emf cell battery arrangements is not included in this discussion The variables that may be adjusted to ensure service for the specified t...

Page 59: ...rule of thumb specifies a maximum voltage drop of 0 75 volts in the feeder loop from the dc distribution to the load and back again using the List 2 drain for that circuit as listed in Table 3 B Voltage drop calculation methods are described in the next section Calculating voltage drop Fill in the selected or calculated system voltage drops below 19 Maximum drop batteries to dc distribution ____ v...

Page 60: ...ssion increases with increasing conductor temperature Conductor Ampacity Two criteria are used to select the actual wire gauge of a given conductor These two criteria are ampacity and voltage drop Ampacity is the current that may be carried safely without overheating In relatively low voltage high current systems such as dc distribution voltage drop limitations are often the determining factors in...

Page 61: ... next larger standard rating above the ampacity Overcurrent protectors may be sized smaller than this maximum rating In general however protectors should be rated as high as allowable to avoid nuisance tripping due to high load conditions or inrush during start up General Guidelines The peak current drain List 2 is used to size the circuit protection for each individual load The fuse or circuit br...

Page 62: ...ge 2000 SR 50 ampere 48 volt switched mode rectifier is currently available with the Lineage 2000 ECS Battery Plant J85500D 3 The maximum number of rectifiers per plant is 12 In the absence of specific customer practices the following procedure is RECOMMENDED 24 Determine the smallest whole number of rectifiers that will provide the normal List 1 plant drain in Table 3 A ____ 25 Determine the smal...

Page 63: ...ver between different vendors of the same capacity battery Floor loading restrictions may limit the potential compactness of the battery arrangement Such limitations of the building structure must be clearly understood before selecting a battery arrangement See Floor plan data under Planning below for more information on floor loading Applications with space restrictions such as standard aisle dep...

Page 64: ...el and bus bars will fit in this space with an ECS controller Only nine rectifiers will fit in this space with a Galaxy controller Additional dc output rectifiers and distribution panels breakers fuses can be configured in a supplementary bay If Lucent Technologies VR batteries are used additional framework called battery supplementary bays is necessary for strings of VR batteries with up to two s...

Page 65: ...r the dc power cabling which will be required as part of a complete cable engineering process Lucent Technologies offers cabling engineering services that are separate from battery plant engineering Contact your Lucent Technologies Account Executive for more information on available services Use wire type RHW or RHH for dc power wiring This type of wire is commonly available in American Wire Gauge...

Page 66: ...5 8 8 52 405348178 10 0 625 Red 8 8 75 406021626 0 250 0 625 Red 6 6 3 405347519 0 250 0 625 Blue 4 4 5 405347576 0 250 0 625 Grey 2 54 405348202 0 250 0 625 Brown 2 8 405347683 0 250 0 625 Green 1 0 56 405348228 0 375 1 0 Pink 1 0 57 405348236 0 375 1 0 Black 2 0 57 405348236 0 375 1 0 Black 2 0 77 406021725 0 375 1 0 Orange 4 0 59 405348251 0 375 1 0 Purple 4 0 27 405347923 0 375 1 0 Yellow 350M...

Page 67: ...attery cables must be engineered to fit the individual installation A wide range of circuit breakers and fuses is available for dc distribution overcurrent protection The ratings of these circuit breakers are from 5 600 amperes and the ratings of thge fuses are from 1 200 amperes The breakeror fuse rating fora given circuit is selected by the criteria covered above under Overcurrent Protection Tab...

Page 68: ... drop requirements outlined above under Calculating Voltage Drop 5 List the sizes based on voltage drop in Table 3 F 6 Indicate the larger size for each load feeder in the column marked Selected Wire Gauge 7 Fill in the circuit breaker or fuse rating e g 10 20 or 30 Amps in Table 3 F for each feeder 8 Record in Table 3 G the wire sizes for each battery feeder 9 Calculate the minimum wire size that...

Page 69: ...s 0 5 volts Based on the discussion above on Battery Sizing and Battery Voltage fill in the following information Is Low Voltage Battery Disconnect Reconnect required _____ yes or no If yes specify the disconnect level _____ 40 5 or 42 5 Emergency disconnect Reserved for future use Table 3 F Load Feeder Wire And Fuse Breaker Size Circuit Number List 2 Drain Minimum Wire Gauge Selected Wire Gauge F...

