151N-A1 · 1200 Amp, 2000 Amp and 800 Amp respectively. The main source of power for the 151N-A1...

Critical Power Product Manual

151N-A1 -48 VDC POWER PLANT

[email protected] www.gecriticalpower.com

Service and Assistance - +1 877 546 3243 © 2015 General Electric Company. All rights reserved. 4390103P Issue 07 May 2015

GE Critical Power 151N-A1 Manual

Issue 7, May 2015

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Product Information Spaces are provided below for recording product information.

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.

Fill in the date code located on the label in the space below.

Fill in the serial number on the label in the space below?

Fill in the ECN Level located on the label in the space below

PART NUMBER:

DATE CODE:

SERIAL NUMBER:

ECN Level: 860 _ _ _ _ P


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Issue 7, May 2015

Table of Contents Product Information.......................................................................................................................................3 Table of Contents..........................................................................................................................................5 List of Tables.................................................................................................................................................5 Contact Information........................................................................................................................................6 Agency Approvals: ........................................................................................................................................6 SECTION 1: SPECIFICATIONS ..................................................................................................................9

1.1 SPECIFICATIONS - PLANT ...........................................................................................................9 1.2 SPECIFICATIONS - BAYS ...........................................................................................................12

SECTION 2: INSTALLATION.....................................................................................................................13 2.1 TORQUE........................................................................................................................................13 2.2 RECOGNIZING DIFFERENT GRADES OF STEEL AND THEIR TORQUE ...............................13 2.3 COMMON TORQUE VALUES .....................................................................................................15 2.4 TORQUE ON FUSE HOLDERS...................................................................................................15 2.5 INSTALLATION - PLANT .............................................................................................................16 2.6 INSTALLATION - BAY..................................................................................................................16

SECTION 3: TEST & ACCEPTANCE PROCEDURES .............................................................................19 3.1 GENERAL.....................................................................................................................................19 3.2 VISUAL OBSERVATION ..............................................................................................................19 3.3 RECTIFIER ALARM TEST ...........................................................................................................20 3.4 DISTRIBUTION FUSE ALARM TEST ..........................................................................................20 3.5 ALARM BATTERY SUPPLY FUSE ALARM TEST ......................................................................20 3.6 HIGH, LOW, & LOW LOW VOLTAGE ALARM TEST ..................................................................21 3.7 RECTIFIER SENSE FUSE ALARM TEST (Optional) ..................................................................22 3.8 LOW VOLTAGE DISCONNECT TEST (Optional)........................................................................22 3.9 EQUALIZE OPERATION & ALARM TEST...................................................................................22 3.10 RECTIFIER REMOTE HIGH VOLTAGE SHUTDOWN (HV) REMOTE RESTART (RRS) TEST.............................................................................................................................................................23

List of Tables 2-1 Determining Bolt Material 14


Issue 7, May 2015

Agency Approvals:

CONTACT INFORMATIONPhone: +1 877 546-3243

Email: [email protected] Web site:

www.gecriticalpower.com

Issue 7, May 2015

WARNINGS 1. Electrical shock hazard. Do not attempt to remove,

maintain, or install this equipment with powerapplied. Personnel that attempt to work on thisequipment with the power applied may subjectthemselves or others to electrical shock that maycause serious injury or death.

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 ordeath.

3. Do not attempt to work on this equipment if it is, orhas been, exposed to a high moisture condition. Itis recommended the equipment be returned toGE to be properly tested. Working on thisequipment during a high moisture condition subjectsthe user to electrical shock that may cause seriousinjury or death.

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.

5. Do not operate this equipment if it has beendropped or otherwise damaged. Trying to operatethis equipment if it has been damaged subjectsyourself or others to electrical shock that may causeserious injury or death.

6. Before you proceed, ensure the input source is notlive and the input circuit breaker(s)/fuse(s) has beentripped or removed. If these procedures have notbeen followed and the input/output power is live,serious personnel injury or death may occur.

