MODULAR -48 VDC, 800 AMP +24VDC, 160 AMP Front Access ... Critical Power Product Manual 129FD...

Critical Power Product Manual

129FDMODULAR -48 VDC, 800 AMP +24VDC, 160

AMP Front Access Switchmode Rectifier System

[email protected] www.gecriticalpower.com

Service and Assistance - +1 877 546 3243 © 2015 General Electric Company. All rights reserved. 4380431PD Issue 25 May 2015

GE Critical Power 129FD Product Manual

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FFAACCTTOORRYY DDEEFFAAUULLTT SSEETTPPOOIINNTTSS AANNDD SSEETTPPOOIINNTT LLIIMMIITTSS

Description Default Range Resolution Battery on Discharge 52.0 VDC 40-60 VDC 100mV Plant High Voltage Alarm 56.5 VDC 40-60 VDC 100mV Low Voltage Alarm 52.0 VDC 40-60 VDC 100mV Plant Low Low Voltage Alarm 46.0 VDC 40-60 VDC 100mV Low Voltage Load Disconnect (A B C)

42.0 VDC 40-60 VDC 100mV

Low Voltage Reconnect (A B C)

49.0 VDC 40-60 VDC 100mV

Low Voltage Disconnect Time 4 h .1-10h .1h Total Current Alarm (% Applied Globally)

100% 0-100% 1%

Ambient Temperature Alarm (Threshold 1)

10°C 0°C to 100°C 1°C

Ambient Temperature Alarm (Threshold 2)

40°C 0°C to 100°C 1°C

Plant Float* 54.0 VDC 50.0-60.0 VDC 100 mV Plant Equalize* 55.0 VDC 50.0-60.0 VDC 100mV Rectifier Max Current 50 ADC 25-55 ADC 0.1 ADC Rectifier HVSD 58.0 VDC 55.0-65.0 VDC 100mVDC Temperature Compensation Slope

72mV per °C

0-240 mV per °C 1mV per °C

Distribution Current Alarm 80% 0-120% 1% Battery Temperature Alarm (Threshold 1)

10°C -40°C to 100°C 1°C

Battery Temperature Alarm (Threshold 2)

50°C -40°C to 100°C 1°C

Low Voltage Battery Disconnect 42.0 VDC 40-60 VDC 100mV

Low Voltage Battery Reconnect 49.0 VDC 40-60 VDC 100mV

Rectifier Current Imbalance .25 .10 – 1.0 1% Rectifier Temp Max 80°C 0-100°C 1°C Limited Recharge Setting 80% 50-100% 1% Max Alarm Test Time 15 Min. 1-255 Min. 1 Min. Float Current Limit 750mADC 0-10000mADC 1mADC Float Current Alarm Delay 12h 1-24h 1h Plant Equalize Time Setting 24 hours 0-36 hours .1 Hr Plant High Voltage Shutdown 59.0 VDC 40-60 VDC 100mV Recharge Rate Factor .20 .02 - .25 .01 Battery Current Variance .20 0 - 1.0 .01 Variance Inhibit Minimum .10 .05 – .25 .01 High Float Current Factor .05 .05 – .25 .01 Midpoint Variance Major 1000 mVDC 300-1000 mVDC 1 mVDC Midpoint Variance Minor 500 mVDC 300-1000 mVDC 1 mVDC

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TTAABBLLEE OOFF CCOONNTTEENNTTSS FACTORY DEFAULT SETPOINTS AND SETPOINT LIMITS ..........................................................................3

TABLE OF CONTENTS ............................................................................................................................................5

LIST OF TABLES ...................................................................................................................................................7 LIST OF FIGURES .................................................................................................................................................7

PRODUCT INFORMATION.....................................................................................................................................9

SECTION 1: GENERAL .........................................................................................................................................13

1.1 GENERAL..................................................................................................................................................13 1.2 RECTIFIER ...............................................................................................................................................14

1.2.1 RECTIFIER BLANK PANEL...............................................................................................................14 1.3 RECTIFIER SHELF...................................................................................................................................14 1.4 CONVERTER.............................................................................................................................................14

1.4.1 CONVERTER BLANK PANEL...........................................................................................................15 1.5 CONVERTER SHELF................................................................................................................................15 1.6 DISTRIBUTION.........................................................................................................................................15 1.7 OPTIONAL LVD (LOW VOLTAGE DISCONNECT) ................................................................................15

1.7.1 (INTERNAL) LOW VOLTAGE LOAD DISCONNECT (LVLD) LIST 70 ........................................16 1.7.2 (INTERNAL) LOW VOLTAGE BATTERY DISCONNECT (LVBD) LIST 73.................................16

1.8 MANUAL BATTERY DISCONNECT.........................................................................................................16 1.8.1 BATTERY DISCONNECT SWITCH ...................................................................................................16

1.9 DIGITAL PLANT CONTROLLER .............................................................................................................16 1.10 OPTIONAL BATTERY / SHUNT MONITORING MODULE (ADAC) ......................................................16 1.11 ACRONYMS...............................................................................................................................................17

SECTION 2: INSTALLATION ..............................................................................................................................19

2.1 BAY PRE-INSTALLATION CHECKS........................................................................................................19 2.2 INSTALLER MECHANICAL AND POWER ELECTRICAL CONNECTIONS ..........................................19 2.3 RECTIFIER INSTALLATION....................................................................................................................34 2.4 CONVERTER INSTALLATION .................................................................................................................34 2.5 CIRCUIT BREAKER / FUSE INSTALLATION .........................................................................................35

SECTION 3: OPERATIONAL CHECKOUT .......................................................................................................37

3.1 GENERAL..................................................................................................................................................37 3.2 INITIAL PHOENIX DIGITAL CONTROLLER START UP ROUTINE .....................................................37 3.3 INITIAL TURN-ON AND SYSTEM OUTPUT VOLTAGE VERIFICATION .............................................38 3.4 DISTRIBUTION FUSE ALARM TEST ......................................................................................................38 3.5 ALARM EXTENSION VERIFICATION.....................................................................................................39 3.6 LOAD SHARING .......................................................................................................................................39 3.7 +24V DISTRIBUTION...............................................................................................................................39 3.8 PLANT HVSD TEST ..................................................................................................................................39 3.9 RECTIFIER HVSD TEST...........................................................................................................................40 3.10 MISCELLANEOUS ADJUSTMENTS ........................................................................................................40 3.11 COMPLETION OF TESTS ........................................................................................................................40

SECTION 4: THEORY OF OPERATION .............................................................................................................41

4.1 GENERAL..................................................................................................................................................41

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SECTION 5: SPECIFICATIONS ............................................................................................................................43

5.1 SYSTEM RATINGS ....................................................................................................................................43 5.2 FACTORY SETTINGS ...............................................................................................................................44

SECTION 6: J-DRAWING ........................................................................................................................ 438129FD SECTION 7: T-DRAWING......................................................................................................................439129FDT SECTION 8: SCHEMATIC DIAGRAM ............................................................................................. 439129FDSD SECTION 9: RECTIFIER SHELF MANUAL....................................................................................... 4380229PD SECTION 10: SM50H48D MANUAL ..................................................................................................... 4380421PD

REFERENCE DOCUMENTATION (Separately bound manual)

Phoenix Digital Plant Controller Manual………………………………………………………………..4380400PD

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List of Tables TABLE 2-1: FRAME GROUND.............................................................................................................................21

TABLE 2-2: CENTRAL OFFICE GROUND........................................................................................................21

