Lucent Technologies Lineage 2000 ECS Battery Plant Product Manual Download | Manualshive

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Lucent Technologies 1200A 24V ECS Battery Plant J85500E-2

Issue 7 October 1998

Engineering, Planning, and Ordering 3 - 17

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 gauge

•

Wire type

•

Crimp lugs

•

Circuit breaker selection

To determine actual wire sizes, the equipment locations, cable
rack and routing systems at the site must be known. Since the
battery plant shares the cabling system with other building
systems, cabling engineering is not completely defined by this
section of the product manual. This section derives the basic 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.

Wire type RHW or RHH should be used for dc power wiring.
This type of wire is commonly available in American Wire
Gauge (AWG) Stranded (e.g., KS-5482) and in a finer stranded
welding type (e.g., KS-20921). Flexible or Welding Wire is
slightly larger than AWG stranded wire of the same gauge,
which may affect the selection of crimp lugs. For example,
different crimp lugs are required for AWG and Weld wire of the
same gauge, for 1/0 gauge and larger.

Flexible power wire (e.g., KS-20921) should be used for sizes
1/0 and larger in applications requiring tight bends, such as small
battery plants in confined locations.

The wire sizes that may be readily terminated at the dc
distribution subsystem are listed in Table 3-D. The distribution
allows direct termination of 4/0 wire. H taps should be used for
larger wire size requirements. Table 3-D specifies the
equipment, the terminal lug requirements, the maximum wire
size to be terminated directly without H taps, the terminal lug
center spacing, the crimp tool to use, the required fasteners, and
provisioning information.

Terminal lugs and hardware not provided may be ordered from
Table 3-E.

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Summary of Contents for Lineage 2000 ECS Battery Plant

Page 1: ...Lineage 2000 1200A 24V ECS Battery Plant J85500E 2 Product Manual Select Code 167 790 038 Comcode 107044778 Issue 7 October 1998 1998 Lucent Technologies ...

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Page 3: ...Lucent Technologies Lineage 2000 1200A 24V 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 1998 Lucent Technologies All Rights Reserved Printed in U S A ...

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Page 5: ...ion 2 1 Rectifier 2 2 Controller 2 3 Batteries 2 3 DC Distribution 2 3 Distribution Bus Bars 2 4 Plant Shunt 2 4 Low Voltage Battery Disconnect Reconnect LVD R Feature 2 4 Distribution Panels 2 5 Circuit Breakers 2 6 DC DC Converter System 2 6 Specifications 2 14 3 Engineering Planning and Ordering Introduction 3 1 Calculations 3 1 Load Equipment Voltage 3 2 Battery Plant Voltage 3 2 Load Drain an...

Page 6: ...a 3 26 Cable Rack and Routing 3 27 Grounding 3 27 Growth 3 27 Reference Material 3 27 Coding and Terminology 3 27 J drawings 3 29 T drawings 3 34 SD drawings 3 35 Spare Parts 3 36 Documentation References 3 36 4 Safety Safety Statements 4 1 Warning Statements and Safety Symbols 4 3 Precautions 4 5 5 Installation Introduction 5 1 Installation Tools and Test Equipment 5 2 Suggested Installation Sequ...

Page 7: ...a Load Circuit 5 14 6 Maintenance Controls and Indicators 6 1 Controller and Rectifier 6 1 CP5 Fuse Board LEDs and Fuses 6 1 DC Circuit Breakers 6 1 Troubleshooting 6 2 Open Distribution Breaker 6 5 Red LVD OPEN LED Lit 6 5 Yellow LVD FAIL LED Lit 6 5 Blown Fuse on CP5 6 6 Repair and Replacement 6 6 Load Circuit Breaker Replacement 6 6 LVD R Contactor Replacement 6 7 LVD Fuse Board CP5 Replacement...

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Page 9: ...C Distribution Panel Front View 2 9 Figure 2 5 ECS DC Distribution Panel Front Door Removed 2 10 Figure 2 6 Plug In Circuit Breaker Mounting 2 11 Figure 2 7 FPS 693AA DC DC Converter 2 12 Figure 2 8 FPS Power Plants 2 13 Figure 3 1 ECS Appearance Package Option 3 25 Figure 3 2 Typical J Drawing A Sheet 3 30 Figure 5 1 DC Distribution Cable Layout 5 7 Figure 5 2 Typical Floor Mounting Detail 5 8 Fi...

