Page 1 Operation, Maintenance, Installation, and Testing Requirements for the 415B Battery Plant ™ (New and Retrofit 4ESS Applications) Product Manual Select Code 167-792-121 Comcode 107972754 Issue 6 September 1999 © 1999 Lucent Technologies...
Page 3 September 1999 Lucent Technologies Operation, Maintenance, Installation, and Testing Requirements for the 415B Battery Plant (New and Retrofit 4ESS ™ Applications) Notice: Every effort was made to ensure that the information in this document was complete and accurate at the time of printing.
Page 5: Table Of Contents
™ Lucent Technologies 415B Battery Plant for 4ESS Table of Contents 1 Introduction Product Manual 1 - 1 415B Battery Plant 1 - 1 Applications 1 - 2 Installation and Testing 1 - 2 Customer Assistance Contacts 1 - 3...
Page 6 ™ Lucent Technologies 415B Battery Plant for 4ESS Design 2 - 6 Power Requirements 2 - 6 Documentation References 2 - 6 3 Safety Information 3 - 1 Rubber Gloves 3 - 1 Admonishments 3 - 1 Safety Statements 3 - 1...
Page 7 ™ Lucent Technologies 415B Battery Plant for 4ESS Rectifier Alarms and High Voltage Shutdown 5 - 8 FA Test 5 - 9 BUHVSD 5 - 9 ISHVSD 5 - 9 Rectifier Equalize Adjustment (on Battery) 5 - 10 AC Failure Test...
Page 8 ™ Lucent Technologies 415B Battery Plant for 4ESS Restrictions 7 - 2 Configuration 1 (Adding One Rectifier) 7 - 2 Configuration 2 (Adding Two Rectifiers) 7 - 2 Configuration 3 (Adding a 5-Rectifier Plant) 7 - 3 Control and Distribution Bay...
Page 9 ™ Lucent Technologies 415B Battery Plant for 4ESS Bolting Hardware 7 - 34 Rectifier and AC Connections 7 - 36 Rectifier Output Connections 7 - 36 Alarms 7 - 36 Control and Distribution Bay Connections 7 - 37 Return Bus Bar Kit (Using New PDF)
Page 10 ™ Lucent Technologies 415B Battery Plant for 4ESS Power Distribution Frame Fuse Alarms 7 - 64 Battery Plant Overall Operation Tests 7 - 64 Energy Management (Efficiency) Algorithm 7 - 64 Power Distribution Frame Shunt Monitors 7 - 65 Battery Reserve Time Prediction Option...
Page 11 Lucent Technologies 415B Battery Plant for 4ESS List of Figures Figure 1-1: 415B Battery Plant 1 - 2 Figure 2-1: Typical 415B Battery Plant AC Feeds 2 - 2 Figure 4-1: Bracket Mounting Locations 4 - 2 Figure 4-2A: AC Distribution Floor Mounting...
Page 12 ™ Lucent Technologies 415B Battery Plant for 4ESS Figure 7-8: Connecting AC to the Rectifiers (K1 Contactor) 7 - 15 Figure 7-9: Partial Sketch of CM2 (208G) Control Board 7 - 23 Figure 7-10: CM1 (329B) Fuse Board 7 - 24...
Page 13 ™ Lucent Technologies 415B Battery Plant for 4ESS List of Tables Table 5-A: DIP Switch Default Settings for 208G Circuit Module 5 - 3 Table 5-B: Load Settings for AC Failure Test 5 - 11 Table 5-C: Circuit Packs/Kit Furnished with the...
Page 15: Introduction
This product manual (Select Code 167-792-121) describes the installation, testing, operating, and maintenance instructions for Manual the 415B Battery Plant, which is shown in Figure 1-1. The following list provides a reference key to the contents of this product manual:...
Page 16: Applications
There are separate EGCMs for the A plant and the B plant. Figure 1-1: 415B Battery Plant The 415B Battery Plant is usually used to power a 4ESS ™ Applications switch, but it can be used for any high power, 140-volt plant.
Page 17: Customer Assistance Contacts
For other customers worldwide, contact your local field support center or your sales representative to discuss your specific needs. Product Repair and Repair and return service is provided for Lucent Technologies Return 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 repair.
Page 18: Warranty Service
For domestic warranty service, contact your Warranty Service Manager (WSM). For international warranty service, contact your sales representative. On-Line Power For Lucent Technologies users logging in from inside the Systems Product corporate firewall, the address of the “Power Systems On-Line Manuals Product Manuals”...
Page 19: System Description
System Description 415B Battery Two 4ESS ™ switches are powered by two independent 415B Battery Plants. Each 415B Battery Plant consists of two Power Plant Overview Distribution Service Cabinets (PDSC), a Control and Distribution Bay, up to four rectifiers, three battery strings, two Power Distribution Frames, an Enhanced Ground Current Monitor, and a Galaxy Controller.
Page 20: Figure 2-1: Typical 415B Battery Plant Ac Feeds
PDSC B2 Rectifier 4 Rectifier 1 Rectifier 2 Rectifier 3 (optional) Plant A Rectifier 4 Rectifier 1 Rectifier 2 Rectifier 3 (optional) Plant B Figure 2-1: Typical 415B Battery Plant AC Feeds 2 - 2 System Description Issue 6 September 1999...
Page 21: Control And Distribution Bay
™ Lucent Technologies 415B Battery Plant for 4ESS Control and The Control and Distribution Bay distributes power for the using equipment, as well as for float and recharge capability for the Distribution batteries, the alarm panel, the plant shunt, Galaxy Controller, dc/dc converters, battery disconnect/reconnect switches, and distribution breakers.