Page 70: ...er to the J85501D 2 or J85501F 1 controller drawing and the Controller Manual for details Alarm System Interface The standard ECS and Galaxy controllers are equipped with connection points for a variety of battery plant alarms The wiring from the controller alarm points to the local and remote reporting alarm systems however is NOT provided with the battery plant Such wiring must be compatible in ...

Page 71: ...Floor Load Heat Load AC Service Cable Rack and Routing Grounding Growth Floor Plan Data There are several types of information that are collectively called Floor Plan Data This information is sometimes published on Floor Plan Data Sheets For the Lineage 2000 ECS Battery Plant Floor Plan Data are given in Figure 4 2 This battery plant information must be combined with the corresponding data for all...

Page 72: ...me to accommodate a two hole cable lug on 62 centers If the frame ground lead is calculated to be larger than 2 AWG the corresponding lug has 3 8 diameter holes on 1 centers In this case the adapter that is always provided with the bay should always be used Refer to Figure 3 5 Growth Building systems should be designed for ultimate growth Cable rack support and ac distribution cabinets should be s...

Page 73: ...ent configurations with combinations of optional features The total number of combinations and permutations of the optional features on a given product may be in the hundreds or thousands For this reason a unique code is not assigned to each combination of options Instead a main code is specified which is followed by a list of identifiably separate options with the quantities for each option The m...

Page 74: ...imilarly The standard drawings for Lucent Technologies battery plants and their components are J T and SD drawings Together these drawings provide the necessary details for engineering planning ordering record keeping installation and repair A thorough understanding of the construction and content of the standard drawings is therefore required for proper error free engineering and ordering of the ...

Page 75: ...umber is one mechanism used to distinguish between vintages of the same product Ordering information may or may not change when a J drawing is reissued The drawing issue must agree with the vintage of product available from Lucent Technologies Reissued drawings are sometimes released prior to actual factory availability to provide time for engineering and order preparation Consult your Lucent Tech...

Page 76: ...idual supplementary lists may be specified for one main list Restrictions on possible combinations of main and supplementary lists are described in the feature descriptions in Table A and or in Engineering Notes see below 5B Ratings The availability for ordering of each List is controlled by the Rating listed in Table A Currently there are two Rating classifications Available AVAIL or no marking a...

Page 77: ... define standard symbols used on the assembly views and in the stocklist to indicate stamping and factory packaging methods Additional manufacturing notes are specific to each J drawing All manufacturing notes should be read and understood by engineering as well as installation since they may include important installation details that the engineer must plan for 9 Engineering Notes For engineering...

Page 78: ...of the T drawing cover sheet are Tables B C and D Table B of the T drawing gives a historical record of the addition and elimination of options This table corresponds to the Record of Change Table on the SD drawing See below As noted earlier there is usually a close correspondence between options defined on the SD and those shown on the T drawing The exact correlation of options and figure numbers...

Page 79: ...cumented on the SD Mechanical parts wire colors wire routing and cable harnesses however are not necessarily shown on the SD The SD drawing package is usually sectionalized similar to the J drawing as follows A sheets are cover sheets including Title Block Supporting Information Sheet Index Option Index All of this information is similar in format to that on T and J drawings B sheets contain the F...

Page 80: ... Information The J85500G 2 battery plant is ordered with List L numbers and Equipped With E W items See Table 3 H A sample order for a G 2 plant containing nine 50 ampere rectifiers a CP2 microprocessor board fourteen 30 ampere breakers two 175 ampere breakers capacitor charge switch feature one 24 position 1 30 ampere fuse block and stile strips in the initial bay and three 50 ampere rectifiers a...

Page 81: ...red equipped in a List 3 supplementary bay customer should specify bay position per Figure 2 3b Item Qty Description 1 1 J85500G 2 L 1 48V 600V ECS plant assem per Fig B E W 1 L 10 1 L KA 1 L 20 circuit breaker panel 14 L AD circuit breaker positions 1 through 9 14 through 18 2 L AP circuit breaker positions B D 1 L CA L 30 fuse panel 2 1 J85500G 3 L 3 supplementary bay E W 1 L 11 1 L K2 2 L K30 1...