Page 10: ......

Page 11: ...ation 3 7 Table 3 C Reserve Capacity 3 8 Table 3 D Field Wiring Specifications 3 18 Table 3 E Lug And Hardware Ordering Codes 3 19 Table 3 F Feeder Current Size 3 22 Table 3 G Minimum Wire Gauge Ampacity All Strings 3 23 Table 5 A Minimum Torque For All Electrical Connections 5 4 Table 5 B Torque and Minimum Yield Strength for Mechanical Connections Using Hex Head Cap Screws 5 4 Table 5 C Installa...

Page 12: ......

Page 13: ...dular J85500E 2 battery plant efficiently integrates rectifiers converters controller and a distribution system in one compact bay Configurations 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 Growth in distribution is achieved by addin...

Page 14: ...erruptible power supply UPS Note The Lineage 2000 ECS Battery Plant J85500E 2 is to be installed only in restricted access areas dedicated equipment rooms equipment closets or the like in accordance with Articles 110 16 110 17 and 110 18 of the National Electrical Code or in accordance with the appropriate requirements of the Electrical Code of the country in which the equipment is installed Figur...

Page 15: ...ent Technologies customers is available around the world during the normal product warranty period and also while specific contractual agreements extend this service For customers in the United States Canada Puerto Rico and the US Virgin Islands call 1 800 CAL RTAC 1 800 225 7822 to contact a product specialist to answer your technical questions and assist in troubleshooting problems For other cus...

Page 16: ...Lucent Technologies 1200A 24V ECS Battery Plant J85500E 2 1 4 Introduction Issue 7 October 1998 conformance issues prior to customer ownership contact your local customer service ...

Page 17: ... mode making it suitable for those applications where battery backup is not necessary or is achieved through the use of an uninterruptible power supply UPS The ECS battery plant is designed as a totally integrated energy system package in which modular front access design facilitates installation and growth One standard equipment bay will accommodate a maximum of 12 Lineage 2000 SR Series 24 volt ...

Page 18: ...nd maintenance without service interruption The Lineage 2000 SR Series 100 ampere rectifiers operate over 208 240 Vac 50 60 Hz nominal single phase input range without any necessary tap changes A power factor correction circuit incorporated in the design insures a power factor of 90 percent or greater for loads above 50 percent of the full load rating The rectifiers provide the ECS controller with...

Page 19: ... microprocessor and a datalogger board The microcomputer board adds sophisticated firmware features such as remote communications alarm history and statistics The datalogger board may be used in conjunction with the microcomputer option to provide general purpose ac and dc voltage and current monitoring and control See the ECS controller manual for further information Batteries The ECS battery pla...

Page 20: ... current shunt in the ECS Battery Plant is connected between the Charge Return Bus and the Discharge Return Bus see Figure 2 2 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 1200 amperes The shunt millivolt signal is sent via the CP5 Fuse Board to the controller whe...

Page 21: ...ntactor failure The LVD sensing circuitry on CP5 is redundant A failure of either voltage detector circuit lights the yellow LVD FAIL LED but the contactor will stay closed A Fuse Alarm Minor MNF is issued when a LVD circuit fails lighting a yellow LED on the controller front panel and sending Power Minor PMN alarms to the alarm reporting center Once the contactor opens it remains open until the R...

Page 22: ... 80 90 and 100 ampere circuit breakers take up two positions on the panel DC DC Converter System The Lineage 2000 FPS series converters represent a significant advancement in space utilization and ease of installation over previously available products A unique Bell Laboratories design which incorporates 100 kHz switching frequency advanced technology and forced air cooling has resulted in convert...

Page 23: ...98 Product Description 2 7 Figure 2 2 ECS Distribution Bus Bars To Loads To Loads To Loads LVD Bus Plant Shunt Circuit Breaker Bus Discharge Return Bus Battery Bus LVD R K1 or Strap Charge Return Bus Distribution Bus Negative Rectifier Bus Positive Rectifier Bus To Rect Shelves ...

