ABB H569-445 User manual

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PRODUCT MANUAL
H569-445 Battery Distribution Fuse/ Circuit
Breaker Bay (BDFB/BDCBB)

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Table Of Contents
Table of Contents ....................................................................................................................................... 2
Table of Figures .......................................................................................................................................... 3
Table of Tables............................................................................................................................................ 4
Introduction................................................................................................................................................ 5
Customer Service Contacts.............................................................................................................................5
On-Line Power Systems Product Manuals and Software ...........................................................................5
Product Description ................................................................................................................................... 7
Overview.............................................................................................................................................................7
Panel Positions and Labeling..........................................................................................................................8
Load Bus Arrangements ................................................................................................................................10
Load Shunt Bus Rearrangement............................................................................................................. 11
Distribution Panels ......................................................................................................................................... 12
Discharge Return Bus Options ..................................................................................................................... 15
VIM1C Meter..................................................................................................................................................... 16
Alarm Connections and ABS Power ............................................................................................................. 17
Installation .................................................................................................................................................19
Preparation ...................................................................................................................................................... 19
Safety.......................................................................................................................................................... 19
Installation Tools and Hardware............................................................................................................. 19
Unpacking ..................................................................................................................................................20
Floor Mounting................................................................................................................................................ 21
Cabinet Extensions – G7 and G8 only ..........................................................................................................23
Cabinet Top Cover ..........................................................................................................................................24
Frame Ground..................................................................................................................................................25
Converting Top-Feed to Bottom-Feed ........................................................................................................26
Converting from 2-Load to 4, 6, or 8-Load .................................................................................................29
PRODUCT MANUAL
H569-445 Battery Distribution Fuse/ Circuit
Breaker Bay (BDFB/BDCBB)

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Connect Input Feeds ......................................................................................................................................30
Connect Breaker/Fuse Loads .......................................................................................................................30
Alarm Connections and ABS Power ............................................................................................................. 31
Configure Panel Positions .............................................................................................................................33
Apply Labels.............................................................................................................................................33
Configure VIM1C Meter ..........................................................................................................................33
VIM1C Meter Reference ............................................................................................................................ 35
Programming the Meter ................................................................................................................................36
Retrofit or Replacement Configuration ......................................................................................................38
Wiring Schematics.................................................................................................................................... 39
Specifications ........................................................................................................................................... 43
Safety ........................................................................................................................................................ 45
Safety Statements ..........................................................................................................................................45
Precautions ..................................................................................................................................................... 46
Revision .................................................................................................................................................... 47
Table of Figures
Figure 1 Panel Positions - Top Feed........................................................................................................... 8
Figure 2 Panel Positions - Bottom Feed .................................................................................................... 9
Figure 3 Load Connection Points G7 and G8........................................................................................... 10
Figure 4 Load Connection Points G101 AND G102...................................................................................11
Figure 5 Installing Breakers/Fuseholders (28 position shown) .............................................................12
Figure 6 Distribution Connections G7 and G8.........................................................................................13
Figure 7 Distribution Connections G101 and G102................................................................................. 14
Figure 8 Two-Pole and Three-Pole Adapter Bus Kits ............................................................................. 14
Figure 9 Distribution Cable Routing ....................................................................................................... 15
Figure 10 External Discharge Return Bus Options on Cable Rack..........................................................16
Figure 11 Bus Bar Hole Pattern and Numbering Schemes.......................................................................16
Figure 12 VIM1 Smart Meter......................................................................................................................17
Figure 13 Cabinet Shipping Pallet ........................................................................................................... 20
Figure 14 Hardware Box Location.............................................................................................................21
Figure 15 Footprint of Cabinets .............................................................................................................. 22

