Lineage® 2000
Secondary DC Distribution Bay
(Mini-Distribution Bay)
J85568E-1
Product Manual
Select Code 157-005-102
Comcode 107098840
Issue 6
January 2008
Product Manual
J85568E-1
Select Code 157-005-102
Comcode 107098840
Issue 6
January 2008
Secondary DC Distribution Bay
Lineage® 2000
(Mini-Distribution Bay)
Notice:
The information, specifications, and procedures in this manual are
subject to change without notice. Lineage Power assumes no
responsibility for any errors that may appear in this document.
© 2008 Lineage Power
All International Rights Reserved
Printed in U.S.A.
J85568E-1 Secondary DC Mini-Distribution Bay
Table of Contents
1 Introduction
General 1 - 1
Additional Information 1 - 1
Customer Service Contacts 1 - 2
Customer Service, Technical Support,
Product Repair and Return 1 - 2
Customer Training 1 - 2
Warranty Service 1 - 2
On-Line Power Systems Product Manuals 1 - 2
EasyView Software 1 - 2
2 Product Description
Overview 2 - 1
Features 2 - 1
Physical Specifications 2 - 2
3 Ordering Information
List Structure 3 - 1
Terminal Lugs 3 - 2
Bay Extenders 3 - 4
Sample Order 3 - 4
Documentation 3 - 4
4 Safety
Admonishments 4 - 1
Safety Statements 4 - 1
Precautions 4 - 2
Warning Statements and Safety Symbols 4 - 3
Electrostatic Discharge (ESD) 4 - 5
Issue 6 January 2008 Table of Contents - 1
J85568E-1 Secondary DC Mini-Distribution Bay
5 Installation
Safety 5 - 1
Tools and Materials Required 5 - 1
Unpacking, Handling, and Frame Installation 5 - 2
Connecting Load and Distribution Cabling 5 - 5
Frame Ground 5 - 6
Fuse or Circuit Breaker Panel 5 - 6
Meter and Alarm Termination Panel 5 - 9
6 Product Warranty
2 - Table of Contents Issue 6 January 2008
J85568E-1 Secondary DC Mini-Distribution Bay
List of Figures
Figure 2-1: J85568E-1 Mini-Distribution Bay (four
fuse panels shown) 2 - 3
Figure 2-2: J85568E-1 Mini-Distribution Bay Factory
Installed in ED8C800-50 G5 Framework (four fuse
panels shown) 2 - 4
Figure 5-1: Typical Floor Mounting Detail 5 - 3
Figure 5-2: Floor Mounting Template 5 - 3
Figure 5-3: Rear View of Mini-Distribution Bay and
A/B Load Connections (four fuse panels shown) 5 - 4
Figure 5-4A: List C Fuse Panel for J85568E-1
Mini-Distribution Bay 5 - 7
Figure 5-4B: List D Circuit Breaker Panel for J85568E-1
Mini-Distribution Bay 5 - 8
Figure 5-5: Fuse Sizes and Ordering Comcodes for
Mini-Distribution Bay 5 - 8
Figure 5-6: Alarm Termination Board 5 - 11
Figure 5-7: Installation Information Label (Rear of
Mini-Distribution Bay) 5 - 12
Issue 6 January 2008 List of Figures - 1
J85568E-1 Secondary DC Mini-Distribution Bay
List of Tables
Table 3-A: J85568E-1 Mini-Distribution Bay Ordering
Information 3 - 1
Table 3-B: Recommended Double Hole Terminal Lugs
for Terminating Load Cables (750KCMIL Maximum) 3 - 3
Table 3-C: Recommended Double Hole Terminal Lugs
for Terminating to Discharge Return Bus or Frame
Ground 3 - 3
Table 3-D: Recommended Single Hole 90° Terminal
Lugs for Terminating to Fuse Block 3 - 3
Table 3-E: Recommended Single Hole Terminal Lugs
for Terminating to Circuit Breakers 3 - 4
Table 3-F: Bay Extenders 3 - 4
Table 5-A: DIP Switch Settings and Alarm Connections
for Generating Frame Alarms 5 - 11
Issue 6 January 2008 List of Tables - 1
J85568E-1 Secondary DC Mini-Distribution Bay
1 Introduction
General This product manual (Select Code 157-005-102) describes the
J85568E-1 Secondary DC Distribution Mini-Bay. This unit is
also known as a Mini-Battery Distribution Fuse Bay
(Mini-BDFB) or Mini-Battery Distribution Circuit Breaker Bay
(Mini-BDCBB). Complementing the 7-foot, 9-foot and
11.5-foot J85568C-1 series of DC Power Distribution Bays, the
Mini-BDFB/BDCBB is a fully assembled rack-mountable unit
that distributes -48 volt dc power in a two-load (A/B)
arrangement.
Additional Information
The Mini-Distribution Bay is a secondary fuse distribution
center for dc power delivered from a central office battery plant
to the using equipment. When floor space is minimized, the
Mini-Bay provides a cost-effective solution for distributing
power without sacrificing reliability or features. It is ideal for a
small central office or customer premise power system
application. It is also well suited for power transition or
modernization projects or for satisfying co-location
requirements for RBOCs to provide dc power access to
Inter-Exchange Carriers (IXCs).
Additional copies of this manual or any other Lineage Power
document may be obtained by calling Lineage Power Customer
Service. Specify the code number for manuals or the drawing
numbers for drawings.
Issue 6 January 2008 Introduction 1 - 1
J85568E-1 Secondary DC Mini-Distribution Bay
Customer Service Contacts
Customer Service, Technical Support, Product Repair and Return, and Warranty Service
For customers in the United States, Canada, Puerto Rico, and the
US Virgin Islands, call 1-800-THE-1PWR (1-800-843-1797).