Page 82: ...rol functions 7 Same as List 5 CP2 with voice response feature 8 Provides optional datalogger circuit pack CP3 for plant controller CP3 is a data acquisition pack that always requires a CP2 circuit pack 9 Same as List 8 with a remote termination panel The remote termination panel allows connection to the CP3 circuit pack from outside the controller 10 Provide optional third or fourth rectifier she...

Page 83: ...reaker with shunt AR 225 ampere breaker with shunt AU 300 ampere breaker with shunt AV 400 ampere breaker with shunt AW 500 ampere breaker with shunt AX 600 ampere breaker with shunt CA Provides a capacitor charge feature for List 20 breaker panel to precharge high inrush loads 30 Fuse panel for twenty four 1 to 30A load fuses 31 Fuse panel for eight 1 to 60A load fuses Lists H and J provide fuse ...

Page 84: ... feature to a plant controller in the field K20 Distribution panel cable kit for List 20 or 36 initial bay H285 226 L 20 feeder cable K30 Provides cable kit for supplementary bay distribution panel K36 Distribution panel cable kit for List 30 to 35 initial bay H285 226 L 36 feeder cable K37 Distribution panel cable kit for List 30 to 35initial bay H285 226 L 37 feeder cable K38 Distribution panel ...

Page 85: ...ier Shelf Assembly RSA and the Lineage 2000 VR series battery may be found on the following documents ECS Battery Plant Assembly and Ordering Drawing J85500G 2 Wiring Diagram T 82673 31 Schematic Diagram SD 82673 01 Product Manual 167 790 035 ECS Controller Assembly and Ordering Drawing J85501D 2 Wiring Diagram None Schematic Diagram SD 82669 01 Product Manual 167 790 033 Optional Circuit Pack Pro...

Page 86: ...s and Rectifier Shelf Assembly Assembly and Ordering Drawing J85702B 2 Wiring Diagram T 82668 30 Schematic Diagram SD 82668 01 Product Manual 167 790 060 Peripheral Monitoring System Manual 167 790 117 VR Series Battery Assembly and Ordering Drawing J85504C 1 Wiring Diagram T 83119 30 Schematic Diagram SD 83119 01 Product Manual 157 622 010 ...

Page 87: ...L OPEN 1 1 3 A 1 1 3 A 2A 0 5 A F 16 F 4 F 17 F 5 F 18 F 6 F 19 F 7 F 20 F 8 F 21 F 9 F 10 F 11 F 12 SPARE FUSES LINEAGE 2000 Haz ard ous Vol tag e Ris k of Elec tric al Sho ck FOR CON TIN UED PRO TEC TIO N AGA INS T RIS K OF FIR E AND SHO CK REP LAC E ON LY WIT H SAM E TYP E AND RAT ING OF FUS E Doo r sho uld be ope ned onl y by ser vice per son nel END PANEL LEFT OR RIGHT LIST KB FRONT STILE STR...

Page 88: ...Figure 3 2 Uniframe Rack Construction of Initial and Supplementary Bay 26 INCHES OVERALL WIDTH 84 INCHES OVERALL HEIGHT 23 50 INSIDE 24 32 MOUNTING CENTERS 6 INCHES 76 INCHES AVAILABLE MOUNTING SPACE 2 INCHES 5 INCH FRAME DEPTH CENTERED IN 12 INCH BASE 12 00 INCH BASE DEPTH 6 00 INCHES TO END OF CABLE BRACKETS REAR COVER ...

Page 89: ...nd Ordering 3 41 Figure 3 3 Bay Dimensions and Clearances NO WALL CLEARANCE REQUIRED FOR ECS CONTROLLER AISLE SPACE REQUIRED FOR GALAXY CONTROLLER INITIAL BAY OR SUPPLEMENTARY FRONT AISLE 18 5 INCHES DEPTH 30 INCHES FRONT AISLE CLEARANCE 84 INCHES HEIGHT 26 INCHES WIDTH END COVER INCREASES WIDTH BY 1 INCH ...