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Figure 16 2-Foot or 4-1/2-Foot Extension Cabinet .................................................................................21
Figure 17 Top Cover for Bottom-Feed Applications............................................................................... 22
Figure 18 Top View of G7.......................................................................................................................... 23
Figure 19 Top View of G8.......................................................................................................................... 23
Figure 20 Top View - G101 and G102........................................................................................................ 24
Figure 21 Top-Feed to Bottom-Feed Cabinet Conversion G7 and G8 ................................................... 25
Figure 22 Top-Feed to Bottom-Feed Cabinet Conversion G101 and G1028 ......................................... 26
Figure 23 2-Load to 6 or 8-Load Conversion........................................................................................... 28
Figure 24 Accessing Customer Interface Board ..................................................................................... 29
Figure 25 Customer Interface Board ....................................................................................................... 30
Figure 26 Meter Menu Map........................................................................................................................31
Figure 27 Panel Wiring Schematic G7 and G8 ......................................................................................... 35
Figure 28 Panel Wiring Schematic G101 and G102.................................................................................. 36
Figure 29 Alarm Wiring Schematic G7 and G8 .........................................................................................37
Figure 30 Alarm Wiring Schematic G101 and G102................................................................................. 38
Table of Tables
Table 1 Torque Settings.............................................................................................................................19
Table 2 Anchor Kits....................................................................................................................................21
Table 3 Isolation and Leveling Kits...........................................................................................................21
Table 4 VIM1C Meter Parameters .............................................................................................................37
Table 5 Alarm Signal Action ..................................................................................................................... 42

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Customer Service Contacts
Customer Service, Customer Training, Technical Support, Product Repair and Return, and Warranty
Service
Services provided include initiating the spare parts procurement process, ordering documents,
product warranty administration, and providing other product and service information.
ABB Energy phones are staffed from 7:00 am to 5:00 pm USA Central Time Zone (GMT -6), Monday
through Friday, on normal business days. At other times, this number is still available, but for
emergencies only.
Introduction
Calling from Phone Number
United States, Canada, Puerto Rico, and the US Virgin Islands [phone]
All other countries [phone]
Or USADCC1+1 877 546 3243
Or contact your local field support center or your sales representative to discuss your specific
needs.
On-Line Power Systems Product Manuals and Software
Product manuals, product line brochures, and software are available on-line. Software includes Easy
View and SNMP MIB.
abbpowerconversion.com
1 The USA direct country code for the country where the call is originating

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Overview
This manual describes the H569-445 Secondary DC Power Distribution Bay. This Battery
Distribution Fuse Bay (BDFB) or Battery Distribution Circuit Breaker Bay (BDCCB) serves as a
secondary fuse or circuit breaker distribution center for - 48V dc power delivered from a central
office battery plant.
Cabinet
• 7-foot tall
• seismic zone 4
• extensions available for 9 and 11-1/2 foot applications (G7 and G8)
Load Buses
• 800A each G7 and G8 - up to 6, G101 and G102 up to 8
• each fed by a battery plant fuse or circuit breaker
• each feeding one or more Distribution Panels
Distribution Panels
• G7 and G8 - up to six, 28 positions each,G101 and G102 up to eight, 20 positions each
• one or more Distribution Panels per Load Bus
• alarm lights and signals individual to each panel
Protectors
• Fuses or Circuit Breakers
• No position or spacing restrictions
• Fuses: TPS or TLS up to 125A
• Circuit Breakers up to 250A
Cabling
• Top or Bottom fed Input and Output cabling without reconfiguring the cabinet.
Return Bars
• Optional internal 2-hole ground bars
• Optional external ground bars mounted to overhead framing or cable rack
Monitoring - VIM1 Smart Monitor (standard)
• Voltage and Current of each load bus or combined current of entire BDFB
• Alarm Status – Red backlight and LED
• Alarm Contacts: Fuse Alarm, Power Loss, Overload
• Redundantly Powered – Load Bus A and Load Bus B and ABS input
• Configurable for numerous BDFB applications
Product Description

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The cabinet is configured for either top or bottom cable entry. The following figures show the
default labeling orientation used for top and bottom fed BDFB’s. Load Bus designations (A, B, C, D,
etc.) are stamped on the labels and the VIM1C meter is programmed to reflect the Load Bus
designations.
A label set is provided for customer specified position labeling: 850018546 for G7 and G8,
850044737 for G101 and G102. If the Load Bus designations change, the VIM1C meter must identify
the new location.
Menu▶Load Parameters▶ First Load locates Load Bus A as upper-left, upper-right, lower-left or
lower-right.
Menu▶Load Parameters▶ Number of Loads identifies the number of load shunts in the BDFB.
Panel Positions and Labeling
G7 and G8 G101 and G102
Figure 1 Panel Positions - Top Feed

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G7 and G8 G101 and G102
Figure 2 Panel Positions - Bottom Feed