This number is staffed from 7:00 am to 5:00 pm Central Time
(zone 6), Monday through Friday, on normal business days. At
other times this number is still available, but for emergencies
only. Services provided through this contact include initiating
the spare parts procurement process, ordering documents,
product warranty administration, and providing other product
and service information.
For other customers worldwide the 800 number may be accessed
after first dialing the AT&T Direct country code for the country
where the call is originating, or you may contact your local field
support center or your sales representative to discuss your
specific needs.
Customer Training Lineage Power offers customer training on many Power Systems
products. For information call 1-972-284-2163. This number is
answered from 8:00 a.m. until 4:30 p.m., Central Time Zone
(Zone 6), Monday through Friday.
Downloads and Software
To download the latest product information, product software
and software upgrades, visit our web site at
http://www.lineagepower.com/
1 - 2 Introduction Issue 6 January 2008
J85568E-1 Secondary DC Mini-Distribution Bay
2 Product Description
Overview The J85568E-1 Mini-Distribution Bay (Power Distribution Bay)
distributes -48Vdc power in a two-load arrangement, with a
300-ampere capacity per load. There are four fuse or circuit
breaker panel positions. Load Bus A connects the top two fuse
or circuit breaker panels. Load Bus B connects the bottom two
fuse or circuit breaker panels. All panel positions must be
equipped with either a fuse or circuit breaker panel or a blank
panel. Each fuse panel is equipped with twelve fuse blocks for
0-60A fuses. Each circuit breaker panel has 12 empty positions
for up to 12 circuit breakers.
This Mini-Distribution Bay is designed to mount in a 23-inch
relay rack. See Figure 2-1. It can also be factory installed in an
ED8C800-50
7′ framework. See Figure 2-2. If the Mini-Distribution Bay is
installed in a 7′ framework that will be located in a 9′ or 11′-6″
environment, bay extenders are available. Ordering information
for the extenders is given in Section 3. Note: Do not mount
Mini-Distribution Bay onto bay extenders. Other equipment
can be added to this framework, which saves valuable floor
space.
The Mini-Distribution Bay offers the same fusing and alarm
monitoring features as the J85568C-series distribution bay, but
in a more compact design. It provides another Lineage Power
alternative to secondary distribution requirements.
Features The following is a list of features provided with this product:
• Fully assembled unit for simplified installation
• Lexan rear protective cover
Issue 6 January 2008 Product Description 2 - 1
J85568E-1 Secondary DC Mini-Distribution Bay
• Internal 2-hole return bus
• Digital current meter
• Visual alarm indication per panel
– Red LED - Fuse Alarm
– Green LED - Power On
– GMT alarm fuse per fuse block
• Remote alarm indication
– (3) Form-C fuse or circuit breaker alarm contacts per
panel
– (1) Form-C power loss alarm contact per panel
– Switch selectable frame alarms
Physical Specifications
Height 33 inches (838mm)
84 inches (2134mm) in framework
Width 23.3 inches (592mm)
Depth 12 inches (305mm)
Weight 112 pounds (4 fuse or circuit breaker panels)
220 pounds in framework
2 - 2 Product Description Issue 6 January 2008
Panel
Position
J85568E-1 Secondary DC Mini-Distribution Bay
23.33
22.33
1
2
33.00
3
12.00
Central Office
White Color
4
Figure 2-1: J85568E-1 Mini-Distribution Bay (four fuse panels shown)
Issue 6 January 2008 Product Description 2 - 3
J85568E-1 Secondary DC Mini-Distribution Bay
ED8C800-50 G5
Framework, List A
(Soft Blue Color)
84.00
25.94
Figure 2-2: J85568E-1 Mini-Distribution Bay Factory Installed in ED8C800-50 G5 Framework (four
fuse panels shown)
2 - 4 Product Description Issue 6 January 2008
J85568E-1 Secondary DC Mini-Distribution Bay
3 Ordering Information
List Structure Table 3-A describes the list structure of the J85568E-1
Mini-Distribution Bay. List 2 provides the assembly with four
empty panel positions. Panel positions 1 and 3 must be equipped
with a fuse or circuit breaker panel to support bus bars. Panel
positions 2 and 4 must be equipped with either a List C fuse
panel, a List D circuit breaker panel or a List B blank panel.
If a relay rack is required, order List A and the factory will install
the Mini-Distribution Bay in a ED8C800-50 framework, as
shown in Figure 2-2.
Table 3-A: J85568E-1 Mini-Distribution Bay Ordering
Information
Description
Assembly, wiring, and equipment for one 33-inch
-48V battery distribution unit for mounting in a
23-inch relay rack. Provides one meter and alarm
termination panel and space for four fuse or circuit
breaker panels in a two-load (A/B) arrangement.
Optional equipment in addition to List 2 for a
23-inch relay rack mounted in a ED8C800-50 G5
framework (soft blue finish).
Optional equipment in addition to List 2 for a blank
panel for panel positions two or four.
Optional equipment in addition to List 2 for a fuse
panel equipped with 12 fuse blocks for 3-60A fuses.
Optional equipment in addition to List 2 for a circuit
breaker panel to hold up to 12 circuit breakers.
List
2
A
B
C
D
Issue 6 January 2008 Ordering Information 3 - 1
J85568E-1 Secondary DC Mini-Distribution Bay
1. The engineer must furnish all terminal lugs for load and
return leads. Hardware for terminating load leads, load
return leads, input battery and return cabling, and frame
ground is provided with List 2.