Page 24: ...S Battery Plant J85500E 2 2 8 Product Description Issue 7 October 1998 Figure 2 3 Low Voltage Disconnect Reconnect Contactor K1 Battery Bus Auxiliary Switch See Side View LVD Bus LVD R Contactor K1 Front View Side View N04 N03 NC2 NC1 ...

Page 25: ...on 2 9 Figure 2 4 ECS DC Distribution Panel Front View LINEAGE 2000 LVD R FAIL OPEN R E C T 1 R E C T 7 R E C T 2 R E C T 8 R E C T 3 R E C T 9 R E C T 4 R E C T 10 R E C T 5 R E C T 11 R E C T 6 M E T E R C P 2 C P 3 C P 1 D B B A T A B S C P 1 R B R E C T 12 U S E R 1 U S E R 2 U S E R 3 Lucent ...

Page 26: ...7 60 60 18 61 40 19 62 62 20 63 42 21 DO NOT EXCEED 300 AMPERE LOAD PER BUS BAR DO NOT EXCEED 300 AMPERE LOAD PER BUS BAR DO NOT EXCEED 300 AMPERE LOAD PER BUS BAR DO NOT EXCEED 300 AMPERE LOAD PER BUS BAR DO NOT EXCEED 300 AMPERE LOAD PER BUS BAR DO NOT EXCEED 300 AMPERE LOAD PER BUS BAR La batterie n est pas deconnectee Risque de choc electrique ou de blessures Ne pas toucher la bourne nue Batte...

Page 27: ...200A 24V ECS Battery Plant J85500E 2 Issue 7 October 1998 Product Description 2 11 Figure 2 6 Plug In Circuit Breaker Mounting TERMINAL BLOCK FOR LOAD CONNECTIONS TO LOAD LINE PWB ALARM LOAD NORMALLY OPEN AUXILIARY CONTACT ...

Page 28: ...Lucent Technologies 1200A 24V ECS Battery Plant J85500E 2 2 12 Product Description Issue 7 October 1998 Figure 2 7 FPS 693AA DC DC Converter Lucent ...

Page 29: ...Lucent Technologies 1200A 24V ECS Battery Plant J85500E 2 Issue 7 October 1998 Product Description 2 13 Figure 2 8 FPS Power Plants ...

Page 30: ...ts pre charge capacitor panel takes up 5 slots 2nd panel option accommodates 21 KS23616 circuit breakers 3 panels maximum Rectifier Shelf Assembly Complement 4 maximum each mounts 3 rectifiers Rectifiers Type Lineage 2000 364B Rating 24 Vdc nominal 100 amperes Complement 12 maximum Converter Shelf Assembly Optional replaces 1 rectifier shelf assembly Complement 1 maximum mounts 6 converters Conver...

Page 31: ... Vertical mounting centers 1 00 inches 25 mm Horizontal mounting centers 22 32 inches 567 mm Dimensions Height 84 inches 2134 mm Width 26 inches 660 mm Depth 18 5 inches 470 mm Depth when equipped with VR batteries 26 inches 660 mm Weight Initial bay equipped with 12 rectifiers 651 pounds 296 kilograms Rectifier Shelf Assembly 25 pounds 11 4 kilograms Rectifier 25 pounds 11 4 kilograms Converter 1...

Page 32: ...cted Emissions FCC Level A Electromagnetic immunity 10V m over the range of 20 to 2000 MHz Notes 1 Specified at a plant voltage of 27 25 Vdc 1200 amperes output and nominal input voltages and frequencies 2 Measured at 5 feet above the floor and 2 feet from the equipment Table 2 A J85500E 2 Battery Plant Specifications ...

Page 33: ... battery plant 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 characterizing the basic power requirements determining the power equipment that satisfies those needs determining the impact on the vario...

Page 34: ...imum 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 voltage disconnects for batteries and for loads Low voltage battery disconnect does ...

Page 35: ...cally use 12 cell battery strings for float voltages that range from 26 04 to 28 20 volts per string Lucent Technologies 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 vendor based on their maintenance and replacement strategies initial cost expected life service requirements and replacement cost Once the battery i...