Page 90: ...ECS GPS Battery Plant J85500G 2 3 42 Engineering Planning and Ordering Issue 6 May 1999 Figure 3 4 Cabling Arrangement LOAD RETURN LOAD BATTERY BATTERY RETURN LOAD DISCHARGE RETURN CHARGE RETURN LOAD BATTERY BUS OPTIONAL WITH K1 NO K1 ...

Page 91: ...NCE WITH OTHER INFORMATION RATING DESCRIPTION LINE LIST CIRCUITS AND FIGURES EQUIPPED QTY CIRCUIT FIG WIRING APPARATUS AH SHOP INSTL AG AF AE AD AC AB AA 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 A A B B C C D D E E 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...

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Page 93: ...s and replacement 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 s...

Page 94: ...e 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 J85500G 2 Connection points and wire types are indicated on the plant wiring diagram T 82673 31 2 All dc leads should be separated wherever possible from ac leads to minimize electrical noise transmitted to the load 3 Pair the battery potential lead with the associ...

Page 95: ... 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 original shipping crate Locate shim and anchor the framework s Figure 4 1 shows typical floor mounting details for concrete floors Other types of floor construction may require other mou...

Page 96: ...lat washers should be furnished under heads of socket cap screws 5 Ferrous screws and washers should have a corrosion protective finish 6 Locking means is required only for connections subject to vibration Bellevile 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 s...

Page 97: ... 5 3 4 190 1 290 1 1 4 580 1 1 2 1010 Table 4 B Torque For All Non Electrical Connections e g Floor Anchors Cap Screw Diameter Torque Ft Lb UNRC Figure 4 1 Typical floor mounting detail HOLD DOWN PLATE 2 PLACES FRAMEWORK BASE FLOOR ANCHOR BOLT HILTI 4 PLACES HOLD DOWN WASHER 4PLACES FLOOR COVERING ...

Page 98: ...port and ground system Hang all cable support systems as well as any auxiliary ground bus bars as dictated by the job application drawings Controller and LVD set up Follow the controller set up procedure given in the ECS or Galaxy Controller manual to complete the steps below 1 Enable disable equalize charge set up 2 Enable disable rectifier restart set up Figure 4 2 Floor mounting template all di...

Page 99: ... pins 2 and 3 of their respective connectors Refer to the ECS controller manual for Table 4 C Installation Reference Documents Step Procedure Reference Document A Unpacking handling and frame installation J85500G 2 drawing B Battery stand assembly Battery manual C Initial battery charge Battery manual Rectifier manual D Cable support and ground system Job application drawings E Controller setup an...

Page 100: ... locations GENERAL PATH OF WIRE SET TO PLANT BUS BARS 4 1 1 1 3 8 P506 P505 2 LVD FUSE BOARD BCB2 CIRCUIT SIDE 3 3 1 1 1 5 P507 P505 1 P508 TB501 12 1 20 P502 40 1 P501 P504 JUMPERS GENERAL PATH OF 846651051 RIBBON CABLE Figure 4 4 LVD fuse board with thermal compensation circuitry BMD1 switch locations GENERAL PATH OF WIRE SET 4 1 10 1 5 6 1 1 3 8 P506 P507 P510 TB501 BMD1 SD 82673 02 P508 TB501 ...

Page 101: ...ibution bus bars and that all dc circuit breakers are off before connecting any load leads Run paired leads supply and return to each load from a dc distribution circuit breaker or fuse and from the discharge return bus The load supply leads are terminated at the breaker and fuse panels directly to the breaker or fuse terminal end The load return leads are terminated at the battery plant end on th...

Page 102: ...t connecting them to the bus bars in the dc distribution subsystem For suggested cable routing within the dc distribution see the J85500G 2 drawing or Figure 3 4 Replace the dc distribution cover panel on the plant framework after all connections have been made at the plant bus bars Terminate the cables from the dc distribution at each battery string according to the manufacturer s documentation M...

Page 103: ...ker trips 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 If the breaker trips again check the wiring to the load circuit Installation procedures for plant growth As your power needs evolve equipment may be readily added to the battery plant to provide any of the following expanded c...

