Lucent Technologies 415B Battery Plant User manual

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

Product Manual
Select Code 167-792-121
Comcode 107972754
Issue 6
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.
However, information is subject to change.
© 1999 Lucent Technologies
All Rights Reserved
Printed in U.S.A.

Lucent Technologies 415B Battery Plant for 4ESS
Issue 6 September 1999 Table of Contents - 1
Table of Contents
1Introduction
Product Manual 1 - 1
415B Battery Plant 1 - 1
Applications 1 - 2
Installation and Testing 1 - 2
Customer Assistance Contacts 1 - 3
Customer Training 1 - 3
Customer Service 1 - 3
Technical Support 1 - 3
Product Repair and Return 1 - 3
Warranty Service 1 - 4
On-Line Power Systems Product Manuals 1 - 4
2System Description
415B Battery Plant Overview 2 - 1
Power Distribution Service Cabinet (PDSC) 2 - 1
Control and Distribution Bay 2 - 3
Alarm Panel 2 - 3
Plant Shunt 2 - 3
Galaxy Controller 2 - 3
DC/DC Converters 2 - 3
Battery Disconnect/Reconnect Switches 2 - 3
Distribution Breakers 2 - 4
Rectifiers 2 - 4
Battery Equalize/Boost Feature 2 - 4
Power Distribution Frame (PDF) 2 - 4
Capacitors 2 - 5
Load Capacitor Charge Tool 2 - 5
Shunts 2 - 5
Remote Peripheral Monitoring Unit 2 - 5
MOV Assembly for PDF Frames 2 - 5
Battery Strings 2 - 5
Enhanced Ground Current Monitor 2 - 6
Current Display 2 - 6
Performance Verification 2 - 6
Alarm Contacts and Alarm Indication Light 2 - 6

Lucent Technologies 415B Battery Plant for 4ESS
2 - Table of Contents Issue 6 September 1999
Design 2 - 6
Power Requirements 2 - 6
Documentation References 2 - 6
3Safety
Information 3 - 1
Rubber Gloves 3 - 1
Admonishments 3 - 1
Safety Statements 3 - 1
Precautions 3 - 2
Personal Safety 3 - 3
Warning Statements and Safety Symbols 3 - 4
Electrostatic Discharge (ESD) 3 - 5
4System Installation
Safety 4 - 1
Unpacking Equipment 4 - 1
Required Tools 4 - 1
General Installation 4 - 2
Mounting Brackets on Control and Distribution Bay 4 - 2
4ESS
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Configurations 4 - 3
Bolting Hardware 4 - 4
Rectifier and AC Connections 4 - 6
Rectifier Output Connections 4 - 6
Alarms 4 - 6
Control and Distribution Bay Connections 4 - 7
RPM Connection 4 - 7
Battery String Protection Module Alarm Connections 4 - 8
Battery String Alarm Connections 4 - 9
Miscellaneous Connections 4 - 9
Rectifiers 4 - 9
Enhanced Ground Current Monitor 4 - 9
5System Testing
Test Equipment Required 5 - 1
Power Up of 415B Battery Plant 5 - 1
Control and Distribution Bay Precharge Procedure 5 - 5
Pre-test Setup 5 - 6
Rectifier Tests 5 - 6
System Test Procedures 5 - 6
Rectifier Walk-in 5 - 7
Current Limit Adjustment 5 - 7
Output Voltage Adjustment Range 5 - 8

Lucent Technologies 415B Battery Plant for 4ESS
Issue 6 September 1999 Table of Contents - 3
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 5 - 11
Galaxy Controller 5 - 12
Galaxy Readouts 5 - 13
DC/DC Converters 5 - 14
Galaxy and Rectifier Interface Leads 5 - 14
Rectifier Fail Alarm (RFA) Leads 5 - 14
AC Fail (ACF) Leads 5 - 14
PH Leads 5 - 15
CB Leads 5 - 15
MAN Leads 5 - 16
VI and VP Leads 5 - 16
HV and RS Leads 5 - 18
TR and TRH Leads 5 - 19
Equalize/Boost Leads 5 - 19
Control and Distribution Bay 5 - 19
Circuit Breaker Panel 5 - 19
Miscellaneous Alarms 5 - 21
BD and VLV Alarms 5 - 21
Battery String Fuse 5 - 21
Battery String Disconnect 5 - 22
Control and Distribution Bay Fuse Alarms 5 - 22
Power Distribution Frame Fuse Alarms 5 - 23
Battery Plant Overall Operation Tests 5 - 23
Energy Management (Efficiency) Algorithm 5 - 23
Power Distribution Frame Shunt Monitors 5 - 24
Battery Reserve Time Prediction Option 5 - 25
Enhanced Ground Current Monitor (EGCM) 5 - 26
Checking and Setting the EGCM’s Offset Control 5 - 26
Checking High and Low Alarm Set Points 5 - 27
Life Test 5 - 27
Heat Scan 5 - 28
6ConnectingTelecommunicationLoadsto
the Power Distribution Frame
Capacitor Charging from the Power Distribution Frame 6 - 1
7Retrofit of 415A Battery Plant
Retrofit Configurations 7 - 1

