Yukon Technical Support Guide (with ES713AD Aux …Product Manual Comcode 108989562 Issue 2 February 2004 Yukon Technical Support Guide (with ES713AD Aux Box) Notice: The information,

Product ManualComcode 108989562Issue 2February 2004

Yukon™ Technical Support Guide(with ES713AD Aux Box)

Notice:The information, specifications, and procedures in this manual are subject to change without notice. Tyco Electronics assumes no responsibility for any errors that may appear in this document.

AC OK

DC OK

ALARM

ES760A

AC OK

DC OK

ALARM

ES760A

AC OK

DC OK

ALARM

ES760A

AC OK

DC OK

ALARM

ES760A

Rectifiers Aux Box

Shelf

STATUS

AmpsV Adjust

Lamp testAlm reset

Yukon™ Technical Support Guide

Issue 2 February 2004 Yukon System Block Diagram

Yukon System Block Diagram

Rectifier

To SupplementalShelf

Rectifier

LVD Board

VTProbe

BatteryString 2

C.O. Ground

Shelf

Aux Box

AC Input

FusePanelMain -48V Output

RS-232 Port(Non-Isolated)

VTProbe

BatteryString 1

SystemController

RS-485Bus

-48VPowerBus

1-Wire®Bus

© 2004 Tyco Electronics Power Systems, Inc. (Mesquite, Texas)All International Rights ReservedPrinted in U.S.A.


Table of Contents

Yukon System Block Diagram

1 RectifiersES760A and ES761A Rectifiers 1 - 2

ES760A 1 - 2ES761A 1 - 2

LEDs 1 - 3Normal LED States 1 - 3Routine Deviations 1 - 3Other LED States 1 - 3Using LEDs to Verify Proper AC Distribution 1 - 4Using LEDs to Confirm Rectifier Redundancy 1 - 4

2 System Controller and LVD BoardIntroduction to the Aux Box 2 - 2

The Control and Display Panel 2 - 2Warning 2 - 3Clearing a Power Minor Alarm: Example 2 - 3Field Replacable Units 2 - 3CONTROLLER STATUS ALARM LED 2 - 3Controller Replacement Indication 2 - 4LVD CARD STATUS LED 2 - 6Normal LED States 2 - 6Routine Deviations 2 - 6Exceptional Deviation 2 - 6

Replacing Fuses 2 - 7Replacing the System Controller and LVD Card 2 - 8

Faceplate Removal 2 - 8System Controller 2 - 8LVD Board Installation 2 - 10LVD Board Removal 2 - 11

Issue 2 February 2004 Table of Contents - 1


3 Fuse PanelWiring the Aux Box 3 - 2

Load Wiring 3 - 2Battery Connections 3 - 3Office Alarm Connector 3 - 41-Wire® Bus Connector 3 - 4

4 Battery Temperature Probes(VT-Probes)Installing Thermal Probes 4 - 2

ES773A Voltage/Thermal Probes (VT-Probes) 4 - 2ES773B Weatherized VT-Probes 4 - 2Attaching Probes to Batteries 4 - 3Checking for Defective

VT- Probes 4 - 3Overview of Checking Procedure 4 - 3

5 System Troubleshooting

2 - Table of Contents Issue 2 February 2004


Issue 2 February 2004 List of Figures - 1

List of Figures

Figure 1-1: ES760A and ES761A Rectifier 1 - 2

Figure 1-2: Removing and Reinstalling a Yukon Rectifier 1 - 3

Figure 2-1: Aux Box Location 2 - 2

Figure 2-2: Aux Box Control and Display Panel 2 - 2

Figure 2-3: Aux Box LED Color Guide 2 - 4

Figure 2-4: Fuse Assignments and Orientation 2 - 7

Figure 2-5: Aux Box Faceplate Removal 2 - 8

Figure 2-6: System Controller Installation/Removal 2 - 9

Figure 2-7: LVD Board Installation 2 - 10

Figure 2-8: LVD Board Installation (continued) 2 - 11

Figure 3-1: Fuse and Bus Bar Location Label 3 - 2

Figure 3-2: ES713A/AD Aux Box 3 - 3

Figure 4-1: ES773A Voltage/Thermal Probes (VT-Probes) 4 - 2


Issue 2 February 2004 List of Tables - 1

List of Tables

Table 1-A: Yukon Rectifier AC Input Requirements 1 - 4

Table 2-A: Configurable Alarm Thresholds/Relays 2 - 5

Table 3-A: Hardware Torque Specifications 3 - 3

Table 5-A: Yukon System Troubleshooting 5 - 2


1 Rectifiers

Rectifier


Rectifier

LVD Board

VTProbe

BatteryString 2

C.O. Ground

Shelf

Aux Box

AC Input



VTProbe

BatteryString 1

SystemController

RS-485Bus

-48VPowerBus

1-Wire®Bus

Issue 2 February 2004 Rectifiers 1 - 1


ES760A and ES761A Rectifiers

Figure 1-1 shows the Yukon rectifier.