2. This Mini-Distribution Bay is configured with two load
buses. Load Bus A connects the top two fuse or circuit
breaker panels. Load Bus B connects the bottom two fuse
or circuit breaker panels. Battery cabling is connected to
each load bus at the top of the unit. A 300A shunt and bus
bar assembly connects battery cabling to each fuse or
circuit breaker panel as required.
3. A digital meter and switch assembly is provided with List
2 in accordance with ED83127-30 Group 14 to monitor the
300A shunts associated with each load.
4. This Mini-Distribution Bay is recommended for top load
feed applications. When bottom load feed is required, the
J85568C-1 bay is recommended because it provides for
cable routing to the floor.
Terminal Lugs Table 3-B lists recommended terminal lugs for different cable
sizes. Hardware for terminating the terminal lugs is provided
with the Mini-Distribution Bay. Recommended torque for these
connections is 260 in. lbs.
Refer to Table 3-C for recommended terminal lugs for the frame
ground connection. Hardware for connecting the frame ground
is furnished with the Mini-Distribution Bay.
Table 3-D provides recommended terminal lugs for terminating
to the fuse block for List C.
Table 3-D provides recommended terminal lugs for terminating
to the circuit breakers for List D.
The information in these tables is also given on a label on the
back of the Mini-Distribution Bay. The label is replicated in
Figure 5-7.
3 - 2 Ordering Information Issue 6 January 2008
J85568E-1 Secondary DC Mini-Distribution Bay
Table 3-B: Recommended Double Hole Terminal Lugs
for Terminating Load Cables (750KCMIL Maximum)
KS-5482
Wire
2/0
-
4/0
-
350
-
500
-
750
-
for Terminating to Discharge Return Bus or Frame Ground
KS-5482
Wire
8
6
4
2
-
KS-20921
Wire
1/0
2/0
-
4/0
-
350
-
500
-
750
WP-91412
List
57
77
59
27
61
86
63
165
135
170
Comcode
405348235
406021725
405348251
405347923
405348277
40602 1915
405348293
406434241
406335141
406434290
Bolt
Size
0.375
0.375
0.375
0.375
0.375
0.375
0.375
0.375
0.375
0.375
Centers Die
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
Table 3-C: Recommended Double Hole Terminal Lugs
KS-20921
Wire
8
6
4
-
2
WP-91412
List
75
3
5
54
8
Comcode
406021626
405347519
405347576
405348202
405347683
Bolt
Size
0.25
0.25
0.25
0.25
0.25
Centers Die
0.62
0.62
0.62
0.62
0.62
Black
Orange
Purple
Yellow
Red
80
Brown
Pink
Black
Yellow
Red
Blue
Grey
Brown
Green
Table 3-D: Recommended Single Hole 90° Terminal Lugs
for Terminating to Fuse Block
KS-5482
Wire
10
8
6
4
2
-
Issue 6 January 2008 Ordering Information 3 - 3
KS-20921
Wire
10
8
6
4
-
2
Terminal
Lug
WP-91412 L97
WP-91412 L104
WP-91412 L112
54106UB (T&B)
54107UB (T&B)
54108UB (T&B)
Comcode Die
406338186
406338350
406338459
402424030
996627196
99662 7253
WT-1300
Red
Blue
Grey
Brown
Green
Mounting
Material
Furnished
With
Panel
J85568E-1 Secondary DC Mini-Distribution Bay
Table 3-E: Recommended Single Hole Terminal Lugs
for Terminating to Circuit Breakers
KS-5482
Wire
10
8
6
4
2
-
KS-20921
Wire
10
8
6
4
-
2
Terminal
Lug
WP-91412 L94
WP-91412 L74
WP-91412 L2
WP-91412 L4
WP-91412 L53
WP-91412 L7
Comcode Die
406338152
405356189
405347436
405347543
405348186
405347659
WT-1300
Red
Blue
Grey
Brown
Green
Bay Extenders Table 3-F gives the ordering information for the 2
extenders. These are used when
installed in a 7′ framework that is located in a 9′ or 11′-6
environment
onto bay extenders.)
2′ extender for 9
4′-6″ extender for 11′-6
. (Note: Do not mount Mini-Distribution Bay
Table 3-F: Bay Extenders
′ environment
″
the Mini-Distribution Bay is
ED8C804-50 G3
environment
ED8C804-50 G5
Mounting
Material
Furnished
With
Panel
′and 4′
-6
″ bay
″
Sample Order An order for a Mini-Distribution Bay containing two fuse
panels, two blank panels and mounted in a framework would
look like this:
Item Quantity Description
J85568E-1 List 2 -48V Mini-Distribution
1
1
2
2
1
Bay
equipped with:
List C Fuse Panels
Pnl Pos 1, 3
List B Blank Panels
Pnl Pos 2, 4
List A Framework
Documentation The following documentation is associated with the
Mini-Distribution Bay:
3 - 4 Ordering Information Issue 6 January 2008
J85568E-1 Secondary DC Mini-Distribution Bay
J85568E-1 Assembly Drawing
SD-83178-01 Schematic
T-83178-30 Wiring Diagram
ED-83127-30 Fuse or Circuit Breaker Panel
157-005-102 J85568E-1 Mini-Distribution Bay Product
Manual
Issue 6 January 2008 Ordering Information 3 - 5
J85568E-1 Secondary DC Mini-Distribution Bay
4 Safety
Please read this section carefully before installing, maintaining,
or repairing the J85568E-1 Mini-Distribution Fuse Bay.