TABLE 2-3A: AC INPUT (FOR INDIVIDUAL FEED).......................................................................................22

TABLE 2-3B: AC INPUT (FOR DUAL FEED) ....................................................................................................24

TABLE 2-3C: AC INPUT (FOR INDIVIDUAL FEED AT THE REAR OF THE RECTIFIER SHELF)......25

TABLE 2-4: -48 VDC LOADS OR +24VDC LOADS...........................................................................................26

TABLE 2-5: -48 VDC LOADS (32 POSITIONS) ..................................................................................................27

TABLE 2-6: -48 VDC LOAD RETURNS...............................................................................................................28

TABLE 2-7: SIX (6) EXTERNAL BATTERY CONNECTIONS (IF REQUIRED)...........................................30

TABLE 2-8: FIVE (5) EXTERNAL BATTERY RETURN CONNECTIONS (IF REQUIRED) .....................30

TABLE 2-9: CUSTOMRER ALARM CONNECTIONS......................................................................................31

TABLE 2-10: OPTIONAL ALARM CABLE (50 FEET OR 100 FEET)............................................................31

TABLE 2-11: RFA OUTPUTS ................................................................................................................................32

List of Figures

FIGURE 1-1: SM50H48D RECTIFIER MODULE ..............................................................................................14

FIGURE 1-2: SM24P20D CONVERTER MODULE............................................................................................14

FIGURE 2-1A: TYPICAL MOUNTING FOR 129FD BAY.................................................................................20

FIGURE 2-1B: TYPICAL MOUNTING FOR 129FD REAR ACCESS RELAY RACK..................................20

FIGURE 2-2A: LIST 110 AC INPUTS (TOP OF BAY) ........................................................................................23

FIGURE 2-2B: LIST 111 OPTIONAL RECTIFIER AC INPUT BOX ...............................................................23

FIGURE 2-2C: LIST 112 DUAL AC INPUTS (TOP OF BAY)............................................................................24

FIGURE 2-2D: LIST 113 OPTIONAL DUAL RECTIFIER AC INPUT BOX...................................................25

FIGURE 2-2E: AC INPUT AT REAR OF RECTIFIER SHELF.........................................................................25

FIGURE 2-3: LOCATION OF –48VDC LOAD CONNECTIONS (23 POSITIONS IN L2) ........................26

LOCATION OF +24VDC LOAD CONNECTIONS (8 POSITIONS IN L2) ..........................26

LOCATION OF –48VDC LOAD CONNECTIONS (32 POSITIONS IN L1). .......................26

FIGURE 2-4: LOCATION OF –48VDC LOAD CONNECTIONS (32 POSITIONS) .......................................27

FIGURE 2-5: LOCATION OF LOAD RETURNS ...............................................................................................28

FIGURE 2-6: LOCATION OF BATTERY CONNECTIONS .............................................................................29

FIGURE 2-7: INSTALLER BATTERY CONNECTIONS (FRONT LOOKING BACK)................................30

FIGURE 2-8: ALARM INTERFACE.....................................................................................................................31

FIGURE 2-9: BTC AND AMBIENT PROBE LOCATION.................................................................................33

FIGURE 2-10: RETAINING SCREW LOCATIONS ON THE RECTIFIER MODULE ................................34

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FIGURE 2-11: RETAINING SCREW LOCATIONS ON THE CONVERTER MODULE .............................34

FIGURE 3-1: DIGITAL CONTROLLER LCD SCREEN ...................................................................................37

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CONTACT INFORMATION

PPRROODDUUCCTT IINNFFOORRMMAATTIIOONN Please take a moment when the product is new to fill in this information.

First, locate the product information label. This is typically located on the upper front of the equipment frame, or on the rear of the frame. Fill in the part number, as it appears on the label, in the space below.

PART NUMBER DATE CODE:

SERIAL NUMBER ECN LEVEL: 860 _ _ _ _ P

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Phone: +1 877 546-3243

Email: [email protected]

Web site: www.gecriticalpower.com


WWAARRNNIINNGGSS CCAAUUTTIIOONNSS 1. Follow proper grounding instructions.

Suivre fonder correctes les instructions.

1. Electrical shock hazard. Do not attempt to remove,maintain, or install this equipment with power applied.Personnel that attempt to work on this equipment withthe power applied may subject themselves or others toelectrical shock that may cause serious injury or death.

Le danger électrique de choc. Pas la tentative pour enlever, maintenir, ou installer cet équipement avec le pouvoir appliqué. Le personnel qui tente traiter cet équipement avec le pouvoir appliqué peut s'exposer ou les autres au choc électrique qui peut causer la blessure ou la mort sérieuse

2. If connecting batteries, remove the battery-box-fuseor trip the circuit breaker. Check batteries andconnections for proper polarity and power beforeconnecting the batteries to the system.

Si connectant des piles, enlever la pile-boîte-le fusible ou trébuche le disjoncteur. Vérifier des piles et des connexions pour la polarité et le pouvoir correcte avant de connecter les piles au système.

2. The use of this equipment by unauthorized oruntrained personnel should not be attempted.Personnel that work on this equipment without theproper training may subject themselves or others toelectrical shock that may cause serious injury or death.

L'usage de cet équipement par le personnel inautorisé ou sans formation ne devrait pas être tenté. Le personnel qui traite cet équipement sans l'entraînement correct peut s'exposer ou les autres au choc électrique qui peut causer la blessure ou la mort sérieuse

3. To remove the circuit breakers or fuses, the DCand/or AC input to the system will need to bedisconnected, thereby disabling the system output tothe load(s). Take the necessary precautions andinform the plant engineer that the system outputpower to the loads will be disabled.

Pour enlever les disjoncteurs ou les fusibles, les données de courant alternatif de et/ou de DC au système auront besoin d'être débranché, de cette façon rendant infirme la production de système au chargement (les chargements). Prendre les précautions nécessaires et informer l'ingénieur de plante que le pouvoir de production de système aux chargements seront rendus infirme. .

4. Before performing any maintenance, ensure AC orDC power is not applied to the system.

Avant d'exécuter n'importe quel entretien, assurer que le pouvoir de courant alternatif ou DC n'est pas appliqué au système.

3. Do not attempt to work on this equipment if it is, or has been, exposed to a high moisture condition. It is recommended the equipment be returned to GE II to be properly tested. Working on this equipment during a high moisture condition subjects the user to electrical shock that may cause serious injury or death.

Pas la tentative pour traiter cet équipement si c'est, ou a été, exposé à une haute condition d'humidité. Il est recommandé l'équipement s'est retourné à GE deux être convenablement essayé. Traiter cet équipement pendant une haute condition d'humidité expose l'utilisateur au choc électrique qui peut causer la blessure ou la mort sérieuse.

5. Fuse holders, fuses, and circuit breakers are not to beloaded to more than 80 percent of their ampererating.

Fondez les supports, fusibles, et des disjoncteurs ne doivent pas être chargés à plus de 80 pour cent de leur estimation d'ampère.

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4. Use of an attachment other than one approved byGE will void any and all warranties, implied orother, and will increase risk of fire, or may possiblycause electrical shock, injury, or death to personnel.

L'usage d'un attachement autrement qu'un approuvé par GE annulera n'importe quel et toutes garanties, implicites ou autres, et augmentera le risque de feu, ou probablement peut causer le choc électrique, la blessure, ou la mort au personnel.