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A load bus is defined as one or more panels protected by a single circuit breaker or fuse at the
battery plant. Cable from the battery plant is terminated at Load Shunt Bus Details rated for 800
amperes. (Two 750 kcmil feeder cables are required per shunt for currents larger than 500 amps per
shunt.) 3/8 inch hardware is provided for this connection. The cabinet may be equipped for 2, 4 or 6
loads. In 2 or 4 load configurations a bus bar link connects some panels together vertically. The 800
ampere capacity per load bus applies even if multiple fuse panels are connected together.
When internal return buses are ordered, load return bus details will be located either at the top or
the bottom of the cabinet as shown depending on if a top cable feed or bottom cable feed was
ordered. These may easily be unbolted and moved if the application requires. 3/8 inch hardware is
provided for load return cables.
Note: All bus bars are copper with a bright tin finish.
Bus bars do not require buffing or the application of NO-OX before connection to terminal
lugs or other bus bars.
Load Bus Arrangements
Figure 3 Load Connection Points G7 and G8

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Figure 4 Load Connection Points G101 AND G102
LOAD SUNT BUS DETAIL
3/8” HARDWARE PROVIDED
LOAD RETURN BUS DETAIL
3/8” HARDWARE PROVIDED
Load Shunt Bus Rearrangement
Sometimes it may be necessary to reconfigure a BDFB in the field. Two common changes are
converting two load BDFB’s from top feed configurations to bottom feed configurations and
changing from a 2-load to a 4, 6, or 8-load BDFB. Additional Load Shunt Bus Kits as shown on Figure
3 and Figure 4 may be purchased separately.

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• Bullet positions per distribution panel
• G7 and G8 28
• G102 and G102 20
• Bullet-style circuit breakers and fuseholders install in any position with no spacing restrictions.
• Single-pole breakers through 100A
• Two-pole breakers through 150A
• Three-pole breakers through 250A
• Fuse holders for fuses to 125A
Installation Notes:
1. Breakers/fuse holders can only be installed one way or
2. Insert each breaker/fuse holder with its alarm pin inserted into the outer alarm pin opening2.
• The hinged panel door will not close properly if a breaker/fuseholder is not properly installed.
3. Un-snap and remove plastic slot fillers in the panel doors as breakers/fuse holders are installed.
Store excess slot fillers in the hardware bin in the back of the cabinet.
4. Ignore Line and Load markings on breakers and fuseholders. They are not consistently applied by all
manufacturers.
Distribution Panels
2Each distribution position has three alarm pin openings. The outer alarm opening is the alarm output. The inner two openings are
provided because some breaker styles have additional pins that require alarm power to generate the output alarm.
Figure 5 Installing Breakers/Fuseholders (28 position shown)

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Figure 6 Distribution Connections G7 and G8

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Figure 7 Distribution Connections G101 and G102
Two-pole breakers require two 850019325 2-pole adapter bus kits. Three-pole breakers require two
850025679 3-pole adapter bus kits. They attach to the distribution panel as shown below. The bus
has 3/8-16 studs on 1 inch centers. Hardware is included. Terminal lugs are sold separately.
Figure 8 Two-Pole and Three-Pole Adapter Bus Kits

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Discharge return bus options for terminating fuse or circuit breaker return leads may either be
internally mounted in the cabinet or externally mounted outside the distribution bay on a cable
rack.
Internal
The internal discharge return bus bar option terminates return cables from the battery plant at the
top (and/or bottom) of the cabinet as shown in Figure 6 and Figure 7. There is a left-side bus that
interconnects to return bars mounted on the left mounted fuse or circuit breaker panels and a right
-side bus for the right mounted panels. The bus at the top of the cabinet is designed for
terminating six or eight 3/8 inch double-hole terminal lugs on 1 inch centers with a tongue width up
to 1.7 inches wide. Each panel mounted discharge return bus is designed for terminating up to 2
gage cable with 1/4 inch double-hole terminal lugs on 5/8 inch centers.
Advantage: The advantage of internal returns is that load leads are paired at the fuse or circuit
breaker and eliminates the need for identification tags on each return lead.
Drawbacks: Both the top and bottom input return connections are required to reach BDFB full
output capacity.
Return capacity limit per side:
only Top OR Bottom Return Bar Connections: G7 and G8 – 1200A G101 and G102 – 1600A
both Top AND Bottom Return Bar Connections: G7 and G8 – 2400A G101 and G102 – 3200A
Cable congestion resulting from twice the number of leads in the distribution bay.
For these reasons, the internal discharge return option is recommended only for applications with
smaller ultimate capacities. For most applications, the external return bus option is recommended.
Figure 9 Distribution Cable Routing
Discharge Return Bus Options