Admonishments Always take precautions to protect personal safety as well as the
equipment when working on power systems. Throughout this
manual, admonishments relating to personal safety are labeled
DANGER or Warning. Those relating to equipment damage
are labeled Caution. Please read all admonishments carefully
and follow safety instructions and warnings.
Safety Statements
– For use 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 U.S. National Electric Code (NEC),
ANSI/NFPA No. 70, and pursuant to applicable
local codes.
– This equipment must not be installed over
combustible surfaces.
– This equipment is to be used in controlled
environments (an area where the humidity is
maintained at levels that can not cause condensation
on the equipment, the contaminating dust is
controlled, and the steady-state ambient temperature
is within the range specified).
– This equipment has been evaluated for use in a
continuous ambient temperature of up to 122°
Fahrenheit (50° Celsius).
– For installations in the United States, UL-listed
compression connectors should be used to terminate
UL-listed field-wired conductors where required.
Issue 6 January 2008 Safety 4 - 1
J85568E-1 Secondary DC Mini-Distribution Bay
For all installations, the appropriate connector
should be applied only to the correct size conductor
as specified by the connector manufacturer, using
only the connector manufacturer's recommended
tooling or tooling approved for that connector.
– If the proper connector for the country of installation
is not provided, obtain appropriate connectors and
follow manufacturer’s and all local requirements for
proper connections. All national and local rules and
regulations must be followed when making field
connections.
– Torque electrical connections to the values specified
on labels or in the product documentation.
Precautions When working on or using this type of equipment, follow these
precautions:
– This unit must be installed, serviced, and operated
only by skilled and qualified personnel who have the
necessary knowledge and practical experience with
electrical equipment and who understand the
hazards that can arise when working on this type of
equipment.
– Because of the hazardous energy supplied to and
within the equipment, make sure the equipment, all
associated framework, and the cable rack are
properly grounded according to local job
instructions before connecting any power.
– Hazardous dc energy and voltage (from batteries and
rectifier output) are present in the unit. Use a
voltmeter to insure no voltage, or the expected
voltage, is present before contacting any uninsulated
conductor surface. Follow the procedures in the
order given to minimize dangerous encounters with
these voltages. Exercise extreme caution when
working near the battery bus bars.
– Capacitors will stay charged for at least one minute
after power is disconnected.
– Use only properly insulated tools.
– Remove all metallic objects (key chains, glasses,
rings, watches, or any other jewelry).
– Wear safety glasses.
– Test circuits before touching.
– Lock out and tag any circuit breakers/fuses when
possible to prevent accidental turn on.
4 - 2 Safety Issue 6 January 2008
J85568E-1 Secondary DC Mini-Distribution Bay
– Be aware of potential hazards in the area you are
working before entering the equipment.
– Identify exposed hazardous electrical potentials on
connectors, wiring, etc. (note the condition of these
circuits, especially any wiring).
– Use care when removing or replacing any covers;
avoid contacting any circuits.
– Use gloves when handling thermally hot
components inside the rectifier. Transformers are
very hot after sustained operation.
Warning Statements and Safety Symbols
The symbols may sometimes be accompanied by some type of
statement; e.g., “Hazardous voltage/energy inside. Risk of
injury. This unit must be accessed only by qualified personnel.”
This symbol identifies the need to refer to
the equipment instructions for important
information.
These symbols (or equivalent) are used to
identify the presence of hazardous ac
mains voltage.
This symbol is used to identify the
presence of hazardous ac or dc voltages. It
may also be used to warn of hazardous
energy levels.
This symbol is used to identify the need
for safety glasses and may sometimes be
accompanied by some type of statement,
for example: “Fuses can cause arcing and
sparks. Risk of eye injury. Always wear
safety glasses.”
Issue 6 January 2008 Safety 4 - 3
J85568E-1 Secondary DC Mini-Distribution Bay
One of these two symbols (or equivalent)
may be used to identify the presence of
rectifier and battery voltages. The symbol
may sometimes be accompanied by some
type of statement, for example: “Battery
voltage present. Risk of injury due to high
current. Avoid contacting conductors with
uninsulated metal objects. Follow safety
precautions.”
This symbol is used to identify the
presence of a hot surface. It may also be
accompanied by a statement explaining
the hazard. A symbol like this with a
lightning bolt through the hand also
means that the part is or could be at
hazardous voltage levels.
This symbol is used to identify the
presence of a hot surface. The marked
item should not be touched without taking
care.
This symbol is used to identify the
protective safety earth ground for the
equipment.
This symbol is used to identify other
bonding points within the equipment.
4 - 4 Safety Issue 6 January 2008
J85568E-1 Secondary DC Mini-Distribution Bay
Electrostatic Discharge (ESD)
– Assume all circuit packs containing electronic
(solid-state) components can be damaged by ESD.
– When handling circuit packs (storing, inserting,
removing, etc.) or when working on the backplane,
always use the appropriate grounding procedure: either
a wrist strap connected to ground or, when standing, a
heel strap with a grounded dissipative floor mat.
– A grounded person must never hand an unprotected
circuit pack to an ungrounded person. A static discharge
from the ungrounded person through the circuit pack to
the grounded person could cause an electrostatic
discharge failure. All persons and equipment at a work
location must be at the same common ground potential
to be static safe.
– Handle all circuit packs by the faceplate or latch and by
the top and bottom outermost edges. Never touch the
components, conductors, or connector pins.
– Do not rub or wipe circuit packs to clean them unless
you and the circuit pack are at the same ground
potential.
– Observe warning labels on bags and cartons. Whenever
possible, do not remove circuit packs from antistatic
bags or cartons until ready to insert into the equipment.