Page 36: ...hat their current drain decreases as the plant voltage decreases Other types of loads are characterized as constant power equipment in that the current increases as the plant voltage drops Load equipment may have a combination of resistive and constant power characteristics In the telecommunications industry List 1 and List 2 are the designations of the load current drains which have historically ...

Page 37: ...r cables and plant discharge capacity since these cannot be readily increased once the plant is installed In Table 3 B fill in the anticipated future drains for the circuits listed in Table 3 A Also include in Table 3 B any additional circuits that may be added and their drains Recalculate the total battery plant drains Reserve Capacity Service and maintenance strategy are important factors in det...

Page 38: ...Technologies 1200A 24V ECS Battery Plant J85500E 2 3 6 Engineering Planning and Ordering Issue 7 October 1998 Table 3 A Initial Load Drain Information Load Circuit List 1 Amps List 2 Amps 1 Battery Plant Total ...

Page 39: ...S Battery Plant J85500E 2 Issue 7 October 1998 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 Battery Plant Total NC No Change C Changed A Added ...

Page 40: ...nimum reserve time below n Minimum battery reserve time ____ hours Battery capacity is usually specified in terms of Ampere Hours a measure of energy The ampere hour rating is the product of a constant discharge current and the time to discharge a fully charged battery to a specified end voltage For comparison purposes most vendors of telecommunications batteries specify ampere hour ratings at the...

Page 41: ...ocess is called Boost Charging while the latter is called Equalize Charging For the purposes of this manual the term Equalize is used to indicate boost or equalize charging Refer 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 ...

Page 42: ... current after a discharge This voltage drop is proportional to the magnitude of the recharge current Any voltage drop from the battery plant bus bars to the terminals of each battery string will tend to slow the rate of battery recharge and delay their readiness for future discharges The same cable resistance responsible for voltage drop during recharge creates a voltage drop during discharge as ...

Page 43: ...y larger cables may usually be tapped down to smaller ones to make the actual connections to the bus bars and battery terminals Battery Size versus Voltage Drop The critical requirement for a battery plant is that the input voltage to the load equipment remain within the proper operating range for the prescribed reserve time Constants imposed by the typical 24 volt battery system are the normal ba...

Page 44: ...rop and Balancing One 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 paragraph Calculating Voltage Drop Fill in the selected or calculated system voltage drops below v Maximum drop batteries to dc distr...

Page 45: ...a given conductor These two criteria are ampacity and voltage drop Ampacity is the current that may be carried safely without overheating the conductor In relatively low voltage high current systems such as dc distribution voltage drop limitations are often the determining factors in sizing conductors In systems such as ac distribution with relatively high voltage and low current ampacity usually ...

Page 46: ...d be rated as high as allowable to avoid nuisance tripping due to high load conditions or inrush during start up Engineering The methods used in the previous section Calculations are appropriate for the engineering of any battery plant The specifications in Section 2 are used in this section to select the specific types and quantities of equipment available with the Lineage 2000 ECS battery plant ...

Page 47: ...sary reserve several strings of small capacity batteries or one or two strings of large capacity batteries may be connected in parallel There are several important considerations in the choice of battery size versus number of strings namely Cost Weight and Space Efficiency Anticipated Growth System Reliability Cost The cost per ampere hour decreases with increasing cell capacity On the basis of in...

Page 48: ... x reserve time in hours minimum recharge factor System Reliability In most battery plants it is possible have an open circuit in the battery subsystem that could remain undetected until ac power is lost and battery power is required Therefore it is a good practice to select battery size such that at least two strings are required for applications where service reliability is critical Multiple str...

Page 49: ...able services Wire type RHW or RHH should be used for dc power wiring This type of wire is commonly available in American Wire Gauge AWG Stranded e g KS 5482 and in a finer stranded welding type e g KS 20921 Flexible or Welding Wire is slightly larger than AWG stranded wire of the same gauge which may affect the selection of crimp lugs For example different crimp lugs are required for AWG and Weld...