Lucent Technologies 415B Battery Plant for 4ESS
4 - Table of Contents Issue 6 September 1999
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 7 - 4
Group 3 (Configurations 1 and 2, Adding 1
or 2 Rectifiers) 7 - 6
Group 4 or 5 (Configuration 3, Adding a
5-Rectifier Plant) 7 - 7
Retrofit System Installation and Testing for One or
Two Rectifiers 7 - 11
Unpacking Equipment 7 - 11
Required Tools 7 - 11
Mounting Brackets on Control and Distribution Bay 7 - 13
Bolting Hardware 7 - 14
Rectifier and AC Connections 7 - 15
Retrofit Connections for the Group 3 to the 415A
System (Adding One or Two Rectifiers) 7 - 16
Rectifier Output Connections for One Rectifier 7 - 16
Second Rectifier Addition 7 - 16
Shunt Connections 7 - 16
Sense Voltage Connections 7 - 17
Alarm Connections 7 - 18
Testing for Group 3 (One or Two Rectifiers) 7 - 19
Required Test Equipment 7 - 19
Simulated Plant-Rectifier Interface Tests Using
Test Set (ITE 7102) 7 - 19
Preparation 7 - 20
Connections 7 - 22
Startup 7 - 22
Internal Tests 7 - 24
Control Test 7 - 25
HV Shutdown and Restart 7 - 25
Phase Failure Test 7 - 26
Completion of Test 7 - 27
Current Limit Adjustment 7 - 28
VI and VP Test Leads 7 - 28
Final Connections 7 - 30
Alarm Lamp 7 - 30
Laptop Computer Settings 7 - 30
System Installation and Testing for Retrofit
Group 4 (5 Rectifier Plant) 7 - 31
Unpacking Equipment 7 - 31
Required Tools 7 - 31
Mounting Brackets on Control and Distribution Bay 7 - 32
4ESS
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Configurations 7 - 33

Lucent Technologies 415B Battery Plant for 4ESS
Issue 6 September 1999 Table of Contents - 5
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) 7 - 37
RPM Connection 7 - 37
Battery String Protection Module Alarm Connections 7 - 38
Battery String Alarm Connections 7 - 39
Miscellaneous Connections 7 - 39
Rectifiers 7 - 39
Enhanced Ground Current Monitor 7 - 39
Test Equipment Required 7 - 41
Power Up of 415B Battery Plant 7 - 41
Control and Distribution Bay Precharge Procedure 7 - 45
Pre-test Setup 7 - 46
System Test Procedures 7 - 47
Rectifier Walk-in 7 - 47
Current Limit Adjustment 7 - 48
Output Voltage Adjustment Range 7 - 48
Rectifier Alarms and High Voltage Shutdown 7 - 49
FA Test 7 - 49
BUHVSD 7 - 49
ISHVSD 7 - 50
Rectifier Equalize Adjustment (on Battery) 7 - 51
AC Failure Test 7 - 52
Galaxy Controller 7 - 52
Galaxy Readouts 7 - 54
DC/DC Converters 7 - 54
Galaxy and Rectifier Interface Leads 7 - 55
Rectifier Fail Alarm (RFA) Leads 7 - 55
AC Fail (ACF) Leads 7 - 55
PH Leads 7 - 55
CB Leads 7 - 56
MAN Leads 7 - 57
VI and VP Leads 7 - 57
HV and RS Leads 7 - 59
TR and TRH Leads 7 - 59
Equalize/Boost Leads 7 - 59
Control and Distribution Bay 7 - 60
Circuit Breaker Panel 7 - 60
Miscellaneous Alarms 7 - 62
BD and VLV Alarms 7 - 62
Battery String Fuse 7 - 62
Battery String Disconnect 7 - 63
Control and Distribution Bay Fuse Alarms 7 - 63

Lucent Technologies 415B Battery Plant for 4ESS
6 - Table of Contents Issue 6 September 1999
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 7 - 67
Enhanced Ground Current Monitor (EGCM) 7 - 67
Checking and Setting the EGCM’s Offset Control 7 - 67
Checking High and Low Alarm Set Points 7 - 68
Life Test 7 - 68
Heat Scan 7 - 69
8Maintenance and Operation
Reference Documentation 8 - 1
9Glossary

