Lucent Technologies Lineage 2000 ECS Battery Plant User manual

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

Product Manual
J85500E-2
Select Code 167-790-038
Comcode 107044778
Issue 7
October 1998
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.

Lucent Technologies 1200A 24V ECS Battery Plant J85500E-2
Issue 7 October 1998 Table of Contents - 1
Table of Contents
1 Introduction
J85500E-2 2 - 1
Applications 2 - 1
Configurations 2 - 1
Customer Training 2 - 3
Customer Service 2 - 3
Technical Support 2 - 3
Product Repair and Return 2 - 3
Warranty Service 2 - 3
2 Product Description
ECS Battery Plant Physical Description 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 and Growth 3 - 4
Reserve Capacity 3 - 5
Charge Capacity and Recharge Time 3 - 9
Battery String Voltage Drop and Balancing 3 - 10
Battery Size versus Voltage Drop 3 - 11

Lucent Technologies 1200A 24V ECS Battery Plant J85500E-2
2 - Table of Contents Issue 7 October 1998
Calculating Voltage Drop 3 - 13
Conductor Ampacity 3 - 13
Overcurrent Protection 3 - 14
Engineering 3 - 14
Rectifier Sizing 3 - 14
Battery Sizing 3 - 15
Initial and Supplementary Bays 3 - 16
Cable and Load Breaker Sizing 3 - 17
Low-Voltage Disconnect/Reconnect Feature 3 - 23
Controller Options 3 - 23
Alarm System Interface 3 - 24
Earthquake Bracing 3 - 24
Appearance Packages 3 - 24
Planning 3 - 26
Floor Plan Data 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
4Safety
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 Sequence 5 - 2
Unpacking, Handling and Frame Installation 5 - 3
Battery Stand Assembly 5 - 5
Initial Charge 5 - 5
Cable Support and Ground System 5 - 5
Controller and LVD Set-up 5 - 6
AC Wiring, Rectifier Installation and Test 5 - 6
Load Wiring 5 - 11
Battery Connections, Disconnect Installation
and Test 5 - 12

Lucent Technologies 1200A 24V ECS Battery Plant J85500E-2
Issue 7 October 1998 Table of Contents - 3
Controller Test 5 - 13
Load Turn-up 5 - 13
Converter Shelf Assembly 5 - 13
Installation Procedures for Plant Growth 5 - 14
Adding 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 6 - 8
7 Product Warranty

Lucent Technologies 1200A 24V ECS Battery Plant J85500E-2
Issue 7 October 1998 List of Figures - 1
List of Figures
Figure 1-1: Lineage® 2000 ECS Battery Plant (Model
J85500E-2) 2 - 2
Figure 2-1: Typical ECS Battery Plant System Block
Diagram 2 - 2
Figure 2-2: ECS Distribution Bus Bars 2 - 7
Figure 2-3: Low Voltage Disconnect/Reconnect
Contactor (K1) 2 - 8
Figure 2-4: ECS DC 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
Figure 5-3: Floor Mounting Template 5 - 9
Figure 5-4: LVD/Fuse Board (CP5) Jumper Locations 5 - 10
Figure 6-1: Fuse Designation and Function for
LVD/Fuse Board (CP5) 6 - 3

Lucent Technologies 1200A 24V ECS Battery Plant J85500E-2
Issue 7 October 1998 List of Tables - 1
List of Tables
Table 2-A: J85500E-2 Battery Plant Specifications 2 - 14
Table 3-A: Initial Load Drain Information 3 - 6
Table 3-B: Anticipated Future Load Drain Information 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: Installation Reference Documents 5 - 5
Table 6-A: Troubleshooting 6 - 4

Lucent Technologies 1200A 24V ECS Battery Plant J85500E-2
Issue 7 October 1998 Introduction 1 - 1
1 Introduction
J85500E-2 This product manual (Select Code 167-790-038) describes the
Lineage®2000 Evolutionary Control System (ECS) Battery
Plant, J85500E-2, which is shown in Figure 1-1.
This member of the ECS family of battery plants operates from
a nominal 208/240 Vac, 50/60 Hz source. It offers a 1200
ampere total plant capacity with a nominal 24 Vdc output in a
totally integrated energy system containing a controller,
rectifiers, circuit breaker distribution panels and an optional
battery disconnect/reconnect feature in one standard equipment
bay.
Applications Designed for a wide range of wireless applications, the modular
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
adding plug-in type circuit breakers (3 through 100 amperes) to
distribution panels or by specifying optional panels that accept
larger breakers (80, 100 or 225 amperes). Adding functionality
to the basic controller is achieved through two optional circuit
packs, one to add microprocessor-based features and the second
to add a datalogger.
For added flexibility, an optional dc-dc converter shelf assembly
is offered that can be mounted in the ECS plant by replacing one
rectifier shelf assembly and three rectifiers. This system