Otherwise, open all circuit packs at a static-safe work
position with wrist straps and dissipative table mats.
– Upon removal from the equipment, immediately put
circuit packs into antistatic packages. Always store and
transport circuit packs in antistatic packaging. Shielding
is not required unless specified.
– Keep all static-generating materials away from all
circuit packs. These materials include common plastics
such as food wrappers, clear plastic bags, styrofoam
containers, packing material, drinking cups, notebooks,
and nonconductive plastic solder suckers. The insulation
on small hand tools does not represent a static hazard.
– Keep adhesive tape (Scotch, masking, etc.) away from
static-sensitive devices.
– When soldering static-sensitive semiconductor devices,
the soldering iron must be grounded to the work table,
which must also be earth grounded.
– Whenever possible, maintain relative humidity above
the 20-percent level.
– Minimize electrostatic discharge when handling circuit
modules.
Issue 6 January 2008 Safety 4 - 5
J85568E-1 Secondary DC Mini-Distribution Bay
5 Installation
Safety Read Section 4, Safety, carefully before installing the J85568E-1
Mini-Distribution Bay.
Tools and Materials Required
The following tools are required to install the Mini-Distribution
Bay:
• Equipment to handle shipping container, remove
Mini-Distribution Bay unit or framework, and erect unit in
final position (minimum lifting capacity of 220 pounds)
• Common electrician’s hand tools, including jeweler’s
screwdriver, electrical tape, wire cutters, and strippers for
8 AWG to 750 MCM
• Common mechanic’s hand tools, including flat blade
screwdriver, socket and torque wrenches for 1/4-inch and
3/8-inch bolts, and a crowbar for uncrating unit
• Proper crimping tools and dies for connectors. The
connectors specified are WP-91412, which may be installed
with compression tools made by Thomas & Betts using
color coded dies
• 3/4-inch drill to bore holes for floor anchors (List A only)
• Anchor bolts (List A only)
• 22-26 gauge stranded or solid wire for connecting alarms
• Terminal lugs for terminating distribution and load cables
• WP-92461 fuses and 1/2-ampere GMT alarm fuses
(comcode 401231501) or circuit breakers
Issue 6 January 2008 Installation 5 - 1
J85568E-1 Secondary DC Mini-Distribution Bay
Unpacking, Handling, and Frame Installation
Before opening the packaging, carefully inspect the outside in
the presence of shipping personnel for signs of damage. If
damaged, follow the shipping carrier's procedure for filing a
damage claim.
Carefully open the packaging to verify that the contents are
complete and undamaged. If the equipment must be returned, it
should be repacked in the original shipping crate.
The following items are shipped loose with the
Mini-Distribution Bay:
• (10) 12-24 x 5/8-inch self tapping screws (not provided with
List A)
• Product manual and drawing service kit containing a copy
of the J85568E-1, T83178-30, and SD83178-01 drawings
• (100) sets of 1/4-20 nuts, lockwashers, and washers for
terminating distribution cabling
• (2) sets of 1/4-20 screws, lockwashers, and washers for
terminating frame ground
• (2) 847257862 bus bars for connecting bottom load feeds
• Cover plates for the framework base (List A only)
If the Mini-Distribution Bay is mounted in the List A
framework, the framework should be secured to the floor. Figure
5-1 shows typical floor mounting details for concrete floors.
Other types of floor construction may require other mounting
methods. Holes can be located using Figure 5-2.
If the Mini-Distribution Bay is to be mounted in a 23-inch relay
rack that is already installed in the field, use the (10) 12-24 x
5/8-inch self-tapping screws that were shipped with the unit for
this purpose.
When the unit is installed, connect the load and distribution
cabling. The Mini-Distribution Bay is for top load feed
applications. When bottom load feed is required, the J85568C-1
BDFB/BDCBB is recommended because it provides for routing
cable to the floor.
5 - 2 Installation Issue 6 January 2008
Hold Down Plate
Framework Base
J85568E-1 Secondary DC Mini-Distribution Bay
Floor Anchor Bolt
Hold Down Washer
Floor Covering
Note: Use 3/4 Inch Drill for Floor Anchor Bolts.
The Required Minimum Drill Depth is 4 Inches.
Figure 5-1: Typical Floor Mounting Detail
1
22
22
1
1.24
18.50
25.94
If interference with floor reinforcing bars occurs during installation of anchoring
hardware at mounting position "1" (primary mounting positions), use position "2"
alternate mounting positions.
1
1
3.72
7.25
1.24
1.20
9.78
Figure 5-2: Floor Mounting Template
Issue 6 January 2008 Installation 5 - 3
Product
n
Manual
Holder
J85568E-1 Secondary DC Mini-Distribution Bay
Frame Ground Connectio
Alarm Termination Board
Bus A
Bus B
Distribution Return Bus
Figure 5-3: Rear View of Mini-Distribution Bay and A/B Load Connections (four fuse panels shown)
5 - 4 Installation Issue 6 January 2008
J85568E-1 Secondary DC Mini-Distribution Bay
Connecting Load and Distribution Cabling
List 2 is configured with two load buses. A 300-ampere shunt
and bus bar assembly connects Load Bus A to the top two fuse
or circuit breaker panels and Load Bus B to the bottom two fuse
panels. Panel positions 1 and 3 must be equipped with List C
fuse panels or List D circuit breaker panels. Panel positions 2
and 4 may be equipped with either a List B blank panel, a List C
fuse panel, or a List D circuit breaker panel.
Figure 5-3 shows a rear view of the Mini-Distribution Bay and
the A/B load connections.