Lucent Technologies 415B Battery Plant for 4ESS
Issue 6 September 1999 List of Figures - 1
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
Configuration 4 - 3
Figure 4-2B: AC Distribution Wall Mounting
Configuration 4 - 3
Figure 4-3: Typical Floor Mounting Detail 4 - 4
Figure 4-4: Floor Mounting Template for Control
and Distribution Bay 4 - 4
Figure 4-5: AC Breaker Locations with Spare 4 - 5
Figure 4-6: Connecting the AC to the Rectifier
(K1 Contactor) 4 - 6
Figure 4-7: Connections for the RPM 4 - 8
Figure 5-1: Circuit Breaker Feeds to Power
Distribution Frames 5 - 20
Figure 7-1: Three Configurations of the
415B Battery Plant 7 - 3
Figure 7-2: H569-429 Groups 3, 4, or 5 7 - 8
Figure 7-3: Typical 415B Retrofit Battery Plant
AC Feeds for Total Replacement 7 - 10
Figure 7-4: Retrofit with One or Two Rectifiers 7 - 12
Figure 7-5: Bracket Mounting Locations 7 - 13
Figure 7-6: Typical Floor Mounting Detail 7 - 14
Figure 7-7: Floor Mounting Template for Control
and Distribution Bay 7 - 14

Lucent Technologies 415B Battery Plant for 4ESS
2 - List of Figures Issue 6 September 1999
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
Figure 7-11: Partial Sketch of CM3 Digital Meter Board 7 - 26
Figure 7-12: Bracket Mounting Locations 7 - 32
Figure 7-13A: AC Distribution Floor Mounting
Configuration 7 - 33
Figure 7-13B: AC Distribution Wall Mounting
Configuration 7 - 33
Figure 7-14: Typical Floor Mounting Detail 7 - 34
Figure 7-15: Floor Mounting Template for Control
and Distribution Bay 7 - 34
Figure 7-16: AC Breaker Locations with Spare 7 - 35
Figure 7-17: Connecting the AC to the Rectifier
(K1 Contactor) 7 - 36
Figure 7-18: Connections for the RPM 7 - 38
Figure 7-19: Circuit Breaker Feeds to Power
Distribution Frames 7 - 61

Lucent Technologies 415B Battery Plant for 4ESS
Issue 6 September 1999 List of Tables - 1
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
Galaxy Controller 5 - 12
Table 5-D: Optional Circuit Packs
for the Galaxy Controller 5 - 12
Table 7-A: BJT1 Connections 7 - 18
Table 7-B: Test Set Connections 7 - 22
Table 7-C: DIP Switch Default Settings
for 208G Circuit Module 7 - 43
Table 7-D: Load Settings for AC Failure Test 7 - 52
Table 7-E: Circuit Packs/Kit Furnished with the
Galaxy Controller 7 - 53
Table 7-F: Optional Circuit Packs
for the Galaxy Controller 7 - 53
Table 8-A: Reference Documentation 8 - 1

Lucent Technologies 415B Battery Plant for 4ESS
Issue 6 September 1999 Introduction 1 - 1
1 Introduction
Product
Manual This product manual (Select Code 167-792-121) describes the
installation, testing, operating, and maintenance instructions for
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:
Section 1 Introduction
Section 2 System Description
Section 3 Safety
Section 4 System Installation
Section 5 System Testing
Section 6 Connecting Telecommunications Loads to
the Power Distribution Frame
Section 7 Retrofit of 415A Battery Plant
Section 8 Maintenance and Operation
Section 9 Glossary
415B Battery
Plant The 415B Battery Plant contains the following subsystems:
• KS-22089 AC Distribution Panel or Cabinet, two required;
also referred to as a Power Distribution Service Cabinet
(PDSC)
• H569-429 Control and Distribution Bay; also referred to as
a Power Board
• J87132B-2 140Vdc, 140A, 60Hz Ferroresonant Rectifier,
two to four required
• J85501F-1 Galaxy Controller
• J85568D-1 Power Distribution Frame (PDF), two required
• KS-20472 Round Cell Batteries, 70 cells/string, up to three
strings
• NE00305-45, G1 Enhanced Ground Current Monitor

Lucent Technologies 415B Battery Plant for 4ESS
1 - 2 Introduction Issue 6 September 1999
Applications The 415B Battery Plant is usually used to power a 4ESS
switch, but it can be used for any high power, 140-volt plant.
Two complete plants are required.
Installation and
Testing Refer to the appropriate sections in the product manuals for installation procedures for the H569-429 Control and
Distribution Bay, the Galaxy Controller, the J87132B-2
Ferroresonant Rectifier, and the J85568D-1 Power Distribution
Frame (PDF). These manuals, along with other documentation,
are listed in the “Documentation References” portion of Section
2.
Figure 1-1: 415B Battery Plant
PDF #1 PDF #2
PDSC A2 or B2
Rect. #4 Rect. #3
Rect. #1 Rect. #2
PDSC
A1 or B1
Control and Distribution Bay
(Power Board) Including
Galaxy Controller
Floor Mounted Power Distribution
Service Cabinets (AC Distribution
Cabinets). Wall mounted version
also available.
Note:
140V / 140A Rectifiers
Remote Power Distribution
Frames (PDF)
Battery Switches
PDF Panel 3
(provides power for
meter and frame
alarm light)
Two identical battery plants, similar to that in the figure, are required. One is called the A plant and
one the B plant.
A maximum of three battery strings (not shown) connect to the C&D Bay.
Also not shown, an Enhanced Ground Current Monitor (EGCM) that monitors the ground current in
the central office ground conductor. There are separate EGCMs for the A plant and the B plant.
1.
2.
3.