5. Do not operate this equipment if it has been droppedor otherwise damaged. Trying to operate thisequipment if it has been damaged subjects yourself orothers to electrical shock that may cause serious injuryor death.

L'usage d'un attachement autrement qu'un approuvé par GE annulera n'importe quel et toutes garanties, implicites ou autres, et augmentera le risque de feu, ou probablement peut causer le choc électrique, la blessure, ou la mort au personnel.

6. Before you proceed, ensure the input source is not liveand the input circuit breaker(s)/fuse(s) has beentripped or removed. If these procedures have not beenfollowed and the input/output power is live, seriouspersonnel injury or death may occur.

Avant que vous procédez, assurez que la source d'entrée n'est pas en vie et le circuit d'entrée breaker(s)/fuse(s) a été trébuché ou a été enlevé. Si ces procédures n'ont pas été suivies et le pouvoir input-output est la blessure de personnel ou la mort en vie et sérieux peut arriver

7. A rack/shelf may contain several operating systems. Ifthere is another system in the general area you want toinstall this system, be cautious of any exposedconnectors or wires and, with permission, removepower to the other systems. Failure to take thenecessary safety precautions subjects the installer ormaintenance personnel to severe electrical shock thatmay cause serious injury or death.

Une étagère/étagère peut contenir plusieurs systèmes d'exploitation. S'il y a un autre système dans le secteur général que vous voulez installer ce système, êtes prudent de connecteurs ou de fils exposés et, avec la permission, enlevez le pouvoir aux autres systèmes. L'échec pour prendre les précautions de sûreté nécessaires exposent le personnel d'installateur ou entretien au choc électrique sévère qui peut causer la blessure ou la mort sérieuse

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8. This equipment may connect to lead-acid batteries.Battery posts, terminals, and related accessoriescontain lead and lead compounds, chemicals known tothe state of California to cause cancer and birth defectsor other reproductive harm. Wash hands aftertouching batteries.

Cet équipement peut connecter des piles mener-acides. Les postes de pile, les terminaux, et lesaccessoires apparentés contient l'avance et lespremiers composés, les produits chimiques connusà l'état de Californie pour causer les défauts decancer et naissance ou l'autre mal reproducteur.Laver des mains après avoir touché des piles.


SSEECCTTIIOONN 11:: GGEENNEERRAALL 1.1 GENERAL

The 129FD system is designed to provide up to an output of 800 Amps at –48VDC when fully equipped with sixteen rectifier modules. Two -48 to +24 VDC converter shelves are also available, and when fully loaded with eight converters supply 160 Amps at +24VDC. 48VDC load distribution is 32 positions without converters and 23 when converters are equipped. Converter outputs have 8 positions on the right side. Additional distribution is available (L20, L21, L31, and L32), and all hardware (1/4” on 5/8”) is provided (lugs must be supplied by the installer.)

The 129FD plant is available in 2 basic system configurations. The first are basic rear access systems available in traditional relay rack configurations using GE II’s exclusive heavy-duty relay rack, or can be shipped loose (on shipping rails) for mounting in any standard 23” NEMA bay or cabinet. The heavy-duty GE relay rack configurations are ZONE 4 NEBS compliant, with up to 1,100 pounds of batteries in the bottom 2 trays. It is ZONE 2 compliant with up to 4 trays of batteries.

The second basic system is a 100% front access version when mounted in the List 120 – List 124 frame. This frame allows for mounting next to walls with full replacement or adding of modular rectifier shelves and battery trays. This frame is NEBS ZONE 4 compliant in any configuration. It is recommended to use the optional List 165 battery hold down bracket in ZONE 4 areas for added protection.

The plant has been designed to provide various distribution options (up to 600A devices). It includes such features as plug-in circuit breakers, plug-in fuse holders of various types, optional built in converter plant capable of +24V at 160 Amps, and either Low Voltage Battery Disconnect (LVBD) or Low Voltage Load Disconnect (LVLD). All plant interfaces for the system are front accessible when placed in a List 120 – List 124 frame. The main source of power for the Power Plant is commercial AC power, which is converted to DC by the modular switchmode rectifiers. Rectifiers are individually AC sourced with an option to supply 2 rectifiers per AC circuit in a diverse method ensuring a low chance of losing 2 critical rectifiers. The system uses a new generation digital controller that focuses on battery health and has hardwire backup.

The plant is fully automatic and provides float and recharge capacity. Alarms are given whenever any plant circuit breaker trips, a fuse fails, a rectifier fails, or the plant output voltage goes out of prescribed limits. The plant can interface with a LAN/WAN. The basic controller offers web browser based monitoring and plant setpoints to be accessed and/or changed. Refer to the controller manual (4380400PD) for complete details.

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1.2 RECTIFIER

The compact SM50H48D rectifier provides 50 Amps at –48VDC (220VAC input) and 25 Amps at –48VDC (110 VAC input). Up to 4 rectifier modules can be equipped in a 23-inch rack-mounted shelf, for a total of 200 Amps per shelf. For rectifier module details, refer to the rectifier product manual (4380421PD) attached at the rear of this manual. Test jacks are located on the bottom left front of each rectifier module to read individual rectifier current.

Lift handle to access test jacks

Front View

FIGURE 1-1: SM50H48D Rectifier Module

1.2.1 RECTIFIER BLANK PANEL

Each rectifier shelf may accommodate up to four rectifier modules. All unused rectifier positions must be covered with a rectifier blank panel (GE part number 4361179P).

1.3 RECTIFIER SHELF

The rectifier shelf provides 200 Amps at –48VDC when fully equipped with four (4) SM50H48D rectifiers. Four fully loaded shelves may be equipped in the system to provide a total of 800 Amps of –48VDC.

1.4 CONVERTER

The SM24P20D converter provides 20 Amps at +24VDC. The high power density, lightweight design, allows up to 4 converter modules to be equipped in a 23-inch rack-mounted shelf, for a total of 80 Amps per shelf. Two fully loaded converter shelves (if equipped) supply a total of 160A.

FIGURE 1-2: SM24P20D Converter Module

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1.4.1 CONVERTER BLANK PANEL

Each converter shelf may accommodate up to four converter modules. All unused converter positions must be covered with a converter blank panel.

1.5 CONVERTER SHELF

The converter shelf (if equipped) provides 80 Amps at +24VDC when fully equipped with four (4) SM24P20D converters. Two fully loaded shelves may be equipped in the system to provide a total of 160 Amps of +24VDC.

1.6 DISTRIBUTION

Two distribution heads are available for the 129FD system. The first (List 1), for use with NO converter shelves (straight –48V, no +24V) has 32 distribution positions, 16 on the left and 16 on the right in vertical “stacks”. Each side is rated 500 Amps and the total system is rated 800 Amps. The second distribution head (List 2) is for use with –48V to +24V converters and allows 23 –48V distribution positions and 8 +24V distribution positions. The +24V distribution is located at the top of the right side “stack”. The converter output distribution is NOT designed to be changed in the field.

Four supplemental distribution cabinets are available (List 20, List 21, List 31, and List 32) that provide additional distribution points and capabilities.

The supplemental cabinets mount above the main distribution cabinet or above another supplemental cabinet. Alarms are sent down via wiring and a connector on the left side of the system. The ground bar in the rear of the supplemental cabinet is connected to the ground bar below by a splice plate to ensure the ground bus rating throughout the entire system is maintained at 800 Amps. The –48V is transferred up the left and right side “stacks” via small splice plates. The rating in the supplemental cabinets (no mater how many) is 350 Amps (continuous) per side maximum. The left side “stack” is always –48V. The right side “stack” is –48V when installed above a List 1 basic, and will be +24V if mounted above a List 2 split bus basic. In the case of List 2 split bus, only a list 20 can be mounted directly on top of the List 2. If List 21, List 31, or List 32 are desired, a list 20 must make the transition from the basic List 2 to the desired supplemental.