Page 22: Battery Equalize/Boost Feature
156.1 volts total. Power The Power Distribution Frame (PDF) bay is the secondary distribution point for the 415B Battery Plant. There are two PDF Distribution bays per plant, and each bay contains six panels of secondary Frame (PDF) distribution fuses to power the loads.
Page 23: Capacitors
™ Lucent Technologies 415B Battery Plant for 4ESS Capacitors Capacitors are located in the PDF bay to add extra energy storage either to help maintain the bus voltage or to aid in the clearing of fuses depending on where a fault condition occurs.
Page 24: Enhanced Ground Current Monitor
The Enhanced Ground Current Monitor (EGCM) is designed to measure and display current present in the 1/0 AWG ground Ground Current cable of the 415B Battery Plant. The EGCM will give an alarm Monitor when user-set current limits are exceeded. The input to the EGCM is protected with a half (1/2) ampere fuse.
Page 25 ™ Lucent Technologies 415B Battery Plant for 4ESS J87132B-2 140Vdc, 140A, 60Hz Ferroresonant Rectifier Assembly Drawing J87132B-2 Wiring Diagram T-83325-30 Schematic Drawing SD-83325-01 Product Manual Select Code 169-792-100 J85501F-1 Galaxy Controller Assembly Drawing J85501F-1 Wiring Diagram T-83217-30 Schematic Drawing SD-83217-01...
Page 27: Safety
Lucent Technologies 415B Battery Plant for 4ESS Safety Information Please read this section carefully before installing, testing, maintaining, or repairing the 415B Battery Plant or any of its subsystems. Also refer to the product manuals of the subsystems for additional safety information. Rubber Gloves...
Page 28: Precautions
When working on or using this type of equipment, follow these precautions: • The 415B Battery Plant and its subsystems must be installed, serviced, and operated only by skilled and qualified personnel who have the necessary knowledge and practical experience with electrical equipment and who understand the hazards that can arise when working on this type of equipment.
Page 29: Personal Safety
™ Lucent Technologies 415B Battery Plant for 4ESS • When servicing the rectifier, disconnect the ac service and the dc battery buses. Use extreme caution when handling the battery bus cables since these cables may transmit hazardous currents from the batteries. The disconnected...
Page 30: Warning Statements And Safety Symbols
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. In the 415B Battery Plant the hazardous dc voltage can cause injury or death. One of these two symbols (or equivalent) may be used to identify the presence of rectifier and battery voltages.
Page 31: Electrostatic Discharge (Esd)
™ Lucent Technologies 415B Battery Plant for 4ESS These symbols are used to identify the safety earth ground or bonding point for the equipment. Electrostatic • Assume all circuit packs containing electronic (solid-state) components can be damaged by ESD. Discharge (ESD) •...
Page 32 ™ Lucent Technologies 415B Battery Plant for 4ESS nonconductive plastic solder suckers. The insulation on small hand tools does not represent a static hazard. • Keep adhesive tape (Scotch, masking, etc.) away from static-sensitive devices. • When soldering static-sensitive semiconductor devices, the soldering iron must be grounded to the work table, which must also be earth grounded.
Page 33: System Installation
Lucent Technologies 415B Battery Plant for 4ESS System Installation Safety Please read Section 3, Safety, carefully before installing, testing, maintaining, or repairing the 415B Battery Plant or any of its subsystems. DANGER The voltage in this plant can cause serious injury. 140 volts is considered to be a hazardous voltage.
Page 34: General Installation
™ Lucent Technologies 415B Battery Plant for 4ESS General Installation Note Install top and bottom door mounting brackets before running the cables to the Control and Distribution Bay bus bars. Mounting Mount the top bracket in Positions 75-73. Mount the bottom in Brackets on Positions 5-3.
Page 35: 4Ess ™ ™ ™ ™ ™ ™ ™ ™ ™ ™ ™ ™ ™ ™ ™ ™ ™ ™ ™ ™ ™ Configurations
™ Lucent Technologies 415B Battery Plant for 4ESS 4ESS ™ The ac distribution for the 4ESS ™ can be either floor-mounted or wall-mounted. Figure 4-2 (A and B) shows both Configurations configurations. Choose the appropriate configuration from the D1 sheet of the T-83360-30 drawing, and locate rectifiers and ac distribution as shown.
Page 36: Figure 4-3: Typical Floor Mounting Detail
™ Lucent Technologies 415B Battery Plant for 4ESS Bolting Hardware The Control and Distribution Bay contains the bolting hardware for mounting both the ac cabinet and Control and Distribution Bay to the floor. Figure 4-3 shows a typical floor mounting detail.
Page 37 ™ Lucent Technologies 415B Battery Plant for 4ESS All hardware for making electrical connections to the KS-22089 ac cabinets can be found inside the cabinet. The input ac lugs are not provided and must be furnished by the line engineer.
Page 38: Alarms
™ Lucent Technologies 415B Battery Plant for 4ESS Rectifier and AC Connections between the ac cabinet and the rectifiers are Connections 6-gauge for 480Vac service. The connections for the 208 or 240 Vac are 4-gauge. The installer must follow all local municipal codes and NEC codes and requirements.
Page 39 ™ Lucent Technologies 415B Battery Plant for 4ESS to the Galaxy Controller product manual for alarm connections to the customer’s panel. Control and Output from the Control and Distribution Bay uses KS-24194, Distribution Bay L13 Red with trace (“A” Plant), and Blue with trace (“B” Plant) Connections braided 2-gauge wire.
Page 40: Figure 4-7: Connections For The Rpm
™ Lucent Technologies 415B Battery Plant for 4ESS First RPM RPM 108040932 To equipment Blue To Galaxy being monitored White Controller Shield TB101 TB102 221F Note: The last RPM Module is terminated with a 560 ohm resistor (CC 405298308) plugged into X1 and X2 sockets inside the RPM.