Lucent Technologies 415B Battery Plant for 4ESS
Issue 6 September 1999 Introduction 1 - 3
Customer
Assistance
Contacts
Customer Training Lucent Technologies offers customer training on many Power
Systems products. For information call 1-972-284-2163. This
numberisansweredfrom8:00 a.m.until4:30p.m.,CentralTime
Zone (Zone 6), Monday through Friday.
Customer Service For customers in the United States, Canada, Puerto Rico, andthe
US Virgin Islands, call 1-800-THE-1PWR (1-800-843-1797).
Services provided through this contact include initiating the
spare parts procurement process for out of service emergencies,
ordering Lucent Technologies documents, and providing other
product and service information.
For other customers worldwide, call 001-972-840-0382. This
numberis answeredfrom8:00 a.m.until4:30p.m.,CentralTime
Zone (Zone 6), Monday through Friday.
Technical Support Technical support for Lucent 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, andthe
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 customers worldwide, contact your local field support
center or your sales representative to discuss your specific needs.
Product Repair and
Return Repair and return service is provided for Lucent Technologies
customers around the world.
For customers in the United States, Canada, Puerto Rico, andthe
US Virgin Islands, call 1-800-255-1402 for information on
returning of products for repair.
For other customers worldwide, contact your sales
representative to discuss your particular circumstances.

Lucent Technologies 415B Battery Plant for 4ESS
1 - 4 Introduction Issue 6 September 1999
Warranty Service For domestic warranty service, contact your Warranty Service
Manager (WSM). For international warranty service, contact
your sales representative.
On-Line Power
Systems Product
Manuals
For Lucent Technologies users logging in from inside the
corporate firewall, the address of the “Power Systems On-Line
Product Manuals” page is http://www.cic.lucent.com/
lineage.html.
Forcustomerslogging infromoutside thefirewall, theaddressis
http://www.lucent8.com/lineage.html. The annual subscription
fee for access to this site is $25.To obtain a password, follow the
instructions on-line or call 1-888-Lucent8 (1-888-582-3688).
When prompted for an order number, enter or say
“167-790-010.”

Lucent Technologies 415B Battery Plant for 4ESS
Issue 6 September 1999 System Description 2 - 1
2 System Description
415B Battery
Plant Overview Two 4ESSswitches are powered by two independent 415B
Battery Plants. Each 415B Battery Plant consists of two Power
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.
The two independent plants are labeled Battery Plant “A”
and Battery Plant “B”. The dc output cables between the
Control and Distribution Bay and the Power Distribution
Frames of each plant are different colors for clarification
purposes. The cables are colored as follows:
• Battery Plant “A” - Red and Red with Black tracer
• Battery Plant “B” - Blue and Blue with Black tracer
Power
Distribution
Service Cabinet
(PDSC)
Commercial ac is brought into two ac distribution panels and
sentto eachrectifierinthe plant.Eachac distributionpanelisfed
from a separate input circuit breaker, ideally from a different
power station. There are two ac distribution panels per battery
plant that can either be free standing or wall mounted. One of
three ac input voltage levels may be utilized for the rectifiers in
the plant: 208V, 240V, or 480V at 60 hertz. Three-phase power
is required.
There are a maximum of four rectifiers in the plant, each having
its own circuit breaker located in one of the ac distribution
panels. The circuit breakers are the type that may be tagged and
locked out for safety. Normally, each ac distribution panel feeds
two rectifiers. Refer to Figure 2-1.

Lucent Technologies 415B Battery Plant for 4ESS
2 - 2 System Description Issue 6 September 1999
Figure 2-1: Typical 415B Battery Plant AC Feeds
3333
2222
1111
SP SP SP SP
800A
800A
800A
800A
200A 200A
200A 200A
Distribution A Distribution B
Bus A Bus B
Rectifier 1
Rectifier 1
Rectifier 2
Rectifier 2
Rectifier 3
Rectifier 3
Rectifier 4
(optional)
Rectifier 4
(optional)
Plant A
Plant B
PDSC A1 PDSC A2 PDSC B1 PDSC B2