Rectifiers are identified by a label on the left hand side.

ES760A The ES760A rectifier draws 7 Amps at 120 VAC and 4 Amps at 200 VAC. It requires forced air for cooling only at temperatures above 50 degrees C.

ES761A The ES761A rectifier draws 10 Amps at 120 VAC and 7.5 Amps at 200 VAC. It requires forced air cooling at all ambient conditions.

Figure 1-1: ES760A and ES761A Rectifier

LEDs

AC OK

DC OK

ALARM

1 - 2 Rectifiers Issue 2 February 2004


LEDs Each rectifier has 3 status LEDs on the front panel. Normal LED states are as follows:

Normal LED States

Routine Deviations ALARM Blinking (red)Communication between the controller and the rectifier has been lost. When replacing a rectifier or controller or upon the return of AC power wait 30 seconds for the ALARM LED to stop blinking.

DC OK Blinking (green)This occurs when recharging batteries from a deep discharge and the rectifiers are in current limit.

Other LED States AC OK On, DC OK Off , ALARM OnThis condition should be cleared by disengaging the rectifier from the shelf, waiting until the rectifier LEDs have extinguished, and reinserting the rectifier back into the shelf. See Figure 1-2 for removing and reinstalling rectifiers.

LED StatusAC OK Illuminated (green)DC OK Illuminated (green)ALARM Not illuminated (red)

Figure 1-2: Removing and Reinstalling a Yukon Rectifier

Handle

Guides

Pry rectifier handlegently with screwdriverand pull handle down.

With rectifier handle open,position rectifier on guidesand slide into shelf.

Issue 2 February 2004 Rectifiers 1 - 3


If this clears the alarm there may be a system problem with cabinet cooling apparatus or lightning protection on a 48V bus leaving the cabinet. The rectifier latch was triggered by an transient event no longer present in the system.

If this does not clear the alarm and other installed rectifiers show the same state, there may be a hard short on the 48V bus.

After this process, if an individual rectifier continues to exhibit a steady red ALARM LED, please return it to the factory for Failure Mode Analysis.

AC OK Off in one or more rectifiersCheck and reset the AC circuit breaker.

Using LEDs toVerify Proper AC

Distribution

The AC OK LEDs can be observed to determine how many rectifiers are served by each AC Circuit Breaker.

Verify that the sum of the input currents for all the rectifiers served by a particular AC Circuit Breaker does not exceed 80% of that breakers rating. Measure the AC line voltage and then use Table 1-A to determine appropriate AC cable and breaker sizes.

Using LEDs toConfirm Rectifier

Redundancy

Remove one rectifier. If DC OK blinks on the remaining rectifiers or batteries begin to discharge:System load exceeds the original design state.

Rectifier redundancy has been lost.

Reinstall the removed rectifier.

Purchase and install an additional rectifier.

Table 1-A: Yukon Rectifier AC Input Requirements

AC Cord Wire Size Input PlugRectifier Information

AC In CBType

Max DC (ea)

AC In Volts

84854517414 AWG

None1-760A 12A 120V or 200-240V

15A1-761A

18A 120V29A 200-240V

848545166NEMA 5-15P

1-760A 12A120V1-761A 18A

848671681

10 AWG None

2-760A 12A20A

200-240V 15A

2-761A18A 120V 30A29A 200-240V 20A

8486716993-760A 12A

120V 30A

200-240V15A

3-761A 29A 30A

1 - 4 Rectifiers Issue 2 February 2004


2 System Controller and LVD Board

Rectifier


Rectifier

LVD Board

VTProbe

BatteryString 2

C.O. Ground

Shelf

Aux Box

AC Input



VTProbe

BatteryString 1

SystemController

RS-485Bus

-48VPowerBus

1-Wire®Bus

Issue 2 February 2004 System Controller and LVD Board 2 - 1


Introduction to the Aux Box

The Auxiliary (Aux) Box contains the System Controller, the LVD Board, and the Fuse Panel which is where all field wiring is terminated. Battery Plant Alarms are indicated by a single tri-colored LED labeled ‘STATUS.’

The Control andDisplay Panel

Some Aux Boxes also have a control and display panel. Figure 2-2 shows how to interact with the display:

Figure 2-1: Aux Box Location

AC OK

DC OK

ALARM

ES760A

AC OK

DC OK

ALARM

ES760A

AC OK

DC OK

ALARM

ES760A

AC OK

DC OK

ALARM

ES760A

Rectifiers Aux Box

Shelf

STATUS

AmpsV Adjust

Lamp testAlm reset

Figure 2-2: Aux Box Control and Display Panel

AmpsV Adjust

Lamp testAlm reset

AmpsV Adjust

Lamp testAlm reset

Normal Operations

Adjusting Rectifier Voltage

Momentarily press to togglebetween volts and amps display.

Press and hold for 5 seconds, untilthe decimal point in the display blinks.

Use up and down buttons to adjust voltage.