Page 104: ...move all jewelry before working in this area Use insulated tools only CAUTION Accidentally or intentionally turning a circuit breaker off may affect service to load equipment Take care not to disturb load carrying circuits 3 Locate the intended new breaker or fuse panel Blank panels must be removed Some can be reused to cover empty space after installation Ensure that breakers are switched to the ...

Page 105: ...d hardware the monitor one string of batteries Read the instruction blow before beginning observe all the safety warnings and notes and follow the instructions step by step Tools Required 5 16 Nutdriver 7 16 Nutdriver Jeweler s Screwdriver Wire Strippers 22 AWG Heat Gun OBSERVE ALL SAFETY WARNINGS AND NOTES BEFORE BEGINNING INSTALLATION WARNING Procedures in this section may cause power alarms to ...

Page 106: ...on See Figure 4 9 for Option 2 Option 3 Mount the 216A Control Unit on the battery stand not the batteries in any convenient location using either the VR Module bracket and 1 or 2 10 32 screws or using the Velcro strips If the Velcro strips are used affix the Velcro hooks to a clean surface on the battery stand and the Velcro loops to the back of the Terminal Block Assembly must be cleaned Conside...

Page 107: ...Contactor to OPEN 7 Unplug the following connectors from the BCB2 LVD Fuse Board Leave the cables dressed P502 from J502 P506 from J506 P501 from J501 P504 from J504 Slide the ribbon cable removed from P502 so the connector is against the plastic holder Dress the excess cable into the distribution Be sure to leave enough cable to allow the door to open completely 8 Remove the cover over the BCB2 L...

Page 108: ...ug 847631363 inserted into P512 14 Connect the 216A Control Unit Interface Cable Assembly 847586815 to P510 on the BMD1 LVD Fuse Board and dress cable out of the distribution and down to the 216A Control Unit connecting to P511 15 Close all doors and ensure all covers are installed properly 16 Replace F507 F508 F509 F511 and F512 with their respective fuses into the BMD1 LVD R Fuse Circuit Pack NO...

Page 109: ...stors with INDIRECT airflow from a heat gun Heat applied directly to the thermistor could cause damage 5 Observe the following steps A minor fuse alarm MNF should be issued at Table 4 D SW500 Reference Conditions 216A Status Plant Voltage Compensation enabled Margin level Compensation Temperature in degrees Celsius SW500 2 SW500 4 0 25 25 53 53 75 75 75 to 65 1 0 Enabled V FLT 72mV C V FLT 72mV C ...

Page 110: ...atteries will not discharge that quickly 6 Allow the thermistors to cool then insert and secure them into the battery string 7 Verify that no alarms are present at this time Figure 4 5 216A Battery Thermal Compensation Control Unit faceplate BATTERY THERMAL COMPENSATION MODULE 216A CNTL MOD YEL INDICATOR STATUS GREEN MODULE CONDITION NORMAL TEMP 53 C TEMP 73 C NO THERMISTORS CONNECTED INPUT P511 P...

Page 111: ...500 Figure 4 7 VR Battery stand placement of thermistors BATTERY THERMAL COMPENSATION MODULE 216A CNTL MOD YEL INDICATOR STATUS GREEN MODULE CONDITION NORMAL TEMP 53 C TEMP 73 C NO THERMISTORS CONNECTED INPUT P511 P512 2 3 UP TO 12V LIMITED TO 15 mA NEC CLASS 2 P511 P512 1 4 5 9 LESS THAN 60 VDC FUSED AT 1 1 3 AMPERES MEASUREMENT TB101 102 TEMPERATURE LAMP TEST 847586807 CLEI ON ON ON FLASH OFF OF...

Page 112: ...1 POS 4 POS 5 POS 6 POS 2 POS 3 LVD R FAIL OPEN BATTERY THERMAL COMPENSATION MODULE 216A CNTL MOD YEL INDICATOR STATUS GREEN MODULE CONDITION NORMAL TEMP 53 C TEMP 73 C NO THERMISTORS CONNECTED INPUT P511 P512 2 3 UP TO 12V LIMITED TO 15 mA NEC CLASS 2 P511 P512 1 4 5 9 LESS THAN 60 VDC FUSED AT 1 1 3 AMPERES MEASUREMENT TB101 102 TEMPERATURE LAMP TEST 847586807 CLEI ON ON ON FLASH OFF OFF ON YELL...