Page 41 ™ Lucent Technologies 415B Battery Plant for 4ESS Battery String The Battery String Protection Fuse Alarm connection was Alarm designed for ease of installation. Use 22-gauge stranded wire to Connections connect the alarm from the BNF2 board to the ED83146-30 G1 protection fuse with a single wire connection.
Page 42 ™ Lucent Technologies 415B Battery Plant for 4ESS 3. Prepare an appropriate length of 1/0, stranded, green-color cable and half-tap this cable to the ground cable in proximity to the EGCM. 4. Install the EGCM on the cable rack above the Control and Distribution Bay in a location where the display can be easily observed.
Page 43 ™ Lucent Technologies 415B Battery Plant for 4ESS unit until the display matches the clamp-on ammeter reading. See Step 2 of this section. 11. The EGCM has its own scan point, OAOO, in the 4ESS ™ office alarm system. Issue 6 September 1999...
Page 45: Power Up Of 415B Battery Plant
• Battery Plant Simulator Test Set (ITE-7102) • Standard installation tools, screwdrivers, etc. • J87132B-2 Rectifier product manual • Galaxy Controller for 415B Battery Plant product manual • Rubber gloves • Windows-based personal computer (PC) with EasyView software installed •...
Page 46 ™ Lucent Technologies 415B Battery Plant for 4ESS – The ac equipment ground is properly connected to each rectifier. – The correct ground cable gauge has been used (minimum #6 for rectifier, #2 for Control and Distribution Bay). – The Enhanced Ground Current Monitor has been properly connected and its alarm contacts have been connected.
Page 47: Distribution Frames
™ Lucent Technologies 415B Battery Plant for 4ESS components, i.e., transformers, inductors, capacitors, etc. – On both Power Distribution Frames, check that RPMs have been properly installed and that dip switches have been properly set and wired. – Check that all fuses have been removed at both Power Distribution Frames.
Page 48 ™ Lucent Technologies 415B Battery Plant for 4ESS 3. Verify that all alarm cables J202 are disconnected at the 208G boards inside all rectifiers. The other end is still connected at the back of the Galaxy Controller. 4. Verify that all the remote sense cables J208 are still connected at both the Galaxy Controller and at all 208G boards in the rectifier.
Page 49: Control And Distribution Bay Precharge Procedure
™ Lucent Technologies 415B Battery Plant for 4ESS 15. Verify that all rectifiers are off before proceeding. 16. Reconnect ALL alarm cables J202 at the 208G boards for all rectifiers. 17. Place a 20-ampere load on the battery plant; turn the ac power switch on rectifier to On and adjust its output to 151.9 volts.
Page 50: Pre-Test Setup
™ Lucent Technologies 415B Battery Plant for 4ESS Note Circuit Breaker #1 also provides power for the alarm circuit. Pre-test Setup These system test procedures are based on the assumption that all installation work has been completed, battery strings have been initially charged, and no working loads have been connected to the battery plant.
Page 51: Rectifier Walk-In
™ Lucent Technologies 415B Battery Plant for 4ESS Rectifier Walk-in 1. With only one rectifier turned on, adjust the battery plant load to be 130-140 amperes. The rectifier assumes full load. 2. Turn the rectifier off via the POWER switch; wait 5 seconds, then turn it back on.
Page 52 ™ Lucent Technologies 415B Battery Plant for 4ESS Output Voltage Before making the Output Voltage Adjustment, follow these Adjustment preliminary steps: Range • Turn off all rectifiers. • Operate Battery Disconnect Switches to Off. • Disconnect the control cable J202 at each 208G board on each rectifier.
Page 53: Fa Test
™ Lucent Technologies 415B Battery Plant for 4ESS Perform the following procedures before continuing test: • Turn all rectifiers to the Off position via the ON/OFF power switch at the rectifier. • Remove all control (J202) and REG (J208) cables at the 208G board in all rectifiers.
Page 54: Rectifier Equalize Adjustment (On Battery)
™ Lucent Technologies 415B Battery Plant for 4ESS 20 seconds, the rectifier will shut down and issue an RFA. Shut the rectifier off via the ON/OFF power switch, and lower the voltage by depressing the LOWER VOLTAGE pushbutton for approximately five seconds.
Page 55: Ac Failure Test
™ Lucent Technologies 415B Battery Plant for 4ESS 9. Turn the rectifier Off via the POWER switch. 10. Disable local equalize by operating DIP switch S205.3 to 11. Repeat Steps 5 through 10 for all rectifiers. 12. Remove load. Reconnect control cables J202 to each rectifier at 208G board.
Page 56: Galaxy Controller
ACF LEDs on the rectifiers light while ac is failed. 7. Restore the system to normal by closing all breakers previously opened. Galaxy The Galaxy Controller for the 415B Battery Plant is ordered as J85501F-1, L4. Table 5-C lists the circuit packs furnished with Controller the controller.
Page 57: Galaxy Readouts
™ Lucent Technologies 415B Battery Plant for 4ESS The following list gives some of the more important Galaxy information that is needed in order to check the configuration. Rectifier J87132B-2 Plant Shunt 600 amperes @ 50 mV High Voltage Shutdown 156.5V...
Page 58: Galaxy And Rectifier Interface Leads
™ Lucent Technologies 415B Battery Plant for 4ESS ampere, adjust Galaxy to agree with the shunt readings, utilizing the ADJ PLI function under the CONFIGURE and PLANT menus. Restore the plant to normal via the MENU key. 4. Remove load.