Hold Amps/Vadjust button for 5 seconds toaccept the new voltage setting. Decimal pointwill stop blinking. Skipping this step forapproximately 15 seconds will cause the newsetting to be discarded.

Note:

Momentarily press to test system LEDs.

Press and hold for 5 seconds toreset alarms and update serial link.

54.4

54.4

2 - 2 System Controller and LVD Board Issue 2 February 2004


If you do not have the display, the System Controller inside the Aux Box allows one to monitor voltage and monitor current (where 10 millivolts equals 1 amp) using a multimeter. The Lamp Test push button on the controller operates similarly to the lower button on the display. The display provides hands free access to this information and the ability to override the factory float set-point.

Warning Before opening the Aux Box for any purpose: Put on safety glasses and consider that unprotected battery voltages and currents will be accessible once the door is removed.

Clearing a PowerMinor Alarm:

Example

If you are attempting to clear a Power Minor alarm indicated by an amber STATUS LED, examine the Rectifier LED displays for any alarm status illuminated Red or loss of AC. Clear rectifier alarms before deciding to open the Aux Box door.

Continuing with the Power Minor (PMN) example: Open the door to the Aux Box by depressing the latch at the top and center of the door. If the LED on the LVD Board is Green, the alarm is caused by a faulty or improperly connected Battery Temperature Probe attached to a battery string. Close the Aux Box door and proceed to the Battery Temperature Probe section of this guide.

Field ReplacableUnits

The Field Replaceable Units inside the Aux Box are: The System Controller, The LVD Board, The Fuses.

The status the Field Replaceable Units contained in the Aux Box can be determined by observing each unit’s LED and using the legend located on the label on the inside of the door as shown in Figure 2-3. Besides the Ringer, which is normally not present, notice that there is only:

One Tri-color LED on the controller, labeled as ‘STATUS’ on the outside of the door, and

One tri-color LED on the LVD board that also serves to indicate blown fuses.

CONTROLLERSTATUS ALARM

LED

There are only five states for the Controller Status Alarm LED: Normal, Power Minor (PMN), Power Major (PMJ), Battery Test, and Battery Discharge.

First use the guide shown in figure 2-3 to determine plant status.



Then use Table 2-A: Configurable Alarm Thresholds/Relays to determine alarm assignment into Power MINOR and Power MAJOR classifications. The default alarm assignment or configuration is shown in BOLD.

ControllerReplacement

Indication

If all system elements are registering a communication loss by displaying a blinking red LED, then the RS485 bus cannot see the controller. The controller is not seated or not functioning. After verifying that the controller and Aux Box are properly seated, replace the System Controller.

Figure 2-3: Aux Box LED Color Guide

RINGER LVD CARD FUSE/C.B. CONTROLLERSTATUSALARM

Normal Normal NormalPMNPMJ

BATTERYTEST

BATTERYDISCHARGE

= Flashing

Open Fuse/C.BOpen ContactorFailed ContactorFailed UnitPower Fault

Force CloseManual OpenCommunicationLoss

FailedUnit

Comm.Loss

Alarm Conditions

Before making anyconnection to this

equipment, refer to theproduct manual and

installation documentsfor safety precautions,important connections,

and operating conditions.

Install only inrestricted

access areas.Must not be

installed overcombustable

surfaces.

Display (If Equipped)

Inside of Aux Box Door

14.13.12.11.10.9.8.7.6.5.4.3.2.1.

(Green)(Green)

(Green)

(Green)

(Amber)

(Amber)

(Amber)

(Red)

(Red)

(Red)

(Red)

(Red)(Red)



Table 2-A: Configurable Alarm Thresholds/Relays(Default alarm assignment or configuration is shown in BOLD)

Alarm Thresholds/Relays Related Commands

obj,attr description sta cha ope type range of values

bda1,thr Battery on discharge threshold 3 3 number 46-55, 51 V

bda1,sev Battery on discharge severity 3 3 text “MAJ”, “MIN”, or “RO”

bda1,acc Battery on discharge relay 3 3 text “R1”, “R2”, or “”

hva1,thr High voltage threshold 3 3 number 50-60, 56 V

hva1,sev High voltage severity 3 3 text “MAJ”, “MIN”, or “RO”

hva1,acc High voltage alarm relay 3 3 text “R1”, “R2”, or “”

bta1,thr Battery high temperature 3 3 number 30-85, 55°C

bta1,sev Battery high temperature severity 3 3 text “MAJ”, “MIN”, or “RO”

bta1,acc Battery high temperature relay 3 3 text “R1”, “R2”, or “”

macf1,sev Multiple AC fail severity 3 3 text “MAJ”, “MIN”, or “RO”

macf1,acc Multiple AC fail relay 3 3 text “R1”, “R2”, or “”

mrfa1,sev Multiple rectifier fail severity 3 3 text “MAJ”, “MIN”, or “RO”

mrfa1,acc Multiple rectifier fail relay 3 3 text “R1”, “R2”, or “”