List 20 provides 20 positions of plug in distribution to increase the number of positions available in the system. When connected, the “hot” bus splice plates block the top 2 positions on the basic (or List 20 directly below). This gives a net gain of 16 positions. List 21 adds the capability to add 6 (3 per side) large frame (GJ type) single pole circuit breakers. 1 single pole and 1 double pole could be used in each side. It is not recommended that circuits larger than 400 Amps be used due to temperature rise at bus splices. Total continuous load on each side of supplemental cabinets should be kept to 350 Amps or less. Breakers are available with or without shunts for optional monitoring.

List 31 adds the capability to add 6 (3 per side) TPL-B (up to 250 Amps) fuse positions. Each position has a shunt for optional monitoring.

List 32 adds the capability to add 4 (2 per side) of TPL-C (275A to 400A) fuses. TPL-B (70A to 250A) can also be inserted with an additional adapted cover. Each fuse holder has a shunt for optional monitoring. It is not recommended that larger than 400 Amp circuits be used due to temperature rise at bus splices.

1.7 OPTIONAL LVD (LOW VOLTAGE DISCONNECT)

There are two schemes available for LVD, either low voltage load disconnect (LVLD) or low voltage battery disconnect (LVBD).

NOTE: Both, L70 and L73, cannot be equipped at the same time.

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1.7.1 (INTERNAL) LOW VOLTAGE LOAD DISCONNECT (LVLD) LIST 70

An optional low voltage load disconnect can be built into the load bus and is accomplished by an 800 amp contactor. During an AC outage the output voltage to the plant drops below a predetermined setpoint, the low voltage disconnect will open the loads (both +24V and -48V) from the plant to avoid possible damage to the batteries or equipment. The batteries and rectifiers are on one side of the contactor, and the loads are on the other side. The plant controller monitors the battery voltage to control the contactor. The contactor replaces a bus plate in the charge bus portion of the plant behind the left side distribution module. Wiring for the LVD module is always present in the plant wiring harness and is plugged in when this option is equipped. The system automatically resets and comes back on line to recharge the batteries and supply current to all loads once the AC source is restored.

1.7.2 (INTERNAL) LOW VOLTAGE BATTERY DISCONNECT (LVBD) LIST 73

List 73 is an optional low voltage battery disconnect that is physically the same and located in the same place as the List 70. There is an extra bus that wraps to the rear of the system and covers the normal rectifier connection positions. By terminating the rectifiers on this bus, the charger outputs are moved to the load side of the LVD contactor. All other wiring and cabling remains the same. The system controller/monitor remains powered during all phases of disconnect operation.

1.8 MANUAL BATTERY DISCONNECT

1.8.1 BATTERY DISCONNECT SWITCH

Located on the plant digital controller interface is a (guarded) battery disconnect slide switch. If the optional battery disconnect is equipped, this switch will allow the user to manually disconnect the battery bus from the plant. To disconnect the batteries, slide the switch to the right position. To reconnect the batteries, slide the switch to the left position.

1.9 DIGITAL PLANT CONTROLLER

The digital plant controller monitors and/or controls voltages, currents, temperatures, and other parameters within the 129FD and displays this data via the LCD screen. The digital plant controller consolidates all data and provides all interface functions for the power system, including both local and remote capabilities for monitoring and providing setpoint information.

For complete details, refer to the digital plant controller manual (4380400PD).

1.10 OPTIONAL BATTERY / SHUNT MONITORING MODULE (ADAC)

The battery/shunt monitor module (also referred to as the ADAC monitoring module) is an optional factory/field configurable device used to monitor load shunts and/or battery measurements. Using a combination of known module types and the battery/shunt monitor module dipswitches, the end user can configure each monitored point as one of five (5) basic measurement types:

• Branch shunt current (30 max per system)• Battery current (24 strings max per system) • Battery temperature (24 strings max per system)• Battery midpoint (24 strings max per system)• Battery sense (6 max per system)

For more information about the optional ADAC module refer to the digital plant controller manual (4380400PD). For ordering information, refer to the J-Drawing attached to the rear of this manual.

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1.11 ACRONYMS

ABS Alarm Battery Supply LVD Low Voltage (Load) DisconnectACO (Audible) Alarm Cut Off MJ Major ALM Alarm MN Minor AO Analog Output MP Mid Point AWG American Wire Gauge MON Monitor BAT Battery NC Normally Closed BC Battery Current NO Normally Open BCX Battery Current (x represents any number) OC Over Current BD Battery Disconnect PE Power Earth (Earth Ground) BS Branch Shunt PL Partial Load BTC Battery Temperature Compensation PMJ Power Major CBS Control Battery Supply PMN Power Minor CFA Converter Fail Alarm PMNR Power Major Return COF Charger Off (GND Signal) PMJR Power Minor Return COM Common PNL Panel CON Charger On (GND Signal) RCC Remote Charger Control DFA Distribution Fuse Alarm REMEQ Remote EqualizeDFAR Distribution Fuse Alarm (Return) RFA Rectifier Fail Alarm DO Digital Output RFA J Rectifier Fail Alarm Major EBD Emergency Battery Disconnect RFA N Rectifier Fail Alarm Minor ECS End Cell Switch RFAR Rectifier Fail Alarm Return EPO Emergency Power Off RS Rectifier Restart EQ Equalize RSR Rectifier Restart Return FA Fuse Alarm RXD Receive GND Ground SG Signal Ground HHVA High High Voltage Alarm SH Shunt HVA High Voltage Alarm SHG Shield Ground HVS High Voltage Shutdown TB Terminal Block LCA Low Current Alarm TR Rectifier Turn On/Off LLV Low Low Voltage TRR Rectifier Turn On/Off Return LOA Low Output Alarm TS Terminal Strip LOAR Low Outputt Alarm return TXD Transmit LSO Load Share Out VM Volt Meter LV Low Voltage WD Watch Dog

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SSEECCTTIIOONN 22:: IINNSSTTAALLLLAATTIIOONN 2.1 BAY PRE-INSTALLATION CHECKS

A. Remove the bay from the shipping container and ensure all items are intact. If the contents are damaged, notify the delivery personnel and GE immediately.

B. Several options are available for the bay and should have been determined when the order was placed. Ensure the plant configuration matches the order.

C. Ensure required single-phase 184 - 264VAC, 45-63 Hz. is available at the selected plant location. Each rectifier position requires a 25A circuit. 4 circuits per 1 ¼” conduit per rectifier shelf.

2.2 INSTALLER MECHANICAL AND POWER ELECTRICAL CONNECTIONS

Installer’s information notes: Power Bay torque requirements will comply with data outlined in the following charts except when otherwise specified by drawing or customer requirements. Floor anchors, AC wireways, overhead structural materials, and batteries should be chosen and torqued to meet customer / manufacturer recommendations.

Note 1: Equipment grounding conductor size (Frame or Chassis) is based on the recommendations of the National Electric Code for copper wire. #6 AWG is minimum size recommended.

Note 2: Fuse or circuit breaker protection external to the system for commercial AC is to be provided by the customer or contractor and should meet National Electrical Code standards.