Page 59: Ph Leads
™ Lucent Technologies 415B Battery Plant for 4ESS PH Leads This test is done with the battery connected to the Control and Distribution Bay and with 10 - 20 amperes of plant load with all rectifiers on. Warning Extra care should be taken while performing the following test.
Page 60: Vi And Vp Leads
™ Lucent Technologies 415B Battery Plant for 4ESS 3. Open the ac breaker to the rectifier at the PDSC. 4. Verify that the voltage on the output capacitors is less than 50 volts. If not, wait until the voltage is less than 50 volts.
Page 61 ™ Lucent Technologies 415B Battery Plant for 4ESS 2. Verify that SW202 position #8 is at the “1” or “closed” position. 3. Configure the controller for rectifiers. You can configure the rectifiers from the front panel of the Galaxy by doing the following: Press MENU→CONFIG→RECT DEF...
Page 62 ™ Lucent Technologies 415B Battery Plant for 4ESS 6. With only rectifier #1 on line and carrying a load of approximately 70 amperes, measure the voltage at test points E101 and E102 of the 329B fuse board. Calculate the actual load on rectifier as follows: The rectifier test points (shunt) will read 50 millivolts at 175 amperes.
Page 63: Equalize/Boost Leads
™ Lucent Technologies 415B Battery Plant for 4ESS 5. Adjust all rectifiers to a float voltage of 151.9 volts at the battery terminals. TR and TRH 1. At TB3, located at the rear of the Galaxy, short terminals 8 Leads and 24 (TR1 and return).
Page 64 ™ Lucent Technologies 415B Battery Plant for 4ESS b. Depress the CAP/CHG pushbutton switch; the red LED lights, then extinguishes. c. With the CAP/CHG pushbutton switch depressed, operate circuit breaker #1 to the On position. d. Release the pushbutton switch.
Page 65: Miscellaneous Alarms
™ Lucent Technologies 415B Battery Plant for 4ESS Miscellaneous Alarms BD and VLV 1. With all rectifiers off, apply a 100-ampere test load to the Alarms plant. Observe the plant voltage on the front panel of the Galaxy. Verify that the BD alarm is generated at 149 ±1Vdc.
Page 66 ™ Lucent Technologies 415B Battery Plant for 4ESS Battery String This test is done with all rectifiers on and at no load. Disconnect 1. At the Control and Distribution Bay, operate battery disconnect switch #1 to Off. OS and MAJOR alarms are initiated and displayed at Galaxy.
Page 67 ™ Lucent Technologies 415B Battery Plant for 4ESS 4. Verify that local MJF and RFA alarms are issued, visual and audible Local Office alarms are initiated, and a remote alarm has been received at the Alarm Center. Power Power Distribution Frame alarms are not sent to Galaxy. A red...
Page 68 ™ Lucent Technologies 415B Battery Plant for 4ESS Note: Pressing ESCAPE returns the screen one level. 2. Place all rectifiers on line at float voltage and apply full load. Record plant voltage. In ten minutes a rectifier will turn off. Record plant voltage.
Page 69 ™ Lucent Technologies 415B Battery Plant for 4ESS 2. Apply a 1-ampere test load to the output of a fuse position on the Power Distribution Frame. 3. Insert the Power Distribution Frame load charge probe into the slot of the alarm fuse associated with the fuse position.
Page 70 ™ Lucent Technologies 415B Battery Plant for 4ESS 1. Place a load of approximately 50 amperes on the plant. Turn off all rectifiers and verify that a BD alarm occurs. Allow the BD alarm to exist for a minimum of 15 minutes.
Page 71: Checking High And Low Alarm Set Points
™ Lucent Technologies 415B Battery Plant for 4ESS 4. If the offset cannot be adjusted properly, refer to the calibration and/or repair procedure in the product manual that is shipped with the EGCM. Checking High Alarm set points can be checked by pressing the POSITIVE and and Low Alarm NEGATIVE alarm test buttons located on the display unit.
Page 72: Heat Scan
™ Lucent Technologies 415B Battery Plant for 4ESS 6. Allow the plant to run at this load for at least 16 hours. 7. At the end of the allotted time, record the plant voltage. Verify that it is within 0.7 volts of the setting in Step 3.
Page 73: Connecting Telecommunication Loads To
™ Lucent Technologies 415B Battery Plant for 4ESS Connecting Telecommunication Loads to the Power Distribution Frame Capacitor Note: This procedure is used when connecting the actual telecommunication load to the plant. Charging from the Power Included as part of the Power Distribution Frame is a Capacitor...
Page 74 ™ Lucent Technologies 415B Battery Plant for 4ESS Perform the following tests to verify proper operation of the Capacitor Charge Unit: 1. Insert the charge probe into an alarm fuse position that has a load connected to it. The charge probe is keyed and can only be inserted in the correct position.
Page 75: Retrofit Of 415A Battery Plant
™ Lucent Technologies 415B Battery Plant for 4ESS Retrofit of 415A Battery Plant Retrofit This section describes the installation, testing, operation, and maintenance instructions for retrofitting the 415A battery plant. Configurations Three retrofit configurations are shown in Figure 7-1 and are...
Page 76 ™ Lucent Technologies 415B Battery Plant for 4ESS Configuration 3 uses the H569-429 Group 4 frame, which is equipped with a six-rectifier alarm panel, battery disconnect/ reconnect switches, a Galaxy Controller, seventeen 100-ampere distribution breakers with precharge and 100 ampere/25mV...
Page 77: Figure 7-1: Three Configurations Of The 415B Battery Plant
™ Lucent Technologies 415B Battery Plant for 4ESS (1) H569-429 Group 24 (wireset for 2 red and red with trace and 2 blue and blue with trace for connecting the rectifier) Configuration 3 Configuration 3 is the installation of up to five rectifiers. It is used in replacing both the A Plant and the B Plant for 4ESS ™...