Page 50: ...s 60 100A Crkt Brkr Adapter Double Hole Adapter Double Hole 2 AWG 5 8 Blue 10 32 Nut Screw No Yes 100A Crkt Brkr Single Hole Double Hole 2 AWG 5 8 Brown 1 4 20 Screw No Yes 225A Crkt Brkr Single Hole Double Hole 4 0 AWG 1 Yellow 5 16 18 Screw No Yes 48V Fuse Panel Single Hole Double Hole 10 AWG 5 8 R5473 10 32 1 4 20 Nuts No Yes Battery Leads Double Hole Double Hole 4 0 AWG 1 Yellow 5 16 18 Nuts N...

Page 51: ...STR Class B FlexClass 1 WP 91412 List Comcode Bolt Size Centers 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 73 52 75 3 5 54 8 56 13 13 20 59 158 405356171 405348178 406021626 405347519 405347576 40534 8202 405347683 405348228 405347758 405347758 405347857 405348251 406434175 10 10 1 4 1 4 1 4 1 4 1 4 5 16 5 16 5 16 5 16 5 16 5 16 5 8 5 8 5 8 5 8 5 8 5 8 5 8 1 0 1 0 1 0 1 0 1 0 1 0 R5473 ...

Page 52: ...e 3 B to meet the voltage drop requirements outlined in paragraph 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 rating 10 20 30 45 or 60 amperes in Table 3 F for each feeder 8 Record in Table 3 G the wire sizes for each battery feeder 9 Calculate the...

Page 53: ...nductors should be rated no less than 75 C Wire conductor size determined by the formula above should be no less than allowed by electrical codes for 75 C wire regardless of insulation temperature rating used and the ampacity of the associated protection device In order to maintain proper spacings as required by Underwriters Laboratories when converting load conductors to the terminal block on the...

Page 54: ...24V ECS Battery Plant J85500E 2 3 22 Engineering Planning and Ordering Issue 7 October 1998 Table 3 F Feeder Current Size Circuit Number List 2 Drain Minimum Wire Gauge Selected Wire Gauge Breaker Rating Ampacity Voltage Drop 1 ...

Page 55: ...evel _____ 20 25 or 21 25 Controller Options The engineering of the ECS controller features involves orderable circuit packs and field movable jumper straps Circuit Packs Circuit pack options for the ECS controller are presented on the J85500E 2 battery plant drawing Refer to that drawing and to the Controller manual for more information on the availability of optional circuit packs Jumper Straps ...

Page 56: ...s provided on the controller circuit packs as detailed in the Controller Manual Earthquake Bracing The earthquake rating for the standard ECS battery plant is Zone 4 upper floors per NEBS TR EOP 000063 Appearance Packages An appearance package option is available for the initial and supplementary bays of the ECS battery plant This option is shown in Figure 3 1 It includes Front Style Strips 846651...

Page 57: ...and Ordering 3 25 Figure 3 1 ECS Appearance Package Option LINEAGE 2000 LVD R FAIL OPEN R E C T 1 R E C T 7 R E C T 2 R E C T 8 R E C T 3 R E C T 9 R E C T 4 R E C T 10 R E C T 5 R E C T 11 R E C T 6 M E T E R C P 2 C P 3 C P 1 D B B A T A B S C P 1 R B R E C T 12 U S E R 1 U S E R 2 U S E R 3 Lucent ...

Page 58: ...e collectively called Floor Plan Data This information is sometimes published on Floor Plan Data Sheets For the Lineage 2000 ECS Battery Plant complete Floor Plan Data is given on a sheet of the J85500E 2 drawing also presented in Table 2 A of this manual This battery plant information must be combined with the corresponding data for all other equipment in the office to engineer the appropriate as...

Page 59: ... for more information Growth As in the selection of protector and wire sizes for load feeders building systems should be designed for ultimate growth Cable rack support and ac distribution cabinets should be sized for the maximum anticipated battery plant capacity Floor space and weight capacity should also account for any increase in battery reserve Reference Material Many customers are familiar ...

Page 60: ...for each option The main code number falls into one of three categories J code ED code H code J codes take the form JxxxxxA y and are used to specify main assemblies stand alone products and units that may have multiple applications ED coding of the form ED xxxxx yy identifies subassemblies that are components of main equipment assemblies For example an ED coded distribution panel assembly may be ...