Lucent Technologies 1200A 24V ECS Battery Plant J85500E-2
1 - 2 Introduction Issue 7 October 1998
provides a -48-volt, 60-ampere source. An ac prewire feature is
available as an option for easier installation at the customer site.
The ECS battery plant is compatible with all flooded and valve
regulated batteries that float within the range of 24 through 29
volts. In addition, the ECS plant is capable of operating in a
batterylessmode,makingitsuitableforthoseapplicationswhere
battery backup is not necessary or is achieved through the use of
an uninterruptible 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.
Figure 1-1: Lineage®2000 ECS Battery Plant (Model J85500E-2)
LINEAGE 2000
LVD/R FA IL
OPEN
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ECS Distribution Panel
ECS Controller
SR 100/24V
Rectifiers
Lucent

Lucent Technologies 1200A 24V ECS Battery Plant J85500E-2
Issue 7 October 1998 Introduction 1 - 3
Customer
Training Lucent Technologies offers customer training on many Power
Systems products. For information call 1-972-284-2163. This
numberisansweredfrom8:00a.m.until4:30p.m.,CentralTime
Zone (Zone 6), Monday through Friday.
Customer
Service Forcustomers in the United States, Canada, Puerto Rico, and the
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 answeredfrom 8:00a.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, 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 customers worldwide, contact your local field support
center or your sales representative to discussyour specific needs.
Product Repair
and Return Repair and return service is provided for Lucent Technologies
customers around the world. For customers in the United States,
Canada, Puerto Rico, and the US Virgin Islands, call
1-800-255-1402 for information on returning of products for
repair.
For other customers worldwide, contact your sales
representative to discuss your particular circumstances.
Warranty
Service For warranty service worldwide, contact your Warranty Service
Manager (WSM). The WSM serves specific customer-groups,
who have taken ownership of the product. For product

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.

Lucent Technologies 1200A 24V ECS Battery Plant J85500E-2
Issue 7 October 1998 Product Description 2 - 1
2 Product Description
ECS Battery
Plant Physical
Description
The Lineage®2000 Evolutionary Control System(ECS) Battery
Plant is shown in Figure 1-1. The ECS battery plant provides
power for the using equipment as well as float and recharge
capability for the battery reserve. The plant operates from a
nominal 208/240 Vac, 50/60 Hz source. It offers a 1200 ampere
total plant capacity with a nominal 24 Vdc output. The ECS
battery plant is compatible with all flooded and valve regulated
batteries. In addition, the ECS plant is capable of operating in a
batterylessmode,makingitsuitable forthose 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, 100-ampere rectifiers, a Lineage®2000 ECS
controller, standard distribution panels accepting breakers from
3 to 100 amperes, optional distribution panels accepting
breakers up to 225 amperes and an optional low voltage battery
disconnect/reconnect feature. One converter shelf assembly
accepting up to six 10-ampere24-volt to -48-volt converters and
-48-volt distribution may be added to the plant, replacing three
rectifiers. Style strips are an optional appearance kit.