Page 78 ™ Lucent Technologies 415B Battery Plant for 4ESS Control and The Control and Distribution Bay distributes power for the using equipment, as well as for float and recharge capability for the Distribution batteries, the alarm panel, plant shunt, Galaxy Controller, dc/dc...
Page 79 ™ Lucent Technologies 415B Battery Plant for 4ESS DC/DC Converters The dc/dc converters are mounted in the Control and Distribution Bay, and their outputs are diode OR’d to provide power to the Galaxy Controller if one of the converters fails.
Page 80: Group 3
Lucent Technologies 415B Battery Plant for 4ESS Battery Equalize/ Boost Feature You will see the terms “Equalize” and “Boost” used throughout the documentation associated with the 415B Battery Plant. In this manual, the terms are interchangeable and mean exactly the same thing.
Page 81: Group 4 Or 5
Growth in plant output capacity is achieved by adding up to five 140-volt ferroresonant rectifiers for the 415B Battery Plant. The fifth rectifier is installed in the floor layout where the previous ac (PDSC) cabinet number two was located in the 415B system.
Page 82: Figure 7-2: H569-429 Groups 3, 4, Or 5
™ Lucent Technologies 415B Battery Plant for 4ESS Fuse Alarm Panel Battery Disconnect Reconnect Switches Galaxy Controller Circuit Breaker Panel (with Capacitor Charge Switch) 140V/48V Converters RPM Panel Group 3 Group 4 or 5 (without distribution) (with distribution, shunts, and RPM panel)
Page 83 ™ Lucent Technologies 415B Battery Plant for 4ESS Two 4ESS ™ switches are powered by two independent 415B Retrofit Battery Plants. Each 415B Retrofit Battery Plant consists of one Power Distribution Service Cabinet (PDSC), a Control and Distribution Bay, up to five rectifiers, up to three battery strings, and a Galaxy Controller.
Page 84: Figure 7-3: Typical 415B Retrofit Battery Plant Ac Feeds For Total Replacement
™ Lucent Technologies 415B Battery Plant for 4ESS Bus A Bus B 800A 800A 800A 800A 400A 400A Distribution A Distribution B PDSC A1 PDSC B1 Rectifier 5 Rectifier 1 Rectifier 2 Rectifier 3 Rectifier 4 (optional) Plant A Rectifier 5...
Page 85: Retrofit System Installation And Testing For One Or Two Rectifiers
™ Lucent Technologies 415B Battery Plant for 4ESS Retrofit System Please read Section 3, Safety, carefully before installing, testing, maintaining, or repairing the 415A Battery Plant or any of its Installation and subsystems. Testing for One or Two DANGER Rectifiers The voltage in this plant can cause serious injury.
Page 86: Figure 7-4: Retrofit With One Or Two Rectifiers
™ Lucent Technologies 415B Battery Plant for 4ESS 27" 19" 28" Configuration 1 27" 27" 19" 28" Configuration 2 Figure 7-4: Retrofit with One or Two Rectifiers 7 - 12 Retrofit of 415A Battery Plant Issue 6 September 1999...
Page 87: Mounting Brackets On Control And Distribution Bay
™ Lucent Technologies 415B Battery Plant for 4ESS Mounting 1. Install top and bottom door mounting brackets before Brackets on running the cables to the Control and Distribution Bay bus Control and bars. Distribution Bay 2. Mount the top bracket in positions 75-73. Mount the bottom bracket in positions 5-3.
Page 88: Bolting Hardware
™ Lucent Technologies 415B Battery Plant for 4ESS Bolting Hardware The Control and Distribution Bay contains the bolting hardware for mounting the frame to the floor. Figure 7-6 shows a typical floor mounting detail. Figure 7-7 is a floor mounting template.
Page 89: Rectifier And Ac Connections
™ Lucent Technologies 415B Battery Plant for 4ESS Rectifier and AC Make ac connections from the failed rectifier of the 415A Connections system. Engineering provides the necessary ac from the existing service. Follow local codes and NEC codes and requirements for connecting the service for the rectifiers.
Page 90: Retrofit Connections For The Group 3 To The 415A
™ Lucent Technologies 415B Battery Plant for 4ESS Retrofit Connections for Notes the Group 3 to Remove 415B charge fuse and replace with bus bar provided. Do not install until the test informs you to. the 415A System (Adding Add a label printed in red to the rectifier fuse head, to read...
Page 91: Sense Voltage Connections
™ Lucent Technologies 415B Battery Plant for 4ESS Notes Final alarm connections to the 415A should not be made until the 415B test is completed. The resistor block is not used on the 415A distribution shunt of the module being monitored by the shunt (+) and (-) terminals of the Galaxy Controller.
Page 92: Table 7-A: Bjt1 Connections
™ Lucent Technologies 415B Battery Plant for 4ESS Alarm The alarm connections from the 415B to the 415A Control and Connections Distribution Bays are wired in parallel using 807A 16/26 SWBD (comcode 105412480). Note Connection of the alarms should be made after the test is complete.
Page 93: Testing For Group 3 (One Or Two Rectifiers)
™ Lucent Technologies 415B Battery Plant for 4ESS Testing for Group 3 (One or Two Rectifiers) Required Test Depending upon the tests to be performed, one or more of the Equipment following may be required. ® • DMM (Digital Multimeter) Fluke 8060A or equivalent meter having ±0.02 percent accuracy on the dc scale...