Page 61: ...and content of the standard drawings is therefore required for proper error free engineering and ordering of the battery plant The drawings associated with this battery plant should be reviewed completely before preparing an order The generic features of J T and SD drawings are described in the following sections J drawings A J drawing consists of the following parts Cover Sheet s containing order...

Page 62: ...FURNISHED PER THIS DRAWING IS IN ACCORDANCE WITH AT T 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 ASSOCIATED DRAWINGS DA DA ...

Page 63: ... 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 Technologies Account Executive for assistance with issue number coordination 4 Sheet index The index lis...

Page 64: ... 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 and Discontinued Availability DA The conditions on discontinu...

Page 65: ... 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 the second most important pa...

Page 66: ...torical 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 between the two drawings is given in Table C Table D gives is an index to the locatio...

Page 67: ... 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 Functional Schematics FSs C sheets list the Apparatus Figures APP...

Page 68: ...cessible Spare Parts The following equipment may be ordered as spare parts For exact ordering codes refer to recommended spares information on the J85500E 2 drawing Rectifiers and fans LVD Fuse Board CP5 Fuses F1 to F18 Load Circuit Breakers CB1 to CB63 Controller Circuit Packs e g 113B CU Refer to the Controller manual for details on spare controller circuit packs In addition to these items any p...

Page 69: ...ing Diagram T 82678 31 FPS Converter Wiring Diagram T 83158 30 Plant Schematic Diagram SD 82678 02 Rectifier Shelf Assembly Schematic Diagram SD 82668 02 Controller Schematic Diagram SD 82669 02 FPS Converter Schematic Diagram SD 83158 01 Plant Product Manual Select Code 167 790 037 Controller Product Manual Select Code 167 790 033 693AA DC DC Converter Product Manual Select Code 167 790 125 115B ...

Page 70: ......

Page 71: ...edicated equipment rooms equipment closets or the like in accordance with articles 110 16 110 17 and 110 18 of the U S National Electrical Code NEC ANSI NFPA No 70 and pursuant to applicable local codes This equipment is to be used in controlled environments an area where the humidity is maintained at levels that cannot cause condensation on the equipment the contaminating dust is controlled and t...

Page 72: ...ectors The short circuit current capability of the battery input to the distribution panel must not exceed 10 000 amperes Fuses circuit breakers may not be provided with the equipment Refer to the product documentation for the proper hardware Use only the parts specified in the equipment documentation Installing fuses or circuit breakers not specified for use in this equipment may result in injury...

Page 73: ...entifies the need to refer to the equipment instructions for important information These symbols or equivalent are used to identify the presence of hazardous ac mains voltage This symbol is used to identify the presence of hazardous ac or dc voltages It may also be used to warn of hazardous energy levels This symbol is used to identify the need for safety glasses and may sometimes be accompanied b...

Page 74: ...ulated metal objects Follow safety precautions This symbol is used to identify the presence of a hot surface It may also be accompanied by a statement explaining the hazard A symbol like this with a lightning bolt through the hand also means that the part is or could be at hazardous voltage levels This symbol is used to identify the presence of a hot surface The marked item should not be touched w...

Page 75: ...d by the batteries or the batteries are not connected to the output of the equipment High leakage currents may be possible on this type of equipment Make sure the equipment is properly safety earth grounded before connecting power Hazardous energy and voltages are present in the unit and on the interface cables that can shock or cause serious injury Follow all safety warnings and practices when se...

Page 76: ...an produce severe arcing Test circuits before touching Lock out and tag circuit breakers fuses when possible to prevent accidental turn on Be aware of potential hazards before servicing equipment Identify exposed hazardous electrical potentials on connectors wiring etc note the condition of these circuits especially wiring Use care when removing or replacing covers avoid contacting circuits ...

Page 77: ...s A suggested test sequence is also provided to check the integrity of the installation effort 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...

Page 78: ...amperes Supply should have both coarse and fine output controls For LVD R option only Six clip leads each capable of carrying 3 amperes Suggested Installation Sequence The plant may be wired with ac from the left side or the right side Typical routing of ac dc and control cabling is shown on the plant assembly drawing J85500E 2 Connection points and wire types are indicated on the plant wiring dia...