7. A rack/shelf may contain several operating systems.If there is another system in the general area youwant to install this system, be cautious of anyexposed connectors or wires and, with permission,remove power to the other systems. Failure to takethe necessary safety precautions subjects theinstaller or maintenance personnel to severeelectrical shock that may cause serious injury ordeath.

8. This equipment may connect to lead-acid batteries.Battery posts, terminals, and related accessoriescontain lead and lead compounds, chemicalsknown to the state of California to cause cancer andbirth defects or other reproductive harm. Washhands after touching batteries.


CAUTIONS 1. Follow proper grounding instructions.

2. If connecting batteries, remove the battery-box-fuse or trip the circuit breaker. Check batteriesand connections for proper polarity and powerbefore connecting the batteries to the system.

3. To remove the circuit breakers or fuses, the DCand/or AC input to the system will need to bedisconnected, thereby disabling the systemoutput to the load(s). Take the necessaryprecautions and inform the plant engineer that thesystem output power to the loads will be disabled.

4. Before performing any maintenance, ensure ACor DC power is not applied to the system.

5. Fuse holders, fuses, and circuit breakers are notto be loaded to more than 80 percent of theirampere rating.


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Issue 7, May 2015

SECTION 1: SPECIFICATIONS 1.1 SPECIFICATIONS - PLANT

A. GENERAL

The 151N-A1 Power Plant is designed to provide distribution and monitoring of -48 VDC. The Plant is rated in varying maximum current capacities of 100 thru 2000 Amps. -48 VDC is fed through a total discharge shunt, which is bussed inside the Main Bay. Lists 1, 2, 3, & 4 are for a maximum of 600 Amp, 1200 Amp, 2000 Amp and 800 Amp respectively.

The main source of power for the 151N-A1 Power Plant is commercial AC power, which is converted to DC by Rectifiers. The Rectifiers provide "load current" and "trickle charge" for floating batteries. The Batteries are for filtering and stand-by reserve. The 151N-A1 Power Plant provides system monitoring, alarming, and distribution of -48 VDC to load circuits.

System operation is such that the Rectifiers float the battery, charge it as required, and provide current to the load circuits. Batteries provide load current during periods of commercial AC failure. Audible (optional) and Visual Alarms are produced when the battery float voltage deviates from system set points.

The MACS System, which is a monitor, alarm, and control system that provides alarming, monitoring, and data storage is an optional system that can be added to the 151N-A1Power Plant. (See MACS Manual for more details).

Fig 1-1: Block Diagram

A brief explanation of the 151N-A1 Plant and the equipment used in the plant are as follows:

PLANT CONFIGURATION

The initial Plant configuration is made up of:

(1) Main Bay, (N + 1, 50, 100, 200 or 400 Amp Rectifiers). (1) Lot of (+) & (-) Plant Bus Bars with 600, 1200, 2000 and 800 Amp Total Discharge Shunt. (1) Battery String.

The (+) & (-) Bus Bars are supported above and in the Power Bays. They are hard bussed into the Main Bay.

Rectifiers Bat

String N

Bat String

2

Bat String

1

Total Discharge

Shunt

Main Discharge Bay

(-) (-)

(-)

(-)

(+) (+)

(+)

(+)


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Plant expansion is easily accomplished by adding Rectifiers and additional Distribution fusing as required.

RECTIFIERS

Rectifiers should be designed to supply the load and maintain batteries in a "full charge" condition. The following Rectifiers can be used:

PEC 1015 50-200 Amp PEC 1011 100 Amp PEC 3874, PEC 3874B 200 Amp PEC 3875, PEC 3875B 400 Amp (See Rectifier Manuals)

NOTE: Number of Rectifiers is determined by peak load current plus one (N + 1).

BATTERY STRINGS

The battery equipment for the 151N-A1 Power Plant consists of 48 Volt battery strings of 23 or 24 cells. The number of Battery strings is determined by peak load current and reserve time required. (Consult factory or refer to Battery Manufacturers Manual).