rf1,sev Ringer fail severity 3 3 text “MAJ”, “MIN”, or “RO”

rf1,acc Ringer fail relay 3 3 text “R1”, “R2”, or “”

faj1,sev Major fuse alarm severity 3 3 text “MAJ”, “MIN”, or “RO”

faj1,acc Major fuse alarm relay 3 3 text “R1”, “R2”, or “”

amj1,sev Auxiliary major alarm severity 3 3 text “MAJ”, “MIN”, or “RO”

amj1,acc Auxiliary major alarm relay 3 3 text “R1”, “R2”, or “”

isd1,sev Imminent shutdown severity 3 3 text “MAJ”, “MIN”, or “RO”

isd1,acc Imminent shutdown relay 3 3 text “R1”, “R2”, or “”

scd1,sev Voltage imbalance detected severity 3 3 text “MAJ”, “MIN”, or “RO”

scd1,acc Voltage imbalance detected relay 3 3 text “R1”, “R2”, or “”

acf1,sev AC fail severity 3 3 text “MAJ”, “MIN”, or “RO”

acf1,acc AC fail relay 3 3 text “R1”, “R2”, or “”

rfa1,sev Rectifier fail severity 3 3 text “MAJ”, “MIN”, or “RO”

rfa1,acc Rectifier fail relay 3 3 text “R1”, “R2”, or “”

rhp1,sev Ringer half-power severity 3 3 text “MAJ”, “MIN”, or “RO”

rhp1,acc Ringer half-power relay 3 3 text “R1”, “R2”, or “”

rls1,sev Rectifier redundancy loss severity 3 3 text “MAJ”, “MIN”, or “RO”

rls1,acc Rectifier redundancy loss relay 3 3 text “R1”, “R2”, or “”

osa1,sev Open string alarm severity 3 3 text “MAJ”, “MIN”, or “RO”

osa1,acc Open string alarm relay 3 3 text “R1”, “R2”, or “”

Non-Configurable Alarms Major: VSense Loss; Contactor 1 Open; Contactor 1 Fail; Major Communication Fail; High Battery Current ShutdownMinor: Thermal Probe Fail; High Battery Current; Minor Communication Fail; Circuit Pack Failure; Mid-cell V Monitor Fail



LVD CARDSTATUS LED

There are only five states for the LVD Card status LED: Normal, Red, Force Close, Manual Open, and Communication Loss. The Red state is multiplexed - see descriptions below.

Normal LED States The only normal state for the LVD card LED is green.

Routine Deviations Communication Loss (blinking red)Communication between the controller and the LVD Card has been lost. When replacing an LVD Card or controller wait 30 seconds for the LED to stop blinking red.

Manual Open (blinking amber)One of the two contactor switches is in the open or up position. This could be inadvertent. These switches should be in the down position unless batteries are being serviced. The top switch services the Battery String 1 contactor. The bottom switch services the Battery String 2 con-tactor. Verify that all battery strings are on-line and the LED is display-ing a steady green before closing the Aux Box Door.

Open Contactor (steady red)A battery string has been connected with reverse polarity. Both contac-tors have opened for protection. Move the slide switches to the up (open) position. Verify and/or correct the battery polarity. Reconnect the batteries by pushing the switches into the down position thus clos-ing the contactors.

Blown Fuse (steady red)A fuse has blown or failed for some reason. Carefully observe the state of each fuse. Replace any blown fuses with fuses of the same rating. If the new fuse also blows, examine the load and all the wiring to the load being served by that fuse.

Force Close (blinking green)This operation is only performed during extended AC outages when the LVD has operated to protect the original batteries and new batteries are being brought on-line to restore service. Squeeze the LVD card in between the slide switches for more than 5 seconds to restore power to the system. Do not release until the LED is steady green.

ExceptionalDeviation

Failed LVD Card (steady red)



Before replacing the LVD Card unplug the fuse alarm input wire to see if this clears the alarm. If it does reattach and find the blown fuse. If it does not clear the alarm, replace the LVD board.

Replacing Fuses

Use Figure 2-4 for fuse assignments and orientation. Blown fuses are indicated as shown. Fuse puller is supplied with the aux box.

Figure 2-4: Fuse Assignments and Orientation

BAT 2 (-) BAT 1 (-)

COGND

BAT (+)RTN

BAT (+)RTN

FUSEALARM

AUX V(-) SIGNAL

F1

F11

F13

F12

F14

F2

F3

F4

F5

F6

F7

F8

F9

F10

MAXIMUM FUSE RATING 15 AMPS

MAXIMUM OUTPUTPOWER 4000 WATTS(SEE LVD OPTIONS)

RTNBUSBAR

Blown Fuses Indicated Here

Note orientation when replacing fuses.



Replacing the System Controller and LVD Card

Both the system controller and the LVD card can be replaced without removing the Aux Box. These instructions show how these components are installed. Reverse the order to remove components.