Note 3: DC wire sizes are based on the voltage drop considerations and the National Electric Code Table 310-16 for copper wire.

Note 4: Installation of the system should be in an area that is accessible to qualified personnel only.

A. Install the system as follows:

1. Put the system into position and secure to the floor. (See Figure 2-1A and Figure 2-1B for boltlocations)

2. Top support the bay from overhead structure per customer standards.

3. Turn all breakers to off and remove any distribution fuses.

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Front Access Frame

Figure 2-1A: Typical Mounting for 129FD bay (all measurements are in inches)

FRONT

Figure 2-1B: Typical Mounting for 129FD rear access relay rack (all measurements are in inches)

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B. All internal wiring that could be done has been accomplished at the factory.

C. The following steps will ensure that all installer wiring is addressed. Refer to the system T-Drawing for terminal details.

D. Install frame grounding to ensure personal and equipment safety. Refer to Table 2-1.

Table 2-1: FRAME GROUND

Connection Terminal Type Torque Recommended Wire Size

Frame Ground

2-hole lug 1/4" on 5/8" centers or 2-hole lug 3/8” on 1” centers

75 in-lbs (for 1/4")

12 ft-lbs (for 3/8”)

6 AWG MINIMUM

E. Connect the battery return ground cable from the C.O. ground bar to the 129FD system ground bus. Use (1) of the (6) 3/8” on 1” center positions at the top of the return bus located in the center rear of the distribution head. Refer to Table 2-2.

Table 2-2: CENTRAL OFFICE GROUND

Connection Terminal Type Torque Recommended Wire Size C.O. Ground 2-hole lug

3/8” on 1” centers 27 ft-lbs 0 AWG or customer standard

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F. NOTE: No AC connections should be made until after the bay has been secured to the structure or frame ground is connected (See Chapter 2).

For L110 and L111, each rectifier shelf requires (4) 2 pole 240VAC, 25A circuits. Each rectifier in this system requires an individual commercial AC input. It is recommended that a single 1/4" conduit with all 4 circuits inside be run for each shelf, whether to an AC box at the top of the system, or to the rear right side of each rectifier shelf.

L112 and L113 are each dual feed input boxes. Two rectifier modules are fed from one 2-pole 240VAC, 50A circuit breaker. L112 and L113 are designed to work with groups of two rectifier shelves. TB1 feeds rectifiers 1 and 5, 2 and 6, 3 and 7, 4 and 8. TB2 feeds rectifiers 9 and 13, 10 and 14, 11 and 15, 12 and 16. It is recommended that a single 1/4" conduit with all 4 circuits inside be run for each terminal block.

Shelf Number / Rectifier Number




TB1 Shelf 1 / Rectifier 1 Shelf 2 / Rectifier 5

Shelf 1 / Rectifier 2 Shelf 2 / Rectifier 6







Run the AC lines to the top of the bay. Refer to Table 2-3A for further wiring information regarding individual feed and refer to Table 2-3B for the L112 or L113 dual feed option. Each input AC wire must be stripped no more then 3/8" (10 mm). Connect the AC lines (L1, L2 and GND) to the terminal blocks for each rectifier, as shown in Figure 2-2. Ground should be connected first.

L110: Top AC connection box. Individual feed up to 4 shelves (used only of L120 – L124 systems).

L111: Top AC connection box. Individual feed up to 3 shelves (used only with GE relay rack systems L126 – L130).

L112: Top AC connection box. Dual feed up to 4 shelves (used only of L120 – L124 systems).

L113: Top AC connection box. Dual feed up to 4 shelves (used only with GE relay rack systems L126 – L130).

Alternative: Relay rack systems (rear access) can be connected at each rectifier shelf.

NOTE: List 110 top of box accepts (6) 11/4” conduits. List 111 top of box accepts (3) 1” or 1 ¼” conduits. List 112 top of box accepts (6) 11/4” conduits. List 113 top of box accepts (3) 1” or 1 ¼” conduits. Each rectifier shelf accepts (1) 1” or 1 ¼” conduit.

Table 2-3A: AC INPUT (for individual feed) Connection Terminal Type Torque Recommended Wire

Size Recommended Feeder Breaker Size

AC Input at Top Strip and insert 45 in-lbs 8 AWG 25 Amp per rectifier module AC Input at Rectifier

#8 one hole lug 36 in-lbs 8 AWG 25 Amp per rectifier module

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Figure 2-2A: LIST 110 AC Inputs (Top of Bay)

Figure 2-2B: LIST 111 Optional Rectifier AC Input Box (Shown with cover removed)

All conduit openings come with plugs installed. Openings on the right end of for conduits to the rectifier shelves. Installer to determine wiring requirements and conduit entry points on top of the box appropriate for the site conditions.

3 rectifier shelves maximum in the system with this option. Enough wire, conduit, and conduit fittings are supplied to wire 3 rectifier shelves.

List 111 optional rectifier AC box (3) rectifier shelves maximum. Rectifier AC installer connections are top of relay rack systems.

Top Support for 5/8” Hardware

Frame Ground 1/4" on 5/8” or 3/8” on 1” Bare and Greased

Use these (3) conduit entrances first unless blocked by overhead structure

TB4

TB1

TB2

TB3


NOTE: One L112 and L113 (dual feed) terminal blocks, one AC Input feeds two rectifier modules.

Table 2-3B: AC INPUT (for dual feed) Connection Terminal Type Torque Recommended Wire


AC Input at Top Strip and insert 45 in-lbs 6 AWG 50 Amp for 2 rectifier module













Top Support for 5/8” Hardware

Frame Ground 1/4" on 5/8” or 3/8” on 1” Bare and Greased

TB1 Rectifier Shelves 1 (Top) and 2

TB2 Rectifier Shelves 3 and 4

Use these (3) conduit entrances first unless blocked by overhead structure

Figure 2-2C: LIST 112 Dual AC Inputs (Top of Bay)

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Figure 2-2D: LIST 113 Optional Dual Rectifier AC Input Box (Shown with cover removed)

All conduit openings come with plugs installed. Openings on the right end of for conduits to the rectifier shelves. Installer to determine wiring requirements and conduit entry points on top of the box appropriate for the site conditions. 4 rectifier shelves maximum in the system with this option. Enough wire, conduit, and conduit fittings are supplied to wire 4 rectifier shelves. List 113 optional rectifier AC box (4) rectifier shelves maximum. Rectifier AC installer connections are top of relay rack systems.

If L110, L111, L112, or L113 has been ordered, connect directly to the rear of the rectifier shelf. Refer to figure 2-2E for the location.

Table 2-3C: AC INPUT (for individual feed at the rear of the rectifier shelf) Connection Terminal Type Torque Recommended Wire


AC Input at Rectifier

#8 one hole lug 36 in-lbs 8 AWG 25 Amp per rectifier module

AC Conduit Entry

AC Input Connections

Figure 2-2E: AC Input At Rear Of Rectifier Shelf (Shown with lexan cover removed)

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NOTE: Two distribution heads exist for the 129FD system. The first distribution option (LIST 1) consists of 32 positions for the –48VDC distribution. The second one (List 2) contains 23 positions for the –48VDC distribution and 8 positions for the +24VDC distribution (if converters are equipped).

G. Connect the –48VDC load(s) to the individual circuit breaker bus bars (from circuit breakers CB1 thru CB24, as required) from the front of the display and control module. Refer to Figure 2-3 (for 23 position) or Figure 2-4 (for 32 position).