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External
The external discharge return bus bar options are shown in Figure 10 and Figure 11. The external bus
is mounted on a standard 15 or 20 inch ladder type cable rack. ED83019-50 Group 13 (150021156)
and Group 13A (150021157) are rated for 2400 amperes of current. Option 150021156 provides the
first bus bar and the cable rack mounting hardware. Option 150021157 provides a bus bar, the
connecting bus bar and insulating standoffs for stacking additional tiers as required. Refer to
ED83019-50 drawing for other ground bar options.
Figure 10 External Discharge Return Bus Options on Cable Rack
Figure 11 Bus Bar Hole Pattern and Numbering Schemes

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Each load bus is equipped with a shunt: 1500 A for G7 and G8, 1600 A for G101 and G102. The VIM1C
monitors these shunts to determine actual currents and the remaining capacity of each load bus.
VIM1C features include fuse/breaker alarms, power loss alarms, individually configurable overload
thresholds, individually configurable power loss, audible, and remote form-C output alarms. The
VIM1 receives redundant power from the A and B panels and external ABS.
Voltage and Current - VIM1C displays voltage, current, and identifies each monitored load bus3.
Alarm Indication - When an alarm occurs, the backlight on the display changes color from green
(normal) to red (alarm active) and the front panel text also changes from “No Alarms” to “Alarms.”
Menus and Keys – Menus are structured with three main menu items: System Parameters, Load
Parameters, and Control/Operations - . Each key menu item has sub items as shown in the menu
map below. Left and Right keys are used to navigate the menu. Up and Down keys are used to
adjust the parameters. The VIM1C includes an audible alarm with a user configurable on/off
feature.
Alarm Connections and ABS Power
At the top of the cabinet is a Customer Interface Board for connecting Output Alarms and Alarm
Battery Supply (ABS) to redundantly power the alarms and the VIM1C meter.
The VIM1C receives redundant power from panels 1 and 2 as well as an external ABS connection, so
the ABS connection is not mandatory for proper operation but some customers require its use.
A Return connection is required for operation of the meter and alarms. The Return connection on
the Customer Interface Board is factory wired when internal return buses are ordered, otherwise it
must be field wired to the external return bus.
• Contacts are rated for 60V, 1/2A.

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• Maximum wire size to the terminal blocks is 12 AWG.
Alarm Outputs consist of single form-C contact for
• Power loss
• Current overload
• Fuse/breaker alarms
Note: there are two connection points for FAJ/CB but they are connected to the same form-C
contact.
3 The default VIM1 screen displays the label “Panel”, rather than “Load Bus”, before the Load Bus identifier.

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Preparation
Safety
Read and follow all safety statements, warnings, and precautions in the Safety section of this
manual and manuals of all other equipment before installing, maintaining or repairing the
equipment.
Installation Tools and Hardware
You will need the following tools and hardware to install the BDFB:
• Material-handling equipment to unload the cabinet at the installation site, remove from
shipping container, and set in final position [minimum lifting capacity: 500 lbs. (227Kg)] Note:
Use the equipment weights and dimensions as a guideline for choosing material-handling
equipment.
• Digital multimeter (DMM) with 0.05% accuracy on dc scale
• Insulated hand tools
• Screwdrivers (flat-blade and Phillips)
• Wire cutters and stripper
• Crimp Tools
• Drill and Drill Bits to install floor anchors
• Torque wrenches 25-720 in-lb
• Sockets: 5/16”, 7/16”, 9/16”, 3/4”, 15/16”, 19mm
Installation

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BDFD
BDFB’s ship on a 42 by 42 inch skid as shown below. A 15/16 inch wrench or socket is required to
remove 5/8 inch diameter shipping bolts from skid. Before opening the packaging, carefully inspect
the outside in the presence of shipping personnel for signs of damage. Carefully open the
packaging to verify that the contents are complete and undamaged. If damaged, follow the
shipping carrier’s procedure for filing a damage claim. If the equipment must be returned, repack in
the original shipping packaging.
Before continuing, verify that the following conditions exist at the installation site:
•Floor is conditioned and clean (refers to removal of any combustible flooring, e.g., carpet, wood,
etc.).
•Job Site Documentation details cabinet locations.
Unpacking