Page 94 ™ Lucent Technologies 415B Battery Plant for 4ESS DANGER AC voltage is present even when the Power switch is in the Off position. DANGER Before turning on any rectifier, be sure that the associated framework and cable rack are properly grounded per local job instructions.
Page 95 ™ Lucent Technologies 415B Battery Plant for 4ESS Warning For safety, the measurements for current shall be made on CM1 at E101 and E102 at the shunt (+) and (-) test points. (See Figure 7-10). 1. Set the ac supply and rectifier controls as follows:...
Page 96: Connections
™ Lucent Technologies 415B Battery Plant for 4ESS Connections Secure the Battery Plant Simulator Test Set (ITE-7102) and support it at a convenient location near the rectifier. Make the connections as detailed in Table 7-B. Note that Table 7-B contains references to Figure 7-9.
Page 97: Figure 7-9: Partial Sketch Of Cm2 (208G)
™ Lucent Technologies 415B Battery Plant for 4ESS S205 P202 Figure 7-9: Partial Sketch of CM2 (208G) Control Board Issue 6 September 1999 Retrofit of 415A Battery Plant 7 - 23...
Page 98: Internal Tests
™ Lucent Technologies 415B Battery Plant for 4ESS SHUNT Shunt Test Points Figure 7-10: CM1 (329B) Fuse Board Internal Tests 1. Disable the internal selective high voltage shutdown by opening S205.1 and S205.2 on CM2 (see Figure 7-9). Then adjust the Output Volts Adjust until the rectifier shuts down.
Page 99: Control Test
™ Lucent Technologies 415B Battery Plant for 4ESS Test switch to NL. The voltage should drop between 0.3 and 0.6 volt. 6. Repeat Step 5 with the Rect Test switch in the FL position. The voltage should increase between 0.1 and 0.46 volt.
Page 100: Phase Failure Test
™ Lucent Technologies 415B Battery Plant for 4ESS S305 S301 S304 S306 S302 S303 Figure 7-11: Partial Sketch of CM3 Digital Meter Board Phase Failure 1. Increase the load to 30-42 amperes. Test 2. With the Power switch still in the On position, turn off the ac service and note that the rectifier has shut down and that the MAN LED on the test box is off.
Page 101 ™ Lucent Technologies 415B Battery Plant for 4ESS 6. Turn off the ac and reconnect the ac input lead. 7. Turn on the ac. The rectifier should restart. On the test box only the PWR and MAN LEDs should light.
Page 102: Current Limit Adjustment
™ Lucent Technologies 415B Battery Plant for 4ESS 7. Repeat Steps 4 through 6 for other rectifier. 8. Verify that the rectifiers are off before proceeding. Current Limit 1. Turn on a rectifier. Adjustment 2. Set load to 160 amperes and on line. Adjust dummy load if the 415A plant is less than 160 amperes.
Page 103 ™ Lucent Technologies 415B Battery Plant for 4ESS Press ENTER; the display will now show RECT 01 TYPE: UNCONFIGURED (flashing) SHUNT mV: 50.00 MAN SW: NONE Press ADJUST + or - to scroll through menu until J87132B-2 appears in TYPE.
Page 104 ™ Lucent Technologies 415B Battery Plant for 4ESS Compare the calculated load current with the current reading at Galaxy. The shunt reading should agree with the Galaxy reading. If not, proceed to Step 7. If the two readings agree, skip to Step 8.
Page 105: Unpacking Equipment
™ Lucent Technologies 415B Battery Plant for 4ESS Display will now show the total current for the 415A and 415B on the laptop. Note: To read total current from the front panel of the Galaxy Controller, follow Menu › Meas › Drv Chan.
Page 106: Figure 7-12: Bracket Mounting Locations
™ Lucent Technologies 415B Battery Plant for 4ESS • Common electrician’s hand tools • Proper crimping tools and dies for connectors used • Common mechanic’s hand tools • 18mm or 3/4-inch drill to bore holes for floor anchors • DMM (Digital Multimeter) with at least .05% accuracy on the dc scale (Fluke 8060A or equivalent) •...
Page 107: Figure 7-13A: Ac Distribution Floor Mounting Configuration
™ Lucent Technologies 415B Battery Plant for 4ESS 4ESS ™ The ac distribution for the 4ESS ™ can be either floor-mounted or wall-mounted. Figures 7-13A and 7-13B show both Configurations configurations. Choose the appropriate configuration from the D8 sheet of the T-83360-30 drawing, and locate rectifiers and ac distribution as shown.
Page 108: Figure 7-14: Typical Floor Mounting Detail
™ Lucent Technologies 415B Battery Plant for 4ESS Bolting Hardware The Control and Distribution Bay contains the bolting hardware for mounting both the ac cabinet and Control and Distribution Bay to the floor. Figure 7-14 shows a typical floor mounting detail.
Page 109: Figure 4-5: Ac Breaker Locations With Spare
™ Lucent Technologies 415B Battery Plant for 4ESS All hardware for making electrical connections to the KS-22089 ac cabinets can be found inside the cabinet. The input ac lugs are not provided and must be furnished by the line engineer.
Page 110: Figure 7-17: Connecting The Ac To The Rectifier (K1 Contactor)
™ Lucent Technologies 415B Battery Plant for 4ESS Rectifier and AC Connections between the ac cabinet and the rectifiers are Connections 6-gauge for 480Vac service. The connections for the 208 or 240 Vac are 4-gauge. The installer must follow all local municipal codes and NEC codes and requirements.
Page 111 ™ Lucent Technologies 415B Battery Plant for 4ESS Control and Output from the Control and Distribution Bay uses KS-24194, Distribution Bay L13 Red with trace (“A” Plant), and Blue with trace (“B” Plant) Connections braided 2-gauge wire. Circuit breakers in the Control and Distribution Bay should be left in the Off position.