Lucent Technologies 1200A 24V ECS Battery Plant J85500E-2
2 - 2 Product Description Issue 7 October 1998
Rectifier The Lineage®2000SR Seriesrectifiersare designedspecifically
for applications where small size, low weight and ease of
installation are of overriding importance. The rectifiers utilize a
combination of switch-mode technology and forced air cooling
to achieve a significant reduction in size and weight over
conventional ferroresonantrectifiers. The plug in, connectorized
design of the rectifiers reduces installation time to minutes,
permitting easy growth and maintenance without service
interruption.
TheLineage®2000 SRSeries 100ampere rectifiers operateover
208/240 Vac 50/60Hz 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 a full complement of
Figure 2-1: Typical ECS Battery Plant System Block Diagram
RECTIFIER
A/C
RECTIFIER
BATTERY
STRING
BATTERY
STRING
BATTERY
BUS
LVD
TO OFFICE
ALARMS
LINEAGE 2000
ECS
FOR ESD WRIST STRAP
CHARGE
RETURN BUS
1200 A
SHUNT
DISCHARGE
RETURN BUS
DISTRIBUTION
TO OFFICE
LOADS
CHARGE
BUS
ALARMS
OUTPUT VOLTS
AMPS
FLOAT
EQ
BD
ACF
MNF
EO
MJF
RFA
µP
SWI
NORM
V
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Lucent Technologies 1200A 24V ECS Battery Plant J85500E-2
Issue 7 October 1998 Product Description 2 - 3
status and alarm signals. The SR Series 100 ampere rectifier is
both UL recognized and CSA certified.
The rectifier status and alarm signals, ac input, and dc output are
all connectorized. The rectifiers plug into a rectifier shelf
assembly that accommodates a maximum of three individual
100 ampere rectifiers. The ECS plant can be equipped with four
rectifier shelf assemblies for a total capacity of 12 SRSeries 100
ampere rectifiers. (See the Lineage®2000 SR Series rectifier
product manual for additional information.)
Controller The ECS controller performs the centralized monitoring, control
and reportingfunctionsfor the ECS battery plant. Thebasic ECS
controller can monitor and control up to 12 rectifiers. It also
provides a single interface point for power alarm and status
reporting.
Two optional expansion circuit packs are available to upgrade
the ECS controller: a microcomputer board equipped with a
powerful 16-bit 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 plant is compatible with all flooded and valve
regulated batteries which accept float voltages within the range
of 24 to 29 Vdc. For appropriate system loadsand reserve times,
selectionof theVRSeriesbatteryenables one tomaximize space
efficiency and fully realize the benefits of front access, modular
growth, ease of installation and maintenance offered by the ECS
battery plant system design. For systems requiring higher
capacities and/or longer reserve times, the Lineage®2000
Round Cell or Unigy®II series of batteries are appropriate.
DC Distribution The ECS dc distribution is shown in Figure 2-2. The distribution
contains the plant charge and discharge bus bars, battery bus,
distribution bus, circuit breaker bus, positive and negative
rectifier bus, plant shunt, optional LVD/R contactor, fuse panel
and circuit breaker panels.

Lucent Technologies 1200A 24V ECS Battery Plant J85500E-2
2 - 4 Product Description Issue 7 October 1998
Distribution Bus
Bars The distribution bus bars include the charge return bus, discharge return bus, battery bus, LVD bus, distribution bus,
circuit breaker bus and positive and negative buses (See Figure
2-2). Battery strings are terminated to the battery bus and the
charge return bus. Positive rectifier outputs are routed to the
distribution circuit breakers through the positive rectifier bus,
the distribution bus and the circuit breaker bus. Negative
rectifier outputs are to the discharge return bus through the
negative rectifier bus, charge return bus and the plant shunt.
The load conductors are terminated on distribution strips above
the circuit breaker panels and the return conductors for load
circuits are terminated on the discharge return bus.
Plant Shunt A current shunt is a sensing device which provides a millivolt
signal proportional to the current flowing through it. The
millivolt-to-ampere ratio of the shunt is the dc resistance of the
shunt (in milliohms), which is thermally stable and accurately
known.
The current shunt in the ECSBattery Plantis connected between
the Charge Return Bus and the DischargeReturn 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 where it is translated back to amperes
and displayed on the digital meter.
Low Voltage
Battery
Disconnect/
Reconnect
(LVD/R) Feature
To prevent costly battery damage due to deep discharges, the
ECS Battery Plant may be equipped with an optional automatic
battery disconnect. This disconnect is designed to isolate
batteriesfrom the load when the plant voltage reaches the lowest
usable battery voltage. The disconnect level is below the
operating range ofmostload equipment,in whichcase service to
the load would already have been lost. The disconnect does not
separate the load circuits from the rectifiers, thus enabling the
rectifiers to begin powering the load as soon as ac power is
restored.
The LVD/R option consists of the LVD/R Contactor, circuitry
on the CP5 Fuse Board and associated wiring. Figure 2-3 is a
pictorial of the contactor (K1). The LVD circuit on CP5
monitors the plant charge bus voltage, designated RB. When the