Cabling from the battery plant is terminated to each load on a
single set of 3/8-inch studs on 1.00-inch centers that are located
on the top right of the unit. If more than one cable is required due
to voltage drop considerations, terminal lugs may be mounted
back-to-back.
(A minimum of two 350 MCM battery input/return cables is
recommended per 300 ampere load.)
The Mini-Distribution Bay is equipped with a distribution return
bus located along the left and bottom sides of the unit. The bus
bar has a 600-ampere current carrying capacity and is equipped
with 1/4-inch studs on 0.625-inch centers for terminating the
(48) distribution return leads. There is also a set of 3/8-inch studs
on 1.00-inch centers located at the top of this bus bar for
terminating load return cabling from the battery plant and the
central office ground connection (if required). If more than two
cables are required, terminal lugs may be mounted back-to-back.
Hardware for connecting the terminal lugs is furnished with the
Mini-Distribution Bay. Refer to Table 3-B for the list of terminal
lug options for load return cabling. Table 3-C lists the terminal
lug options available for the distribution return cabling. If
voltage drop considerations require distribution cable sizes
larger than 2 gauge, the installer must gutter tap down to 2 gauge
before connection in the unit. Recommended torque values for
terminating distribution cabling is 75 inch/lbs.
Note
All bus bars used in this product are copper with a solder plate
finish. Bus bars do not require buffing or the application of
no-ox before connection of terminal lugs or other bus bars.
Issue 6 January 2008 Installation 5 - 5
J85568E-1 Secondary DC Mini-Distribution Bay
Frame Ground The frame ground connection is located on the top rear crossbar.
Connection is made using a 1/4-inch double hole terminal lug on
0.625-inch centers. Refer again to Table 3-C for recommended
terminal lugs for the frame ground connection. Hardware for
connecting frame ground is furnished with the Mini-Distribution
Bay.
Fuse or Circuit Breaker Panel
The List C fuse panel is shown in Figure 5-4A. Each panel is
equipped with twelve fuse blocks for 3-60A fuses and an alarm
circuit module. Fuse sizes and ordering comcodes are listed on a
label on the front of the Mini-Distribution Bay. See Figure 5-5.
Recommended alarm fuses are GMT .18A, comcode
402328926. The fuse block is UL listed and uses the WP-92461
List 100-110 series of fuses. These fuses offer a big advantage
over other fuse types in that they are UL recognized to UL
standard 198L “DC INDUSTRIAL FUSES” with a 170 Vdc,
100,000-ampere interrupt rating. These fuses also have color
bands to indicate the amperage rating of the fuse.
The List D circuit breaker panel is shown in Figure 5-4B. Each
circuit breaker panel has 12 circuit breaker positions and an
alarm circuit module. Circuit breaker sizes and ordering
comcodes are listed on a label on the front of the
Mini-Distribution Bay. See Figure 5-5. The circuit breakers are
sized from 3 to 100 amperes. They are UL listed. The circuit
breakers are rated at 80Vdc with a 10,000A interrupt capacity.
There are labels on the front of the fuse or circuit breaker panel
for stamping the type of equipment being powered and the fuse
or circuit breaker size required. Distribution cabling is
terminated to each fuse block or circuit breaker on a 1/4-inch
stud. Table 3-D lists the recommended terminal lugs for fuse
blocks. Table 3-E lists the recommended terminal lugs for circuit
breakers. Hardware for connecting these lugs is furnished with
the Mini-Distribution Bay. The recommended torque value is 75
inch/lbs.
The alarm circuit module, BEP1, consists of two circuits, one for
monitoring power loss to the fuse or circuit breaker panel and the
other monitoring for fuse or circuit breaker failures. Alarms are
indicated by LEDs on the panel and by Form-C contact closures.
A green LED illuminates to indicate power is present on the
panel. If power is lost, the green LED extinguishes and a set of
Form-C contacts operates. When a fuse or circuit breaker
operates, a red LED illuminates on the panel and three sets of
5 - 6 Installation Issue 6 January 2008
J85568E-1 Secondary DC Mini-Distribution Bay
Form-C contacts operate. These alarm contacts are isolated and
referenced as audible, visual, and remote fuse or circuit breaker
alarms. These arbitrary references are provided as a suggested
standard for connecting alarm monitoring equipment.
The signals from the four sets of Form-C contacts from each
alarm module are connected via ribbon cables to an alarm
termination board located at the top of the Mini-Distribution
Bay. This termination board provides a convenient point for
installation to connect alarm monitoring systems. Each set of
contacts is a Form-C or transfer type, i.e., a combination of
normally open (NO) and normally closed (NC) contacts with
one side of each in common (C). Either a closure on alarm or an
open on alarm might be required for the alarm monitoring
equipment.