Page 112: Figure 7-18: Connections For The Rpm
™ Lucent Technologies 415B Battery Plant for 4ESS First RPM RPM 108040932 To equipment Blue To Galaxy being monitored White Controller Shield TB101 TB102 221F Note: The last RPM Module is terminated with a 560 ohm resistor (CC 405298308) plugged into X1 and X2 sockets inside the RPM.
Page 113 ™ Lucent Technologies 415B Battery Plant for 4ESS Battery String The Battery String Protection Fuse Alarm connection was Alarm designed for ease of installation. Use 22-gauge stranded wire to Connections connect the alarm from the BNF2 board to the ED83146-30 G1 protection fuse with a single wire connection.
Page 114 ™ Lucent Technologies 415B Battery Plant for 4ESS 3. Prepare an appropriate length of 1/0, stranded, green-color cable and half-tap this cable to the ground cable in proximity to the EGCM. 4. Install the EGCM on the cable rack above the Control and Distribution Bay in a location where the display can be easily observed.
Page 115 Calibrated clamp-on dc current meter (0.1 ADC sensitivity) • Standard installation tools, screwdrivers, etc. • J87132B-2 rectifier product manual • Galaxy Controller product manual for 415B Battery Plant • Rubber gloves • Windows-based personal computer (PC) with EasyView software installed •...
Page 116 ™ Lucent Technologies 415B Battery Plant for 4ESS – The correct ground cable gauge has been used (minimum #6 for rectifier, #2 for Control and Distribution Bay). – The Enhanced Ground Current Monitor has been properly connected and its alarm contacts have been connected.
Page 117: For 208G Circuit Module
™ Lucent Technologies 415B Battery Plant for 4ESS – If not using the Area Bus Center: on both Power Distribution Frames, check that RPMs have been properly installed and that dip switches have been properly set and wired. PDF #1 should be set at 0A and PDF #2 to 0B.
Page 118 ™ Lucent Technologies 415B Battery Plant for 4ESS 5. Verify that all alarm cables J202 are disconnected at the 208G boards inside all rectifiers. The other end is still connected at the back of the Galaxy Controller. 6. Verify that all the remote sense cables J208 are still connected at both the Galaxy Controller and at all 208G boards in the rectifier.
Page 119 ™ Lucent Technologies 415B Battery Plant for 4ESS 17. Verify that all rectifiers are off before proceeding. 18. Reconnect ALL alarm cables J202 at the 208G boards for all rectifiers. 19. Place a 20-ampere load on the battery plant; turn the ac power switch on rectifier to On and adjust its output to 151.9 volts.
Page 120 ™ Lucent Technologies 415B Battery Plant for 4ESS 5. Verify that all the green LEDs on the Power Distribution Frames are lit. Note Circuit Breaker #1 also provides power for the alarm circuit. Pre-test Setup These system test procedures are based on the assumption that...
Page 121 ™ Lucent Technologies 415B Battery Plant for 4ESS System Test Procedures Warnings A limited recharge alarm may occur at the Galaxy Controller during these tests. Whenever rectifiers have been turned on, their output filter capacitors stay charged for several minutes. Do not place hands inside a rectifier until these capacitors have discharged to a safe level (below 50 volts).
Page 122 ™ Lucent Technologies 415B Battery Plant for 4ESS Current Limit 1. With two rectifiers turned on and on line, set plant load to Adjustment be 170-180 amperes. 2. Set both rectifier voltage outputs to be 151.9 volts so that they share the load as much as possible.
Page 123 ™ Lucent Technologies 415B Battery Plant for 4ESS 4. Return the rectifier to float voltage (151.9 volts). 5. Turn the rectifier off. 6. Repeat Steps 1 through 5 for all rectifiers. Rectifier Alarms This test verifies that each rectifier shuts down and issues a...
Page 124 ™ Lucent Technologies 415B Battery Plant for 4ESS 6. Turn on the rectifier via the ON/OFF power switch, and record the voltage on the display; This recorded voltage will be used to reset the rectifier in Step 11. 7. Set the load to 2 amperes and adjust to 161.5 volts and observe the rectifier remains operational.
Page 125 ™ Lucent Technologies 415B Battery Plant for 4ESS • Remove all load. • Reconnect the control (J202) and REG (J208) cables to the 208G board of each rectifier. Reinstall the REG fuses. • Turn on all rectifiers and wait 10-20 seconds.
Page 126: Table 7-D: Load Settings For Ac Failure Test
ACF LEDs on the rectifiers light while ac is failed. 7. Restore the system to normal by closing all breakers previously opened. Galaxy The Galaxy Controller for the 415B Battery Plant is ordered as J85501F-1, L4. Table 7-E lists the circuit packs furnished with Controller the controller.
Page 127: Table 7-E: Circuit Packs/Kit Furnished With The Galaxy Controller
™ Lucent Technologies 415B Battery Plant for 4ESS Table 7-E: Circuit Packs/Kit Furnished with the Galaxy Controller Power Supply BJJ1 Independent Controller BJB2 Intelligent Controller BJH3 Remote Peripheral Monitor (RPM) Interface BJM1 Fuse Board BJF4 Terminal Board BJT1 Display BJG1...
Page 128 ™ Lucent Technologies 415B Battery Plant for 4ESS Note The “Boost” voltage level is equal to 2.23 volts per cell, or 156 volts. After configuration has been checked and values confirmed as indicated above, proceed to the next section. Galaxy Readouts 1.