Table 2-4: -48 VDC LOADS or +24VDC LOADS

Connection Terminal Type

Torque Maximum Wire Size Per Position

Maximum Breaker Size

-48VDC Loads

2-hole lug 1/4" on 5/8" centers

75 in-lbs 8 AWG to 1 AWG (Single Pole) 100 Amp per position (CB)

-48VDC

Left side (when facing front of bay) List 1 or List 2

-48VDC

+24VDC

Right side (when facing front of bay) List 2 (List 1 is all –48VDC)

Figure 2-3: Location of –48VDC Load Connections (23 positions in L2) Location of +24VDC Load Connections (8 positions in L2)

Location of –48VDC Load Connections (32 positions in L1) no +24VDC Load positions are available in L1 Distribution.

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Table 2-5: -48 VDC LOADS (32 positions)

Connection Terminal Type

Torque Maximum Wire Size Per Position

Maximum Breaker Size

-48VDC Loads


75 in-lbs 8 AWG to 1 AWG (Single Pole) 100 Amp per position (CB)

-48VDC Loads

2-hole lug 3/8" on 1” centers

75 in-lbs 27 ft-lbs

8 AWG to 1 AWG (Single Pole) 100 Amp per position (CB) 350 Amps per side (Fuse)

LIST 32 3/8" on 1” centers

Splice plate blocks 2 positions per side

LIST 20 1/4" on 5/8” centers

Splice plate blocks 2 positions per side

LIST 1 1/4" on 5/8” centers

Figure 2-4: Location of –48VDC Load Connections (32 positions)

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H. Load returns are to be connected to the system ground return bus. Refer to Figure 2-5. See Table 2-6.

NOTE: Load returns are the same for both distribution options.

Table 2-6: -48 VDC LOAD RETURNS

Connection Terminal Type Torque Maximum Wire Size Per Position Load Returns (small circuits)


75 in-lbs 1 AWG on all positions.

Load Returns (large circuits)

2-hole lug 3/8" on 1” centers

37 ft-lbs 4/0 MAX

Return Splice Plates

List 20

List 1

Figure 2-5: Location of Load Returns

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NOTE: Prior to any battery connections to the plant battery bus, the user must remove F1 (CONTRL fuse) from the plant interconnect card (620668P or 6200668P-1) located within the distribution head. The F1 fuse is a 3-amp GMT fuse.

I. Front access rack mounted batteries. If battery trays were ordered, the battery cabling from the systems down to 1-hour reserve time. If shorter reserve time is used, larger wire should be used. The battery cabling has 1/4" hole lugs that will connect to most front access battery types. The cables have heat shrink over the lugs to ensure protection until batteries are installed and connected. The trays can be mounted at various height spacing to accommodate various sizes of front access batteries. Refer to J-438129FD battery tray figures for more details. A different front retainer rail is available for deeper batteries. Foam strips are provided to put on the right side of the left 3 batteries to maintain spacing between cells. There is a battery hold down clamp available that should be adjusted down on the batteries (if equipped) prior to connecting the battery cables to the battery strings. It will capture the batteries and not allow them to jump the front keeper during a seismic event. Connect the battery cables to the battery strings. Follow battery manufacturers required torque specifications. Refer to Figure 2-6.

Battery Connection

Battery Return Connection

Figure 2-6: Location of Battery Connections

Larger battery cabling and disconnect devices can be substituted if reserve times for batteries is projected to be less than 1 hour, requiring high current rates to and from the batteries. Consult GE engineering.

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J. If external batteries are to be used, mount and strap batteries per manufacturers recommendations and customer standards (connect the battery power cabling from the 129FD distribution).

Refer to Figure 2-7.

Table 2-7: SIX (6) EXTERNAL BATTERY CONNECTIONS (IF REQUIRED)

Connection Terminal Type Torque Recommended Wire Size

Battery Rack Mounted

2-hole lug 3/8” on 1" centers 27.0 ft/lbs Installer sized per customer.

Floor Mounted Batteries


Table 2-8: FIVE (5) EXTERNAL BATTERY RETURN CONNECTIONS (IF REQUIRED)

Connection Terminal Type Torque Recommended Wire Size Battery Returns

(Refer to Figure 2-7)


Five (5) External Battery Return Connections (Ground)

Six (6) External Battery Connections (-48VDC)

Figure 2-7: INSTALLER BATTERY CONNECTIONS (Front looking back)

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K. Located within the distribution head (toward front, center), as shown in Figure 2-8, is where the PWB containing installer connections for the system alarms is located. This PWB is referred to as the Alarm Extension Board. Alarm contacts are accessed using an Amp Champ connector. To access this board, remove the two fasteners found on the front of the distribution head cover, and open the door. Optional 50’ and 100’ alarm cables are available; refer to T-439129FD for color code.

Table 2-9: CUSTOMER ALARM CONNECTIONS

Connection Terminal Type Recommended Wire Size Customer Alarms Screw Cage Clamp 14 AWG Maximum

Table 2-10: OPTIONAL ALARM CABLE (50 FEET OR 100 FEET)

II Part Number: Length: J-Drawing List Number: 6370457P-50 50 Feet 916370457P-100 100 Feet 92

Alarm Connections inside distribution head.

Figure 2-8: Alarm Interface

NOTE: Each of the 16 extended alarms are factory set to “Open On Alarm”. Refer to the plant digital controller manual (4380400PD) for details on how to change the factory alarm settings.

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L. Individual RFA output connections

The 129FD system is enabled with individual rectifier failure alarm (RFA) outputs. To utilize these outputs, the optional cable must be ordered. This option should be specified at the time the order is placed and it will be factory installed. The mating connector that is required to connect to the RFA alarms is included in a kit and may be ordered in two different lengths.

GE PART NUMBER LENGTH

6370424P-50 50 feet

6370424P-100 100 feet

Wire the RFA outputs per Table 2-11 (as required). The factory setting is ground on alarm (the RFA COM connections are not to be connected).

NOTE: If equipped, the RFA cabling will be tied to the top of the system. Each set of cables will have a label stating the shelf number.

The pin-out of each RFA cable (one per shelf) is shown below.

TABLE 2-11: RFA OUTPUTS Individual RFA wiring chart

Pin # Description Rect # Color 1 RFA 1 RECT 1 BL/WH 4 RFA 2 RECT 2 OR/WH 2 RFA 3 RECT 3 GN/WH 5 RFA 4 RECT 4 BR/WH 3 RFA COM WH/BL

Shelf #1

6 RFA COM WH/OR 1 RFA 1 RECT 5 BL/WH 4 RFA 2 RECT 6 OR/WH 2 RFA 3 RECT 7 GN/WH 5 RFA 4 RECT 8 BR/WH 3 RFA COM WH/BL

Shelf #2


Shelf #3


Shelf #4

6 RFA COM WH/OR

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M. Battery Temperature Compensation Probe Installation

The 129FD system is enabled with battery temperature compensation. To utilize BTC, the optional BTC probe must be ordered. This option should be specified at the time the order is placed and it will be factory installed. The BTC probe must be attached to the 2nd (numbered right to left) negative battery terminal. Refer to Figure 2-9 for the BTC connection point within the 129FD and refer to Table 2-12 for BTC probe and extension cables part numbers.

N. Ambient Temperature Probe Installation

The 129FD system ambient temperature probe is optional. This option should be specified at the time the order is placed. The ambient temperature probe is placed within the distribution head to monitor plant temperature. Refer to Figure 2-9 for the ambient temperature probe connection point within the 129FD and refer to Table 2-12 for ambient temperature probe and extension cables part numbers.