EQUIPMENT TYPE
Red LED
Green LED
SPARE
FUSE
ALARM
POWER
ON
FUSE SIZE (AMPS)
FUSES
Front View
ED83127-30 G5
Rear View
Figure 5-4A: List C Fuse Panel for J85568E-1 Mini-Distribution Bay
Alarm
Circuit
Module
BEP1
Issue 6 January 2008 Installation 5 - 7
J85568E-1 Secondary DC Mini-Distribution Bay
EQUIPMENT TYPE
Red LED
FUSE/CB
Green LED
ALARM
POWER
ON
FUSE/CB (AMPS)
Front View
Alarm Circuit
Module BEP1
Rear View
Figure 5-4B: List D Circuit Breaker Panel for J85568E-1 Mini-Distribution Bay
Figure 5-5: Fuse Sizes and Ordering Comcodes for Mini-Distribution Bay
5 - 8 Installation Issue 6 January 2008
J85568E-1 Secondary DC Mini-Distribution Bay
Meter and Alarm Termination Panel
The top panel on the Mini-Distribution Bay is a meter and alarm
termination panel. It consists of a digital meter and A/B switch
wired to the current monitoring shunts of each load and an alarm
termination circuit board. The purpose of the alarm termination
board is to provide an easy access point for the installer to
connect alarm monitoring equipment to the Mini-Distribution
Bay. The alarm termination board is shown in Figure 5-6. It
contains four 12-position screw type terminal blocks for
monitoring the four sets of Form-C contacts of each fuse or
circuit breaker panel (three for fuse or circuit breaker failure and
one for power loss). Each fuse or circuit breaker panel may be
monitored individually by connecting alarms to each of the four
terminal blocks. The left terminal block is connected to fuse or
circuit breaker panel #1, the next to fuse or circuit breaker panel
#2, the third to fuse or circuit breaker panel #3, and the right
terminal block to fuse or circuit breaker panel #4. Alarm wiring
is connected to the terminal block by simply stripping the wire,
placing the wire in the terminal, and tightening the screw. The
recommended wire size is 22-26 gauge.
There are twelve DIP switches between each terminal block.
Each DIP switch is associated with a terminal block position and
is factory set to the open position. If a frame alarm is needed,
simply close the DIP switches associated with that alarm. See
Table 5-A. Alarm monitoring equipment requires either a
closure on alarm or an open on alarm. When a frame alarm is
needed as one of the alarms, simply close the DIP switch settings
according to Table 5-A. Alarm wiring is connected at P201
terminal block (C contact) and P204 terminal block (NO or NC
contact). For example, if a frame fuse or circuit breaker alarm
(visual) is required with closure on alarm, close positions 1 and
3 on switches SW2, SW4, and SW6. Then connect a pair of
alarm wires to P201
pin 7 (C) and to P204 pin 9 (NO). It may be desirable to monitor
for power loss to load A or B. Connect alarm wiring to pins 1 and
either 2 or 3 (as required) of terminal block P201 or P202 to
monitor load A. Connect a second pair of wires to either terminal
block P203 or P204 to monitor load B. For a frame power loss
alarm, set DIP switches and connect alarm wires as shown in
Table 5-A.
A label depicting the equipment layout, terminal lug options,
and alarm termination board designations is located on the clear
cover on the back of the unit to assist installation personnel. See
Figure 5-7.
Issue 6 January 2008 Installation 5 - 9
J85568E-1 Secondary DC Mini-Distribution Bay
If wiring for Open on Alarm (AUD, VIS, or REMOTE), strap
across the common and normally closed contacts in the empty
fuse panel positions of the 847206737 PWB assembly on the
rear of the alarm and meter panel. For example, if fuse panels are
located in positions 1 and 3 with blank panels in positions 2 and
4, then:
Fuse or circuit breaker Alarm (Audible): Strap from P202
position 4 to
P202 position 5
Strap from P204
position 4 to
P204 position 5
Fuse or circuit breaker Alarm (Visual): Strap from P202
position 7 to
P202 position 8
Strap from P204
position 7 to
P204 position 8
Fuse Alarm or circuit breaker (Remote): Strap from P202
position 10 to
P202 position 11
Strap from P204
position 10 to
P204 position 11
If wiring for Open on Alarm (POWER LOSS), strap across the
common and normally open contacts in the first empty fuse or
circuit breaker panel position only. From the example above:
Power Loss: Strap from P202
position 1 to
P202 position 3
5 - 10 Installation Issue 6 January 2008
J85568E-1 Secondary DC Mini-Distribution Bay
Table 5-A: DIP Switch Settings and Alarm Connections
for Generating Frame Alarms
Closure on Alarm (FAJ: C and NO Contacts; PWR Loss: C and NC Contacts)
Alarm Type DIP Switch Setting
Power Loss
Fuse or Circuit Breaker Alarm (Audible)
Fuse or Circuit Breaker Alarm (Visual)
Fuse or Circuit Breaker Alarm (Remote)
Close Positions 1 and 2 on SW1, SW3, and SW5
Close Positions 4 and 6 on SW1, SW3, and SW5
Close Positions 1 and 3 on SW2, SW4, and SW6
Close Positions 4 and 6 on SW2, SW4, and SW6
Open on Alarm (FAJ: C and NC Contacts; PWR Loss: C and NO Contacts)
Alarm Type DIP Switch Setting
Power Loss
Fuse or Circuit Breaker Alarm (Audible)
Fuse or Circuit Breaker Alarm (Visual)
Fuse or Circuit Breaker Alarm (Remote)
Close Position 3 on SW1, SW3, and SW5
Close Position 5 on SW1, SW3, and SW5
Close Position 2 on SW2, SW4, and SW6
Close Position 5 on SW2, SW4, and SW6
Alarm
Connection
P201 P204
pin 1
pin 4
pin 7
pin 10
pin 2
pin 6
pin 9
pin 12
Alarm
Connection
P201 P204
pin 1
pin 4
pin 7
pin 10
pin 3
pin 5
pin 8
pin 11
Figure 5-6: Alarm Termination Board
Issue 6 January 2008 Installation 5 - 11
J85568E-1 Secondary DC Mini-Distribution Bay
BUNDLE CABLES IN SETS OF FOUR.
IT MAY BE NECESSARYTO STACK
BUNDLES.