Page 113: ... F 4 F 17 F 5 F 18 F 6 F 19 F 7 F 20 F 8 F 21 F 9 F 10 F 11 F 12 SPARE FUSES LINEAGE 2000 Hazardous Voltage Risk of Electrical Shock FOR CONTINUED PROTECTION AGAINST RISK OF FIRE AND SHOCK REPLACE ONLY WITH SAME TYPE AND RATING OF FUSE Door should be opened only by service personnel BATTERY THERMAL COMPENSATION MODULE 216A CNTL MOD YEL INDICATOR STATUS GREEN MODULE CONDITION NORMAL TEMP 53 C TEMP ...

Page 114: ...ery Thermal Compensation Control Unit installed on frame 801724857 SCR 1 4 20 x 5 8 847312592 Bracket 901252726 Screw 10 32 x 7 16 E W Lock Washer 2 Places 847589900 Terminal Board Assy See Fig 4 10 107617516 216A Control Unit See Fig 4 6 P512 To Next 216A or Terminator Plug if Last Module P511 Mates with P510 on BID1 CP ...

Page 115: ...47589900 Terminal Board Assembly 847307410 Temp Sensor Cable Assy 1 per Temp Sensor 10 Ft Long Temp Sensor 1 Temp Sensor 8 Temp Sensor 2 Temp Sensor 7 Temp Sensor 3 Temp Sensor 6 Temp Sensor 4 Temp Sensor 5 R BK Shield 1 R BK Shield 2 R BK Shield 3 R BK Shield 4 24 Ga 1 8 15 9 J1 Shield 8 BK R Shield 7 BK R Shild 6 BK R Shield 5 BK R 12 11 10 9 8 7 6 5 4 3 2 1 TB101 TB102 ...

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Page 117: ...VD 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 for an ECS controller They provide power for controller functions and rectifier regulation When a fuse blows the colored indicator white orange or green pops up and an alarm ...

Page 118: ... Fuse A distribution breaker or fuse which should be closed may be in the open position for one of three reasons Table 5 A Troubleshooting Observed Condition Probable Cause Procedure Controller Subsystem Red or yellow LEDs lit No LEDs or Display lit Meter inaccuracy Office alarms issued False alarms issued Blown fuse on LVD Fuse board See Troubleshooting in Controller Manual Rectifier Subsystem Re...

Page 119: ...reaker or Fuse Replacement below Red LVD OPEN LED Lit The Red LVD OPEN LED indicates that the LVD Contactor is de energized i e open The contactor may be open due to one of four reasons 1 Plant voltage is below the disconnect threshold 2 The contactor has failed and must be replaced See procedure for LVD R Contactor Replacement below 3 There is an open circuit in the wiring that powers the contact...

Page 120: ...ed with the faulty breaker or fuse to verify that the breaker or fuse is truly open The voltage relative to the battery bus bars or distribution panel bus 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 ...

Page 121: ...or FAJ MJF and its associated alarms retire LVD R Contactor Replacement The following assumptions are made contactor coil has failed THE CONTACTOR IS OPEN the rectifiers 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 distr...

Page 122: ...equipment is required standard screwdriver Procedure Refer to Figure 4 3 and T 82673 31 drawing WARNING Failure to follow procedure could result in service interruption 1 Remove control cable from front of rectifiers so rectifiers will remain on 2 Strap out low voltage contactor if equipped to keep batteries connected 3 Open distribution panel 4 Unplug the following connectors from the LVD Fuse Bo...

Page 123: ...ed as spare parts For exact ordering codes refer to recommended spares information on the J85500G 2 drawing Rectifiers and fans Circuit Breakers Refer to ED83119 30 Fuses 1 200 ampere LVD Fuse Board CP5 Fuses F1 to F21 Controller Circuit Packs Refer to the Controller manual LVD Fuse Thermal Compensation Board BMD1 CU 216A Thermal Compensation Control Unit In addition to these items any piece part ...

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Page 125: ...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 126: ...eadily 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 shall be...

Page 127: ...ontractors 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 warranty ...

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