TABLE 2-12: BTC and Ambient Probe Part Numbers DESCRIPTION PART

NUMBER J-DRAWING LIST NUMBER

Battery Temperature Compensation Probe 6370390P-1 L61 Ambient Temperature Probe 3750113P L605 Foot Extension Cable 6370454P L62 10 Foot Extension Cable 6370454P-10 L63 15 Foot Extension Cable 6370454P-15 L64 20 Foot Extension Cable 6370454P-20 L65

Figure 2-9: BTC and Ambient Probe Location

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2.3 RECTIFIER INSTALLATION

A. Remove the blank filler panel where the rectifier module will be inserted.

B. Ensure the AC circuit breaker in the AC power service cabinet is set to the off position.

C. Insert the rectifier into the rectifier shelf. The module should slide in easily. Do not force it into the shelf or damage to the module or plant backplane could occur.

D. Push lightly on the front of the module until the module is against the face of the shelf. Secure the module to the cage with the module retaining screws (Refer to Figure 2-10).

Figure 2-10: Retaining screw locations on the rectifier module

NOTE: If ordered as part of a complete system, the rectifiers will come in the shelves from the factory.

2.4 CONVERTER INSTALLATION

A. Remove the blank filler panel where the converter module will be inserted.

B. Verify that the DC input breaker on the front of the converter module is in the “OFF” position and insert the converter into the converter shelf. The module should slide in easily. Do not force it into the shelf or damage to the module or plant backplane could occur.

D. Push lightly on the front of the module until the module is against the face of the shelf. Secure the module to the cage with the module retaining screws (Refer to Figure 2-11).

Figure 2-11: Retaining screw locations on the converter module

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2.5 CIRCUIT BREAKER / FUSE INSTALLATION

CIRCUIT BREAKERS ALARM ON ELECTRICAL TRIP ONLY. THEY MUST BE INSERTED SO THAT AUXILARY ALARM CONTACTS MATE WITH PWA CONTACTS BEHIND PLUG-IN POSITIONS. FUSE HOLDERS MUST BE INSERTED ACCORDING TO THE LINE/LOAD MARKING ON THE UNIT.

THIS SIDE OF DEVICE IS CLAMPED IN WHEN FRONT DOOR CLOSES.

CB/FUSE HOLDER KEEPER BAR SHOWN IN LOCKED NORMAL USAGE POSITION. LOOSEN (4) NUTS AND SLIDE TO OUTSIDE WHEN INSERTING AND REMOVING OVER-CURRENT DEVICES. TYPICAL BOTH SIDES.

WHEN INSERTING DOUBLE POLE DEVICES. ENSURE BOTTOM HALF IS IN AN ODD NUMBERED POSITION AND TOP HALF IS IN AN EVEN NUMBERED POSITION.

SELECT SINGLE POLE CIRCUIT BREAKERS PER TABLE H (in J-438129FD).

LUG HARDWARE SUPPLIED IN BAGS WITH UNIT FOR DISTRIBUTION LOAD + AND – LEADS.

LINE BUS

SCALE 0.750 TYPICAL INSERTION OF DISTRIBUTION MODULES (CB, TPC FUSE, AND GMT FUSES)

OUTPUT BUSSES

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SSEECCTTIIOONN 33:: OOPPEERRAATTIIOONNAALL CCHHEECCKKOOUUTT 3.1 GENERAL

The following procedure should be followed after installation. After performing any maintenance to the system, follow the procedure detailed in section 3.3.

It is assumed that the system is installed in the plant, input power is available, outputs are tied to the applicable loads, and all other system interfaces have been made.

NOTE: Alarms will be sent. Notify alarm surveillance personnel.

3.2 INITIAL PHOENIX DIGITAL CONTROLLER START UP ROUTINE

1. Remove F1 (CONTRL fuse) from the plant interconnect card (620668P or 6200668P-1) locatedwithin the plant distribution head. F1 is a 3 Amp GMT fuse.

2. Remove all rectifier modules and converter modules from the plant.

3. If equipped, turn each battery string breaker “ON” (one string at a time). This will apply batterypotential to the power plant.

4. Once all battery string disconnect breakers are “ON”, replace F1 (CONTRL fuse) into the plantinterconnect card (6200668P or 6200668P-1), located within the plant distribution head. F1 is a 3Amp GMT fuse. This will start the digital controller initialization / self-test process.

5. The plant digital controller initialization / self-test will start within 30 seconds. During the start up,the LCD screen will flash “SELF TESTS PASSED”. Each LED on the front of the digital controllerwill cycle in order from the top left position to the bottom right position. Refer to Figure 3-1 for avisual representation of what the digital controller LCD screen will display once the plant digitalcontroller self test is complete.

Figure 3-1: Digital Controller LCD Screen

NOTE: Figure 3-1 represents a typical digital controller LCD screen.

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3.3 INITIAL TURN-ON AND SYSTEM OUTPUT VOLTAGE VERIFICATION

1. Install each rectifier module.

2. If equipped, verify that each input breaker (on the front of each converter module) is in the “OFF”position and install each converter module.

3. Apply “AC Power” to each rectifier, one at a time. Each rectifier will start up and begincommunications with the plant digital controller. Once “AC Power” has been applied to all of theinstalled rectifier modules, visually verify that the green LED “AC OK” and the green LED “DCOK” are illuminated on each rectifier module. Verify that the RECTIFIER MAJOR (or RECTIFIERMINOR) LED and the AC FAIL LED on the plant digital controller are extinguished. If the systemis equipped with converters, the plant digital controller should still be reporting a POWER MAJORalarm.

4. If equipped, turn "ON" each converter breaker (located on the front of each converter module), oneat a time. When all converters in the bay have successfully been powered on, the POWER MAJORLED on the plant digital controller will extinguish.

5. The plant digital controller OK LED (green) and FLOAT MODE (green) should be the only twoLEDs illuminated on the front of the plant digital controller panel. If any alarms are still showing onthe plant digital controller, refer to section 6.2.

a. Verify that the only front panel LEDs illuminated are SYSOK and FLOAT MODE.b. Verify the controller reports no alarms.c. Verify communications to the rectifier by looking at status of all rectifiers.d. Verify communications to the converters by looking at status of all converters.e. Verify plant voltage displayed on controller is ± 0.05V of voltage measured between +24V

bus, and GND bus using an external calibrated meter.f. Verify Plant Voltage is equal to the Float Voltage Setpoint ± 0.05V.

NOTE: Before performing the following tests, verify that the plant is operating normal (showing no alarms). The only two LEDs illuminated on the front of the plant digital controller should be the Green SYSOK LED and the Green FLOAT LED.

3.4 DISTRIBUTION FUSE ALARM TEST

The following procedure will demonstrate what happens during a distribution fuse failure.

A. Simulate a circuit breaker trip by temporarily strapping the two alarm pins (use an empty circuit breaker position, if available) in the distribution head (once for the –48V distribution and once for the +24V distribution, if equipped). The following will occur:

1. The Red PMJ LED and the Red DISTRIBUTION FUSE LED will illuminate on the front of the plantdigital controller panel.

B. Remove the temporary jumper from the distribution head and the system will react as follows:

1. The Red PMJ LED and the Red DISTRIBUTION FUSE LED will extinguish and the plant will returnto normal operation.

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3.5 ALARM EXTENSION VERIFICATION

Each of the sixteen extended alarms can be tested (one at a time) for proper function. Refer to the plant digital controller manual (4380400PD) for details regarding alarm testing.