TIE TO CROSS BARS
WHEN APPROPRIATE
TIE ALL TO
BAR-TIES
TIE TO CROSS BARS
WHEN APPROPRIATE
TIE ALL TO
BAR-TIES
BAR-TIE
BAR-TIE
INPUT
FEEDER CABLES
BAR-TIE
RECOMMENDED CABLING PLAN
FOR FULLY LOADED PLANT
DISCHARGE RETURN BUS
TIE DOWN
12 1
PANEL #1
BUS A
24
PANEL #2
BUS A
TOP CROSS-BAR
MIDDLE CROSS-BAR
12 1
PANEL #3
BUS B
(-48V)
24
PANEL #4
BUS B
(-48V)
TOP CROSS-BAR
(-48V)
13
(-48V)
3" FROM WALL
13
5.5" FROM WALL
INPUT
FEEDER CABLE
BUS A
TIE DOWN
TIE DOWN
INPUT
FEEDER CABLE
BUS B
BAR-TIE
BAR-TIE
TIE TO
FRONT SIDE
OF BAR-TIE
TIE TO
BACK SIDE
OF BAR-TIE
Figure 5-7: Installation Information Label (Rear of Mini-Distribution Bay)
5 - 12 Installation Issue 6 January 2008
J85568E-1 Secondary DC Mini-Distribution Bay
6 Product Warranty
A. Seller warrants to Customer only, that:
1. As of the date title to Products passes, Seller will have the right to
sell, transfer, and assign such Products and the title conveyed by
Seller shall be good;
2. During the warranty period stated in Sub-Article B below, Seller’s
Manufactured Products (products manufactured by Seller), which
have been paid for by Customer, will conform to industry standards
and Seller’s specifications and shall be free from material defects;
3. With respect to Vendor items (items not manufactured by Seller),
Seller warrants that such Vendor items, which have been paid for by
Customer, will be free from material defects for a period of sixty
(60) days commencing from the date of shipment from Seller’s
facility.
B. The Warranty Period listed below is applicable to Seller’s Manufactured
Products furnished pursuant to this Agreement, commencing from date
of shipment from Seller’s facility, unless otherwise agreed to in writing:
Warranty Period
Product Type New Product Repaired Product*
Central Office
Power Equipment
*The Warranty Period for a repaired Product or part thereof is six (6) months
or, the remainder of the unexpired term of the new Product Warranty Period,
whichever is longer.
C. If, under normal and proper use during the applicable Warranty Period,
a defect or nonconformity is identified in a Product and Customer
notifies Seller in writing of such defect or nonconformity promptly after
Customer discovers such defect or nonconformity, and follows Seller's
instructions regarding return of defective or nonconforming Products,
Seller shall, at its option attempt first to repair or replace such Product
without charge at its facility or, if not feasible, provide a refund or credit
based on the original purchase price and installation charges if installed
by Seller. Where Seller has elected to repair a Seller’s Manufactured
Product (other than Cable and Wire Products) which has been installed
by Seller and Seller ascertains that the Product is not readily returnable
for repair, Seller will repair the Product at Customer’s site.
With respect to Cable and Wire Products manufactured by Seller which
24 Months 6 Months
Issue 6 January 2008 Product Warranty 6 - 1
J85568E-1 Secondary DC Mini-Distribution Bay
Seller elects to repair but which are not readily returnable for repair,
whether or not installed by Seller, Seller at its option, may repair the
cable and Wire Products at Customer’s site.
D. If Seller has elected to repair or replace a defective Product, Customer
shall have the option of removing and reinstalling or having Seller
remove and reinstall the defective or nonconforming Product. The cost
of the removal and the reinstallation shall be borne by Customer. With
respect to Cable and Wire Products, Customer has the further
responsibility, at its expense, to make the Cable and Wire Products
accessible for repair or replacement and to restore the site. Products
returned for repair or replacement will be accepted by Seller only in
accordance with its instructions and procedures for such returns. The
transportation expense associated with returning such Product to Seller
shall be borne by Customer. Seller shall pay the cost of transportation of
the repaired or replacing Product to the destination designated by
Customer.
E. Except for batteries, the defective or nonconforming Products or parts
which are replaced shall become Seller's property. Customer shall be
solely responsible for the disposition of any batteries.
F. If Seller determines that a Product for which warranty service is claimed
is not defective or nonconforming, Customer shall pay Seller all costs of
handling, inspecting, testing, and transportation and, if applicable,
traveling and related expenses.
G. Seller makes no warranty with respect to defective conditions or
nonconformities resulting from actions of anyone other than Seller or its
subcontractors, caused by any of the following: modifications, misuse,
neglect, accident, or abuse; improper wiring, repairing, splicing,
alteration, installation, storage, or maintenance; use in a manner not in
accordance with Seller’s or Vendor’s specifications or operating
instructions, or failure of Customer to apply previously applicable Seller
modifications and corrections. In addition, Seller makes no warranty
with respect to Products which have had their serial numbers or month
and year of manufacture removed, altered, or experimental products or
prototypes or with respect to expendable items, including, without
limitation, fuses, light bulbs, motor brushes, and the like. Seller’s
warranty does not extend to any system into which the Product is
incorporated. This warranty applies to Customer only and may not be
assigned or extended by Customer to any of its customers or other users
of the Product.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE IN
LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES,
INCLUDING BUT NOT LIMITED TO WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. CUSTOMER’S SOLE AND EXCLUSIVE REMEDY SHALL
BE SELLER’S OBLIGATION TO REPAIR, REPLACE, CREDIT, OR
REFUND AS SET FORTH ABOVE IN THIS WARRANTY.
6 - 2 Product Warranty Issue 6 January 2008
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