Page 79: ...ing carrier s procedure for filing a damage claim 2 To ensure personnel safety and equipment protection use appropriate equipment during handling of crates and uncrated equipment Use the equipment weights and dimensions given in Section 2 as a guideline for choosing material handling tools Move crated equipment to an area with adequate space and tools for unpacking and handling 3 Carefully open th...

Page 80: ... 3 8 16 7 16 14 1 2 13 5 8 11 3 4 10 15 21 50 15 21 50 100 180 280 500 71 125 19 27 65 19 27 65 135 240 385 585 97 172 19 27 65 135 240 385 585 97 172 23 33 80 165 290 465 710 118 209 Table 5 B Torque and Minimum Yield Strength for Mechanical Connections Using Hex Head Cap Screws Cap Screw Diameter Grade 2 Minimum Yield Strength PSI Torque Ft Lb UNRC 1 4 3 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 1 1 8 ...

Page 81: ...job application drawings Table 5 C Installation Reference Documents Procedure Reference Document Unpacking Handling and Frame Installation J85500E 2 Drawing and Installation Template Initial Battery Charge Rectifier Manual Cable Support and Ground System Job Application Drawings Controller Setup and LVD Test Controller Manual AC Wiring Rectifier Installation and Rectifier Test Rectifier Manual J85...

Page 82: ...05 1 and J505 2 on CP5 Fuse Board a To provide a disconnect voltage of 21 25 0 5 volts plug these jumpers across pins 1 and 2 of their respective connectors b To provide a disconnect voltage of 20 25 0 5 volts plug the jumpers across pins 2 and 3 of their respective connectors 3 Refer to the ECS controller manual for acceptance testing procedures for the CP5 circuit pack and the associated LVD R o...

Page 83: ... the OFF position Figure 5 1 DC Distribution Cable Layout TO BATTERIES LOAD RETURN LOAD RETURN SYSTEM GROUND BRACKET BATTERY LVD BATTERY BUS BAR DISCH RTN BUS BAR CHG RTN BUS BAR LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW DC DISTRIBUTION DISCH RTN BUS BAR BATTERY STRAP BUS BAR BATTERY BUS BAR PANEL DOOR RIGHT TO LOAD RETURNS TO LOADS DC DISTRIBUTION TO BATTERIES TO LOAD ...

Page 84: ... 2 Typical Floor Mounting Detail Framework Base 844218784 Hold Down Plate 2 Places 405889254 Floor Anchor Bolt 12 Millimeter Part Number 0003266520 Hilti 4 Places 841628571 Hold Down Washer 4 Places Floor Covering Note Use 3 4 Inch Drill for Floor Anchor Bolts The Required Minimum Drill Depth is 4 Inches ...

Page 85: ...at mounting position 1 primary mounting position then alternate locations 2 and 4 shall be selected as follows 3 94 2 00 18 00 2 00 3 94 2 00 2 00 25 88 1 17 7 25 9 59 3 25 Location 2 If interfering bar at 1 runs perpendicular to equipment lineup Location 3 If interfering bar at 1 runs parallel to equipment lineup Location 4 Permitted only if two reinforcing bars running perpendicular and parallel...

Page 86: ...85500E 2 5 10 Installation Issue 7 October 1998 Figure 5 4 LVD Fuse Board CP5 Jumper Locations J505 2 GENERAL PATH OF CABLE 4 1 1 1 3 8 P506 P505 2 LVD FUSE BOARD BCB4 CIRCUIT SIDE 3 3 1 1 1 5 P507 P505 1 P508 TB501 12 1 20 P502 40 1 P501 P504 J505 1 ...

Page 87: ...es the use of two termination positions 1 To install a circuit breaker first verify that the circuit breaker is in the OFF position 2 Plug in the circuit breaker and visually verify that the line load and alarm connections are properly mated See Figure 2 7 3 Remove the knockout from the associated position on the cover Mark the new circuit on the distribution cover label Spare circuit breakers may...

Page 88: ...ing Replace the dc distribution cover panel on the plant framework after all connections have been made at the plant bus bars 4 Terminate the cables from the dc distribution at each battery 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 ...

Page 89: ...akers A circuit breaker may trip immediately due to inrush current when the plant is initially turned on This 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 Converter Shelf Assembly Follow the Initial Start up and Checkout procedure given in the ECS FPS DC DC Converter Plant manual t...