Faceplate Removal The Aux Box faceplate must be removed to insert the system controller, LVD, and ringer boards. Open the faceplate by pressing the faceplate release tab at the top of the faceplate, and allowing the faceplate to swing down. To remove the faceplate, press on the thin side walls near the hinge of either side of the open faceplate until the hinge is free of the chassis receptacle and pull out.

System Controller The ES740AD controller is identical to the ES740A except that it is provided with a display option. It has a receptacle to which a flex-cable from the door of display Aux Boxes must be attached. This step should be performed at the very end.

ESD NOTE: You must properly protect yourself against ESD discharge prior to installing the following circuit cards. Connect wrist strap or similar device to the ESD Grounding Connector shown in Figure 2-5.

Figure 2-5: Aux Box Faceplate Removal

Faceplate Release Tabfor Opening Faceplate

With Faceplate Open,Press Thin Sidewalls onEither Side to Remove.

ESD Grounding Connector



Controller InstallationThe system controller slides into the right-most slot on the Aux Box. Gently insert the controller into the slot until it engages its mating receptacle in the shelf. Push against the ejector latch until the controller mates to the receptacle.

If installing into any of the display Aux Boxes (any Aux Box with a "D" suffix), the display board cable will have to be connected to the controller. Note the ZIF connector P5 on the controller (see Figure 6-1). Lift up the top of the ZIF connector and slide in the ribbon cable from the display board and push down on the connector to secure the cable.

Controller RemovalIf removing the controller, use the ejector latch to disengage the controller card from its mating receptacle on the Aux Box. Handle the controller by holding it against the edges or by the insulator and guide it out.

If removing from any of the display Aux Boxes (any Aux Box with a "D" suffix), the display board cable will have to be removed prior to fully removing the controller. Slide the controller out about halfway. Note the ZIF connector P5 on the controller (see Figure 6-1). Lift up the top of the ZIF connector and pull out the ribbon cable from the connector. The controller may now be fully removed.

Figure 2-6: System Controller Installation/Removal

Ejector Latch

System Controller

Ribbon Cable

UninsulatedSide

ZIF ConnectorsPull the top of connector up to release theribbon cable. Push down to lock the cable inplace. With the Aux Box faceplate open, theuninsulated side of the ribbon cable facestowards the front of the Aux Box on bothconnectors (display board and controllerboard.)



LVD Board Installation

1. Refer to Figure 2-7 to begin. Note the card guides on the left-most slot of the Aux Box, insert LVD card until it is prevented from being inserted any further. A tab on the top-front of the LVD card will hit the chassis to prevent it from being inserted any further.

2. Connect the alarm sense lead from the fuse board on the Aux Box to one of the two pins marked FUSE ALM INPUT pins on the top-front of the LVD board. If using needle nose pliers, avoid collapsing the terminal barrel by grasping the terminal barrel where it is filled with wire. Use the available LVD alarm board pins to estimate the length of the terminal barrel. This will allow the system controller to alarm for any fuse opening.

Figure 2-7: LVD Board Installation

Connect to Either TwoLVD Alarm Board PinsLabeled FUSE ALM INPUT

Fuse Alarm Wire fromFuse Distribution Board

Note: If using any of thedistribution boards, connect thefuse alarm wire to either of thetwo LVD board alarm pinswhile the LVD board is in thisposition.

Slide LVD Board forward as far asit will go in the left-most position.



3. Shift the card all the way to the right until the top-front tab lines up with the chassis slot and the mounting-tab on the card lines up with the mounting post on the Aux Box (Figure 2-8). It helps to slide the bottom edge of the board to the right first. Once it seats against the fuse circuit card, rotate the top edge up in a clockwise direction to seat against the card guides in the chassis. Press firmly against the non-component side of the LVD card during this process to make sure the back edge of the board, where the connector is, has also shifted to the right.

4. Insert until it engages its mating receptacle in the shelf. Secure the Aux Box to the shelf using the nut provided.

5. If the ES712_LVD_A or ES712_LVD_D is being used, place the contactor disconnect switche(s) in the OFF position. They will be placed in the ON position when the installation procedure has been completed. Neither the ES712_LVD_B nor the ES712_LVD_C boards have disconnect switches.

LVD Board Removal

Replacing LVD Boards requires removing the ringing module, if one is being used.

CAUTIONRemoving LVD board will require placing a nut-driver into contact

with parts that are at the nominal -48V bus. Insulated tools are required to remove the LVD Boards.

Figure 2-8: LVD Board Installation (continued)

Slide LVD Board Right UntilTab Aligns with Chassis Slot

Push LVD Board so that theTab Slides into the Chassis Slotand the LVD Board Mounting Tabis on the Mounting Post

Tab

Chassis Slot

Mounting PostMounting Tab



3 Fuse Panel

Rectifier


Rectifier

LVD Board

VTProbe

BatteryString 2

C.O. Ground

Shelf

Aux Box

AC Input



VTProbe

BatteryString 1

SystemController

RS-485Bus

-48VPowerBus

1-Wire®Bus

Issue 2 February 2004 Fuse Panel 3 - 1


Wiring the Aux Box

Use the label on the insulator flap (shown in Figure 3-1) as a wiring guide.