NOTE: All recommended float and alarm set points stated in this manual are typical for 24 cell operation and may not represent every application.

When specific set points (as listed on Production Test Specification 4650014P-1 thru 7) are required, set point option must be specified (See 4650014P-1 to P-7).

B. ELECTRICAL SPECIFICATIONS

1. INPUT

AC Input for the different Rectifier Modules is specified in the Rectifier manuals.

2. OUTPUT

Float: 48 to 54 VDC (Not to exceed 57 VDC). Equalize: 0 to 7 volts above float.

NOTE: For new battery installations where the batteries will receive an initial charge of 60 volts, consult the Rectifier manual.

3. PROTECTION

a. Input: Protection for the different Rectifier Models are either circuit breakers or fuses at the ACService Source. If circuit breakers are used on the AC Input, they must be capable of withstanding high inrush currents of 1500 Amp for ½ cycle.

b. Output: Protection of plant outputs is by various optional Fuse, Circuit Breaker, andDistribution Panels. Refer to J-438151NP-A1 drawing for correct sizing.


Issue 7, May 2015

C. PERFORMANCE SPECIFICATIONS

The performance specifications for Rectifiers used in the 151N-A1 Plant are as follows:

1. REGULATION

a. Static: ±½% for all AC input, output load, and temperature conditions.

b. Dynamic: Voltage transient is less than 5% and will return to and stay within regulation bandwithin 200ms when a 20% to 100% step load is applied.

2. CURRENT WALK-IN

Current Walk-in protection of Rectifier controls output current to eliminate damage by overshoot.

NOTE: Consult Rectifier Manual for complete specifications.

D. ENVIRONMENTAL SPECIFICATIONS

1. OPERATING TEMPERATURE

0°C to +50°C Ambient

2. STORAGE TEMPERATURE

-40° to +85°C Ambient

3. COOLING: Convection - Keep ventilating passageways of the Plant unobstructed to insureadequate cooling during operation.

E. FLOOR PLAN ARRANGEMENTS

Floor plan arrangements of this equipment should take in consideration the following guidelines:

1. Battery Strings should be electrically connected between the Rectifiers and the Power Bays.Battery String #1 should always be closest to the Power Bays. Reason - the batteries provide filtering to reduce plant noise levels.

2. Ample room for expansion should be considered for future Battery Strings and the Rectifiers.

3. Physical arrangement of Rectifiers, Batteries, & Distribution Bays should be such that cabling beheld to a minimum. Reason - voltage drop held to a minimum.

NOTE: Consult job information that applies.


Issue 7, May 2015

1.2 SPECIFICATIONS - BAYS

A. MAIN DISCHARGE BAY

The Main Discharge Bay contains the Meter and Alarm Panel that provide features of metering, monitoring, controlling, alarming, and distribution fuses for the 151N-A1 Power Plant. Capacity of Main Distribution Bay is 2000 Amps maximum.

B. DISTRIBUTION FUSE PANELS

Distribution Fuse Panels ranging in size from 0-60 Amp "non" type to 61-800 Amp OSP/RL fuse link type are available in the 151N-A1 Power Plant.

NOTE: Load fuses should not be loaded to more than 80% of their ampere rating.

NOTE: If UL listed distribution fuses are required then use TPL type as listed in Table H of drawing J-438151NP-A1.

C. DISTRIBUTION CIRCUIT BREAKER PANELS

Distribution Circuit Breaker panels ranging in size from 1-400 Amps are available for the 151N-A1 Power Plant. See drawing J-438151NP-A1 for more details.

NOTE: Load circuit breakers should not be loaded to more than 80% of their ampere rating.

D. MECHANICAL SPECIFICATIONS

The mechanical specification of the 151N-A1 Power Plant is as follows:

1. The configuration of the Plant can be mounted in either a box frame or a relay rack.

2. See List L101-L108 of drawing J-438151NP-A1 for the choice of relay rack sizes that are available.

3. See List L115-L121 of drawing J-438151NP-A1 for the choice of box frame sizes that are available.

NOTE: See drawing J-438151NP-A1 for further physical dimensions and recommended mounting.