3.6 LOAD SHARING

Refer to the plant digital controller manual (4380400PD) for details. Each rectifier should be sharing the load at ±5 Amp.

3.7 +24V DISTRIBUTION

If the optional converter plant is equipped, load the +24V distribution to half of the rated current. Measure the +24V distribution bus to ground and verify that the plant digital controller converter voltage is ±1V of that reading. Verify that the converters share the current at ±1 Amp. Refer to the plant digital controller manual (4380400PD) for details on navigating to the converter section to read the voltage and current of the converters.

CAUTION: Batteries must be connected to plant, or an external source applied to bus for HVSD testing. This is to keep bus voltage present for powering the controller, as the rectifiers will shut down during test. Testing without a bus voltage source could result in a lockout condition of the rectifiers. This is of particular concern with Rectifier HVSD testing. If an external supply is used to maintain bus power, it must have a current capability of 5 amps for the controller, plus current requirements of any load on plant that must be maintained as well as additional load that is added to obtain the 15% load on the rectifier modules.

3.8 Plant HVSD Test

A. Notify alarm reporting center of site of potential alarm activity. B. Verify system is powered on, and operating normally with proper float voltage, and batteries connected,

or other bus supply source. C. Verify each of the rectifier modules are loaded to a minimum of 15%. D. Set Plant HVSD setpoint, located in PLANT/SETP menu, to 0.5V below the Float Voltage setpoint of

the plant (53.5V for a 54.0V float setting). 1. Observe all rectifiers shutdown. The Green DC OK indicator on the face of each rectifier will

flash intermittently indicating shutdown of rectifier output. E. If additional load was applied in Step-C above, it may be removed at this time. F. Restore Plant HVSD setpoint, located in PLANT/SETP menu, to 59.0VDC, or customer defined setpoint

value. 1. The rectifiers will remain in the shutdown condition.

G. Turn OFF AC power input to all of the rectifiers, and leave off until all front panel indicators on the rectifiers extinguish.

H. Turn AC power back ON to all rectifier modules. 1. Verify all rectifier modules return to normal operation. The DC OK indicator on each module

face should be Steady ON. I. Plant HVSD Test complete

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3.9 Rectifier HVSD Test

A. Notify alarm reporting center of site of potential alarm activity. B. Verify system is powered on, and operating normally with proper float voltage, and batteries connected,

or other bus supply source. C. Load is not required for this test. D. Set Rect HVSD setpoint, located in PLANT/SETP menu, to 55.0V. E. Set plant Float Voltage setpoint, located in PLANT/SETP menu, to 55.2V.

1. Observe all rectifiers shutdown. All rectifiers will try to restart one time after a few seconds, andwill then shutdown, and lockout. The Red RFA indicator on the face of each rectifier will turn ON steady indicating internal shutdown of rectifier output.

F. Restore Rectifier HVSD setpoint, located in PLANT/SETP menu, to 58.0VDC, or customer defined setpoint value.

G. Restore plant Float Voltage setpoint, located in PLANT/SETP menu, to 54.0V, or customer defined setpoint value. 1. The rectifiers will remain in the shutdown condition.

H. Turn OFF AC power input to all of the rectifiers, and leave off for a period of (2) minutes. I. Turn AC power back ON to all rectifier modules.

1. Verify all rectifier modules return to normal operation. The DC OK indicator on each moduleface should be Steady ON.

J. Rectifier HVSD Test is complete.

3.10 MISCELLANEOUS ADJUSTMENTS Refer to page 3 for factory settings. If the site engineer wants any of the setting verified (or changed) refer to the plant digital controller manual (4380400PD) for details.

3.11 COMPLETION OF TESTS

If the initial turn-on and operational checks are complete and the system is operating properly, the tests are complete. Perform normal clean up, collect all tools, and close all access doors, etc. If there was a problem with the test and acceptance procedures, it is advisable to call GE Field Service (refer to the FOREWARD section of this manual for telephone number).

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SSEECCTTIIOONN 44:: TTHHEEOORRYY OOFF OOPPEERRAATTIIOONN

4.1 GENERAL

The system is configured with up to sixteen rectifier modules to produce 800 Amps (4 Rect. Shelves) of -48 VDC. Two converter shelves are available to produce 160 Amps of +24 VDC (when fully equipped with eight converters).

The system accepts 176V~275V at 45Hz-65Hz, as an input source. The rectifiers will operate at lower voltages with reduced output. The voltage is applied to the individual rectifier modules through the AC input terminal block on the top of the bay. The plant controller is interfaced with the output and alarms of the rectifier modules via factory-installed wiring.

Each modular rectifier and/or converter may be hot inserted, meaning the rectifiers may be removed or installed without shutting down the entire plant.

This plant is designed to supply –48VDC nominal power to a Telecom grade load while simultaneously floating storage batteries. In the event of a commercial AC failure, the system seamlessly powers the load from the batteries. When the commercial AC returns, the plant automatically returns to load to the rectifiers and recharges the batteries in preparation for the next commercial AC power failure.

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SSEECCTTIIOONN 55:: SSPPEECCIIFFIICCAATTIIOONNSS 5.1 SYSTEM RATINGS

A. INPUT RATINGS (per rectifier module)

Voltage Current Frequency176-275 VAC single

phase, 220VAC Nominal 20 Amps at 100%

load 45-65HZ

90-175 VAC single phase, 120VAC Nominal

20 Amps at 100% load 45-65HZ

B. OUTPUT RATINGS-RECTIFIER

Each rectifier supplies 50 Amps at –48VDC with an input voltage of 176 – 275 VAC.

Each rectifier supplies 25 Amps at –48VDC with an input voltage of 90 – 175 VAC.

Each converter (optional) supplies 20 Amps at +24VDC.

C. OUTPUT RATINGS-DISTRIBUTION

The –48VDC distribution is rated at 800 amps total current (500 Amps maximum per side). The +24VDC distribution is rated at 160 Amps total.

D. MISCELLANEOUS RATINGS

Regulation: (At 0 - 100% load)

< 0.1% line < 0.1% load

Noise: <32 dBrnc (Voice Band). <100 mV rms (Wideband, 10Hz-20Mhz) <250 mV Peak to Peak (Wideband, 0 - 100 MHZ) <50 mV Peak to Peak Ripple

Filtering: 32 dBrn-c when connected to batteries with an AH rating of four (4) times the load current

Temperature: Operating: 0 to +50°C (+32°F to +122°F) Storage: -40 to +85°C (-40°F to +185°F)

Altitude: Sea Level to 4800 feet: 0°C to +50°C (+32°F to +122°F) 4800 feet to 7000 feet: 0°C to +45°C (+32°F to +113°F) 7000 feet to 10000 feet: 0°C to +40°C (+32°F to +104°F)

Humidity: <95% Non-condensing

Shock: This equipment, in its shipping container, withstands shock developed during shipping without physical damage or degradation of the electrical performance.

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Vibration: This equipment, in its shipping container, withstands vibration encountered in shipping without physical damage or degradation of the electrical performance.

Ventilation: System Ventilation openings should not be blocked and the ambient temperature of the air entering the system should not exceed 50°C (122°F)

5.2 FACTORY SETTINGS

For factory settings, refer to page 3.

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MODULAR -48 VDC, 800 AMP +24VDC, 160 AMP Front Access ... Critical Power Product Manual 129FD...

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