Load Wiring The ES713A/AD Aux Boxes are provided with a fused distribution board for 14 load connections. Load connections are made using Amp FastOn Tabs, the mating tab should be 0.032 in by 0.187 in and should be the insulated types. Tyco Electronics recommends Amp Part Number 2-520411-2 for 22-18AWG conductors and Part Number 3-520412-2 for 16-14 AWG conductors. Note that all nominal loads are to be at 80% of the fuse value. Also note that the total power from the distribution module is limited by the LVD board chosen. Refer to Section 8 of the Yukon product manual for more details.

Figure 3-1: Fuse and Bus Bar Location Label

BAT 2 (-) BAT 1 (-)

COGND

BAT (+)RTN

BAT (+)RTN

FUSEALARM

AUX V(-) SIGNAL

F1

F11

F13

F12

F14

F2

F3

F4

F5

F6

F7

F8

F9

F10

MAXIMUM FUSE RATING 15 AMPS

MAXIMUM OUTPUTPOWER 4000 WATTS(SEE LVD OPTIONS)

RTNBUSBAR

3 - 2 Fuse Panel Issue 2 February 2004


The fuse distribution board is provided with an alarm sense wire that must be connected to a Fuse Alarm Input pin on the LVD board. This allows the system controller to detect open fuses, and send appropriate alarms and contact closures.

BatteryConnections

Battery Negative Terminals: Batt 1 and Batt 2 are lug terminations for the battery negative connections. The terminals accept M5 lugs on 5/8-inch centers.

Note that the forced reconnect switches (S110 and S210) and the manual disconnect switches (S100 and S200) correspond to Batt 1 and Batt 2, respectively.

Battery Positive Terminals: Terminals for the positive battery conductors. Terminals accept M5 lugs on 5/8-inch centers.

C.O. Gnd: Terminal for the C.O. ground connection. Terminals accept M5 lugs on 5/8 in centers.

Figure 3-2: ES713A/AD Aux Box

C.O. Ground

LVD Board

14 Position FastonTab Fuse Board

Batt1 and Batt2Negative Terminals

Access GateOffice AlarmConnector

1-Wire BusConnector

®

Batt 1 and Batt 2Positive Terminals

Table 3-A: Hardware Torque Specifications

HardwareTorque

N·m in·lbs

Metric M5 4 35

12-24 4 35

Issue 2 February 2004 Fuse Panel 3 - 3


Office AlarmConnector

Also known as the Host Interface Connector, this connector provides access to the alarm relay pins, has inputs to perform the Plant Battery Test and has inputs to alarm for external equipment failure. The connector has the following pin designations.

The connector is a 24-pin AMP MIRCO MATE-N-LOK connector. It mates to a MICRO MATE-N-LOK receptacle with housing 2-794617-4 and contact sockets 794606-3 for 20-24 AWG conductors.

Cable assembly 848667689 provides 6-ft (1.8 m) of cable terminating on one end in the mating connector and is un-terminated on the other end. Users may order this part, size and terminate accordingly for the application.

1-Wire® BusConnector

This is an RJ-45 connector and connects devices such as the ES771A Remote Voltage Monitor Module, ES772A Remote Distribution Module (to be developed) and the ES773A Voltage/Thermal Probes. Future developments will allow for a cable assembly to connect the Yukon system to an un-grounded PC for custom programming of the system controllers.

Pin Designation Color Pin Designation Color1 PMJ NO BK 2 PMJ C BR

3 PMJ NC R 4 PMN NO O

5 PMN C Y 6 PMN NC G

7 R2 NO BL 8 R2 C V

9 R2 NC S 10 R1 NO W

11 R1 C W-BK 12 R1 NC W-BR

13 RESERVED W-R 14 RESERVED W-O

15 RESERVED W-Y 16 RESERVED W-G

17 RESERVED W-BL 18 RESERVED W-V

19 PBT_IN W-S 20 SIG_RTN W-BK-R

21 RESERVED -- 22 RESERVED --

23 AUX_PMJ W-BK-R 24 AUX_PMJ_RTN W-BK-O

13 24

1 12

Receptacle Pin Numbering(looking at receptacle)

3 - 4 Fuse Panel Issue 2 February 2004


4 Battery Temperature Probes(VT-Probes)

Rectifier


Rectifier

LVD Board

VTProbe

BatteryString 2

C.O. Ground

Shelf

Aux Box

AC Input



VTProbe

BatteryString 1

SystemController

RS-485Bus

-48VPowerBus

1-Wire®Bus

Issue 2 February 2004 Battery Temperature Probes (VT-Probes) 4 - 1


Installing Thermal Probes

ES773A Voltage/Thermal Probes

(VT-Probes)

VT-Probes are used to measure battery temperatures for slope thermal compensation, and to measure battery voltage for battery voltage imbalance detection. They convert temperature measurements into serial data and transmits them to the system controller using the 1-Wire® bus from Maxim. They can also send battery voltage measurements to the system controller when used with the ES771A Remote Voltage Monitor. All probes are provided with a ptc device to protect against accidental short circuit during voltage measurements. Note: The Yukon system cannot use the thermal probes that are used with other Tyco Electronics power systems, e.g., CPS4000. The ES773A VT-Probe must be used.