Page 90: ...c distribution subsystem is described below Adding a Load Circuit The following procedure provides the steps to add a new load circuit to an operating battery plant 1 See Section 3 for details on sizing and obtaining additional circuit breakers 2 Alarms may be issued during the installation process e g by a new circuit breaker in the OFF position Notify the alarm reporting center that alarms may b...

Page 91: ...n install these leads by following Installation Step 7 in Sequence of Tasks above 6 Mark the new circuit on the distribution cover panel label 7 For safety close the dc distribution front cover before proceeding to the next step 8 Turn on the load circuit breaker If the circuit breaker trips immediately when turned on it may be due to inrush current and does not necessarily indicate a fault condit...

Page 92: ... Technologies 1200A 24V ECS Battery Plant J85500E 2 5 16 Installation Issue 7 October 1998 9 When all work on the dc distribution is complete close the distribution cover and notify the alarm reporting center ...

Page 93: ...ct 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 F12 are also located on the CP5 LVD Fuse Board and provide power for controller functions and rec...

Page 94: ...the load If a breaker has tripped off the overcurrent problem should be cleared before restoring power to the load by resetting the breaker See paragraph Troubleshooting for information on tripped breakers Troubleshooting Table 6 A provides a list of observable trouble conditions their possible causes and the necessary corrective action for each cause The table is organized by the subsystem in whi...

Page 95: ...AD RECTIFIER 10 F 1 F 13 F 7 F 2 F 14 F 8 F 3 F 15 F 9 F 4 F 16 F 10 F 5 F 17 1 1 3 A 0 5 A F 11 F 6 F 18 F 19 F 20 F 21 SPARE FUSES 1 1 3 A MINOR FUSE ALARMS MINOR FUSE ALARMS MAJOR FUSE ALARMS MAJOR FUSE ALARMS 1 1 3 A 2A F 12 REG LEAD RECTIFIER 5 REG LEAD RECTIFIER 11 REG LEAD RECTIFIER 6 REG LEAD RECTIFIER 12 113B METER CP2 AND CP3 CP1 RECTIFIER INTERFACE POWER RECTIFIER CP1 INTERFACE POWER AL...

Page 96: ... Troubleshooting 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 a manually turned off b overcurrent trip c breaker failure Open Distribution Breaker LVD OPEN LED lit a failed LVD contactor b low voltage c faulty wiring d LVD ...

Page 97: ...er as described in paragraph Load Circuit Breaker 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 open circuit i...

Page 98: ... the load connection associated with the faulty breaker to verify that the breaker is truly open The voltage relative to the battery bus bars or circuit breaker bus bar should be approximately the float voltage of the plant If the faulty breaker is in fact still closed the load equipment which it powers must be shut down so that no current flows through the breaker 5 Unplug the faulty breaker from...

Page 99: ...lt condition Attempt to close the circuit breaker a second time If the breaker trips again check the wiring to the load circuit 10 Note that Fuse Alarm Major MJF and its associated alarms retire 11 When all work on the dc distribution is complete refasten the cover panel LVD R Contactor Replacement The following assumptions are made Contactor coil has failed THE CONTACTOR IS OPEN The rectifiers ar...

Page 100: ...new contactor and then mount new contactor using hardware from Step 4 6 Plug P501 into J501 on LVD Fuse board CP5 and verify that contactor closes 7 Replace covers close distribution door and verify that LVD FAIL and LVD OPEN lights are not lit LVD Fuse Board CP5 Replacement The following equipment is required standard screwdriver Warning Procedures in this paragraph may cause power alarms to be i...

Page 101: ...rom J501 P504 from J504 TB501 from J501 3 Remove the 5 mounting screws 4 Unplug P508 from J508 connector Leave the cable dressed 5 Set jumpers J505 1 and J505 2 on replacement LVD Fuse Board CP5 per J85500D 1 drawing for desired disconnect voltage 6 Reconnect P508 and J508 connector 7 Mount the replacement board to the distribution panel using the hardware from Step 3 8 Reconnect the following con...

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Page 103: ...ranties 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 shipped...

Page 104: ...dily 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 b...

Page 105: ...ntractors 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 w...

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