Page 129 ™ Lucent Technologies 415B Battery Plant for 4ESS Galaxy and For this series of tests, set the load to 10 to 20 amperes. The batteries should be connected to the load. Rectifier Interface Leads Rectifier Fail 1. Turn off rectifier. Replace fuse on the 329B board with a Alarm (RFA) blown fuse.
Page 130 ™ Lucent Technologies 415B Battery Plant for 4ESS 5. Verify that the rectifier has an alarm and does not cause an RFA, the PH LED lights at the rectifier, and that minor, rectifier, and ac alarms are present at Galaxy.
Page 131 ™ Lucent Technologies 415B Battery Plant for 4ESS 9. Repeat this procedure for each rectifier. MAN Leads This test is done with the battery connected to the Control and Distribution Bay, 10 - 20 amperes load, and all rectifiers on.
Page 132 ™ Lucent Technologies 415B Battery Plant for 4ESS Press ENTER to store information selected. Press ESCAPE to return to RECT DEF and select G02 for rectifier two. Configure rectifier number two the same as above and continue for all rectifiers.
Page 133 ™ Lucent Technologies 415B Battery Plant for 4ESS HV and RS Leads The following HV tests should only be performed with a test load and on battery. 1. With all rectifiers on line and a plant load of approximately 20-40 amperes, adjust output of rectifier #1 up until it assumes the total plant load from the other rectifiers.
Page 134 ™ Lucent Technologies 415B Battery Plant for 4ESS 3. Deactivate the boost command via the Galaxy. The path is MENU → MODE→ ENTER. 4. Verify that the rectifiers return to the correct float voltage. Control and Note: Skip this section if using the Area Bus Center (ABC).
Page 135: Figure 5-1: Circuit Breaker Feeds To Power
™ Lucent Technologies 415B Battery Plant for 4ESS PDF #1 (PD60 A or PD61 B) Plant A or B Panel 1 Panel 2 Control and Distribution Bay Panel 3 Panel 4 Bus 1 Bus 2 Panel 5 Panel 6 Bus 3...
Page 136 ™ Lucent Technologies 415B Battery Plant for 4ESS Miscellaneous Alarms BD and VLV 1. With all rectifiers off, apply a 100-ampere test load to the Alarms plant. Observe the plant voltage on the front panel of the Galaxy. Verify that the BD alarm is generated at 149±1Vdc.
Page 137 ™ Lucent Technologies 415B Battery Plant for 4ESS Battery String This test is done with all rectifiers on and at no load. Disconnect 1. At the Control and Distribution Bay, operate battery disconnect switch #1 to Off. OS and MAJOR alarms are initiated and displayed at Galaxy.
Page 138 ™ Lucent Technologies 415B Battery Plant for 4ESS 4. Verify that local MJF and RFA alarms are issued, visual and audible Local Office alarms are initiated, and a remote alarm has been received at the Alarm Center. Power Note: Skip this procedure if using the existing ABC bays.
Page 139 ™ Lucent Technologies 415B Battery Plant for 4ESS c. Press ENTER to store and save the information. Note: Pressing ESCAPE returns the screen one level. 2. Place all rectifiers on line at float voltage and apply full load. Record plant voltage. In ten minutes a rectifier will turn off.
Page 140 ™ Lucent Technologies 415B Battery Plant for 4ESS • If using PDFs, set RPM address on PDFs to OA and OB for second RPM. Retrofit Control and Distribution Bay RPMs are preset to 01, 02, and 03. OA and OB currents read at Galaxy will be secondary currents.
Page 141 ™ Lucent Technologies 415B Battery Plant for 4ESS 13. Remove all fuses from the Power Distribution Frame. Battery Reserve Refer to Section 3, Installation, in the Galaxy Controller product manual and verify that the thermistor has been installed properly Time Prediction at the battery.
Page 142 ™ Lucent Technologies 415B Battery Plant for 4ESS 2. Verify that the polarity of the current reading on both the sensor and the clamp-on probe are the same. 3. Adjust the multi-turn offset control on the EGCM so that the display and the current probe read the same current.
Page 143 ™ Lucent Technologies 415B Battery Plant for 4ESS 3. Turn on all rectifiers and verify that the plant voltage is set to 151.9 volts. 4. Set the load to 140 amperes per rectifier. 5. Record the plant voltage. Verify that it is within 0.7 volts of the setting in Step 3.
Page 145: Table 8-A: Reference Documentation
™ Lucent Technologies 415B Battery Plant for 4ESS Maintenance and Operation Reference Table 8-A provides reference documentation for installation, maintenance, and alarm wiring for the 415 Battery Plant. Documentation Table 8-A: Reference Documentation Description Product Manual Select Code Maintenance for the Control and...
Page 147 ™ Lucent Technologies 415B Battery Plant for 4ESS Glossary Alarm Battery Supply Alternating Current AC Failure ADJ PLI Adjust Plant Current ADJ PLV Adjust Plant Voltage Battery on Discharge BD Boost Battery Discharge during Boost BUHVSD Backup High Voltage Shutdown C&D...
Page 148 ™ Lucent Technologies 415B Battery Plant for 4ESS Equipment Ground EGCM Enhanced Ground Current Monitor Electrostatic Discharge Electronic Switching System Full Load High Float Voltage ISHVSD Internal Selective High Voltage Shutdown Light Emitting Diode Major Alarm Minor Alarm Normally Closed (state when energized)
Page 149 ™ Lucent Technologies 415B Battery Plant for 4ESS Rect Rst Rectifier Restart Regulation Rectifier Fail Alarm Rectifier on Threshold Remote Peripheral Monitor Terminal Block Remote Transfer, or Transfer a 2 to 10 volt signal from the rectifier, where 2 volts = 0 amperes from the rectifier and 10 volts = 125% of full load from the rectifier.

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