Connector J2: This 4-position connector serves to connect the VT-Probe to the Aux Box using the 848652939 cable. It is connected to other VT-Probes by daisy-chaining using either the 848657391 (5-ft) or the 848657383 (10-ft) cable.

Connector J1: This 2-position connector serves to connect the VT-Probe to J2 on other VT-Probes by daisy-chaining them together.

ES773BWeatherized

VT-Probes

These are ES773A probes that have been additionally protected so that they survive in the environments typically seen by batteries in outdoor cabinets. All cables have been connected to the probe and sealed prior to shipping from the factory.

Figure 4-1: ES773A Voltage/Thermal Probes (VT-Probes)

J1

J2

4 - 2 Battery Temperature Probes (VT-Probes) Issue 2 February 2004


Attaching Probes toBatteries

The Yukon Power System may be used with a maximum of four strings of batteries.

WARNINGBatteries contain hazardous electrical energy, sulfuric acid, and

explosive hydrogen gas. Follow all precautions noted in the literature accompanying the batteries.

Place batteries on battery trays or other satisfactory supporting surface and interconnect per manufacturer’s instructions so as to create a 48V string.

Installing Thermal Probes for Thermal Compensation

If thermal compensation is to be used, connect the ES773A VT-Probe or the ES773B Weatherized VT-Probe to the negative terminal of the batteries that are to be monitored. Remove the battery negative lug from the battery and attach the VT-Probe such that the receptacles (ES773A) or the cables (ES773B) on the probes are readily accessible. Secure bolt to battery and torque per manufacturer's specification. Do not connect any cables to the probe(s), they will be connected during the start-up procedure.

Checking forDefective

VT- Probes

If multiple VT-Probes are being used and the Thermal Probe Fail (PMN) alarm is being generated, use the following steps to determine which probe in a chain of probes has failed.

Overview ofChecking

Procedure

The controller issues an alarm when it thinks it has lost a thermal probe. The CLE command forces the controller to re-inventory the system. If a thermal probe is removed from a system with no alarms, and no new alarm is issued, the removed probe was defective. Therefore, alternately removing thermal probes and issuing the CLE command allows failed probes to be identified.

Note that this procedure requires running the CLE command. The CLE function may be initiated by either depressing the front panel switch on the system controller for greater than 5 seconds.

The controller should have its LED illuminated in amber color. To determine the faulty probe, follow the instructions noted below. Note that the first probe is the probe closest to the Aux Box.

1. Disconnect the cable to the 4-position connector of the second probe in the daisy chain of probes. That is, only the first probe should be connected to the system. Run the CLE function. If

Issue 2 February 2004 Battery Temperature Probes (VT-Probes) 4 - 3


afterwards the system controller illuminates its LED in green color, the probe is operational.

To verify this, disconnect the cable to the 4-position connector of the first probe from the Aux Box and connect it to the 4-position receptacle of the second probe, including the chain of probes connected to the second probe, and run the CLE command. If the first probe is defective, the system controller’s LED should be illuminated in green color.

2. If the first probe was good, remove the cable to the 4-position connector of the third probe from the chain and run the CLE command. If afterwards the system controller illuminates its LED in green color, both the first and second probes are operational. Had the system controller illuminated its LED in amber color it would indicate that the second probe was defective.

To verify this, disconnect the cable from the Aux Box to the 4-position connector of the first probe and connect it to the 4-position receptacle of the third probe, including the chain of probes connected to the third probe, and run the CLE command. If the second probe is defective, the system controller’s LED should be illuminated in green color.

3. Continue this procedure until the defective probe has been found. Once the defective probe has been found, replace it with a new probe and run the CLE command. The system controller should be illuminating its LED in green color.

4 - 4 Battery Temperature Probes (VT-Probes) Issue 2 February 2004


5 System Troubleshooting

Rectifier


Rectifier

LVD Board

VTProbe

BatteryString 2

C.O. Ground

Shelf

Aux Box

AC Input



VTProbe

BatteryString 1

SystemController

RS-485Bus

-48VPowerBus

1-Wire®Bus

Issue 2 February 2004 System Troubleshooting 5 - 1


ContLE

AM

s

lace

RE

is

RE

t ow, e. be

AM

RE

tage ly

RE

AM ve.

Table 5-A: Yukon System Troubleshooting

roller D

User Interface Display

Rectifier LED

LVD Board LED

Possible Problem(s) Possible Solution(s)

BER MIN, AC Fail ALARM GREEN

Single Rectifier not receiving ac power.

• AC input circuit breaker has opened.

• AC input voltage is out of range.

1. Verify ac power to rectifier iavailable.

2. Verify rectifier input circuit breaker is closed.

3. If problem not corrected, reprectifier.

D

MIN, AC FailMAJ, Multiple

AC FailMAJ, Battery

on Discharge

None GREEN

Multiple rectifiers not receiving ac power, batteries are powering load.

• AC input circuit breakers have opened.

• AC input voltage is out of range.

• Internal rectifier fault.

1. Verify ac power to rectifiersavailable.

2. Verify rectifier input circuit breakers are closed.

3. If problem is not corrected, replace rectifiers.

DMAJ, Battery

on DischargeAC OKDC OK

GREENRectifier output voltage has fallen below the battery on discharge threshold set by the user.

If commercial ac power is presenbut the system voltage remains lcall your local field representativInvestigate other alarms that maypresent such as rectifier related problems.

BERMIN, Rectifier

Fail (Note 1)

AC OKALARM(Note 1)

GREENRectifier output has dropped below 36V, rectifier has entered hiccup mode.

Replace rectifier.

D

MIN, Rectifier Fail

MAJ, Rectifier Fail (Note 1)

AC OKALARM(Note 1)

GREEN

All rectifier outputs have dropped below 36V, all rectifiers have entered hiccup mode.Defective controller.

Remove controller; if output voldoes not go to set-point previousset by user, call your local field representative.

DMAJ,

Contactor 1 Open

AC OKDC OK

AMBER(Blinking)

One or both of the LVD contactors is open; someone may have manually opened LVD contactor.

Place disconnect switch in ON position.

BERMIN, Battery

High Temperature

AC OKDC OK

GREENBatteries have exceeded temperature threshold set by user.

Call your local field representati

5 - 2 System Troubleshooting Issue 2 February 2004


No

so,

for

er

e.

AM

erly

Aux

e.

RE

AM

ing

nd

the

e.

ContLE

ne No response.RED

(Blinking)RED

(Blinking)

Controller failure, all devices on the communication bus reporting loss of communication with controller.

Check controller to ensure it is properly inserted into its slot. If perform the following steps:

1. Remove the controller board1 minute and then reset.

2. If problem persists, replace controller with new controllboard.

3. If problem still persists, callyour local field representativ

BERMIN, Thermal

Probe FailAC OKDC OK

GREEN Battery thermal probe failed.

1. Ensure thermal probe is propconnected to thermal probe cable.

2. Ensure cable is properly connected to the rear of the Box.

3. If problem persists, replace thermal probe per ensuing instructions.


DMAJ, Fuse

MajorAC OKDC OK

REDOne or more of the output circuit breakers or fuses have opened.

Reset circuit breakers or replace fuse.

BERMIN, Rectifier

FailAC OK

ALARMNormal

Single rectifier thermal alarm: Excessive ambient temperatureMultiple rectifier failure

1. Verify that there is no obstruction of the vertical airflow path.

2. Reset the rectifier by removthe rectifier, waiting approximately 30 seconds, areplacing the rectifier.

3. If problem persists, replace rectifier.



roller D


Rectifier LED

LVD Board LED


Issue 2 February 2004 System Troubleshooting 5 - 3


RE 30s

the

e.

RE

nd

the

e.

AM

ing

nd

the

e.

RE

2)

r

NoteNote

ContLE

D

MIN, Rectifier Fail

MAJ, Multiple Rectifier Fail

MAJ, Battery on Discharge

AC OKALARM

NormalMultiple rectifier thermal alarm: Excessive ambient temperatureMultiple rectifier failure

1. Verify that there is no obstruction of the vertical airflow path.

2. Reset rectifies by removing them, waiting approximatelyand replacing them.

3. If problem persists, replace rectifiers.


DMAJ, High

VoltageAC OK

ALARMNormal

High output voltage from rectifier(s)Rectifier(s) high voltage shutdownInternal rectifier(s) failure

1. Reset the rectifier(s) by removing the rectifier(s), waiting approximately 30s areplacing the rectifier(s).



BERMIN, Minor

Communica-tion Fail

RED Blinking Single

rectifier

GREENRectifier lost communication with controller.

1. Reset the rectifier by removthe rectifier, waiting approximately 30 seconds, areplacing.



DMAJ, Major

Communication Fail

GREENRED

(Blinking)LVD Board lost communication with the controller.

1. Replace LVD Board. (Note

2. If problem persists, call youlocal field representative.

1: While in hiccup mode, the rectifier will attempt to restart every 10 seconds. 2: Refer to Section 5, LVD board Removal for removal details. Note that the power system will continue to power

the load while the LVD board is out of the system; however, there will be no possibility of battery backup until the LVD board is replaced.


roller D


Rectifier LED

LVD Board LED


5 - 4 System Troubleshooting Issue 2 February 2004

Documents

Yukon Technical Support Guide (with ES713AD Aux …Product Manual Comcode 108989562 Issue 2 February 2004 Yukon Technical Support Guide (with ES713AD Aux Box) Notice: The information,