Issue 7, May 2015

SECTION 2: INSTALLATION 2.1 TORQUE

Torque refers to the tightening (or loosening) effort required for specific materials, sizes, and threads of threaded bolts / screws. Minimum torque requirements are listed in accompanying tables. When the fastener and mating material are different, the values for the weaker material will be used.

All loosening (or breakaway) torque will be 50% of the values assigned for the tightening torque, for a given combination unless specifically noted otherwise. At this value no loosening shall occur. The 50% figure represents an acceptable relationship when normal variations of fasteners, materials, and friction values are considered, for short time periods.

Torque applications of bolts embedded in a formed material, and to which a threaded nut will be attached, will be governed by specifications outlined for the particular application under observation. In no case will values for the bolt and nut alone be used, but these must be modified by the type of embedment, as determined by table included herein, or by the engineering authority as noted on an associated drawing.

All bolts and screws used to fasten electrical (carrying a minimum of 10 Amps) or thermal surfaces together are required to have proper torquing.

2.2 RECOGNIZING DIFFERENT GRADES OF STEEL AND THEIR TORQUE

When determining torque to be used, it is important to know the grade of steel of the bolt. Consult the chart below (Table 2-1) by looking at the cap of the screw and matching the pattern to one on the chart. Read to the right to determine the torque required in reference to the bolt size. This table should be used to determine torque only if it is not specified by the equipment drawing or customer requirements.

Refer to Section 2.3 if the bolt type is not covered in this table.


Issue 7, May 2015

1-1/

8

404

740

665

900

850

1110

1200

1440

1

255

470

495

670

550

700

760

910

7/8

172

315

322

450

362

468

502

602

3/4

128

200

213

303

228

297

315

377

5/8

79

124

128

170

142

178

192

230

9/16

56

87

94

100

128

140

168

1/2

38

59

64

85

69

90

98

118

7/16

26

40

43

46

59

64

77

3/8

16

26

27

29

37

39

47

5/16

9.4

14

15.3

17

20

24

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105,

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125,

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150,

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Table 2-1: Determining Bolt Material

Fine

or

Coa

rse

Thre

ad

Fast

ene

r


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2.3 COMMON TORQUE VALUES

The following chart defines the torque specifications for typical telephone power equipment. This table should be used to determine torque only if it is not specified by the equipment drawing or customer requirements.

LOW CARBON STEEL SILICONE BRONZE COPPER STUDS

SIZE OF BOLT

THRU COPPER IRON CLAMPS

DRY LUBED DRY LUBED DRY LUBED DRY LUBED

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

1 1/8 1 1/4

5.1 9.4 16 26 38 56 79 128 172 255 404

4 8

14 23 34 50 71 115 155 229 364

69* 123* 18 29 40 52 86 115 178 240 361

62* 110* 16 26 36 46 77 103 160 216 325

14.5

32

69

13

29

62

51* 89* 13 21 29 39 63 84 120 140 170 200

46* 80* 12 19 26 35 56 76 108 126 153 180

READINGS ARE IN FOOT POUNDS EXCEPT (*) THESE READINGS ARE IN INCH POUNDS LUBED MEANS LUBRICATED THREADS

1. If grease is used on the threads and under the turned member, reduce values given by 10%.

2. All values given are for clean threads that are free of burrs, chips and other imperfections. Also,all mating surfaces are considered to be flat, parallel and free of burrs.

3. When torquing any threads on studs mounted to fuse holders, always hold the second nut. DONOT apply torque to the stud-plastic housing interface.

4. All torque values are for free running nuts. For nuts that are self-locking (nylon plug or indented),the "Run down" torque must be added to these values.

5. The turned member will be the nut, unless otherwise noted (such as with a tapped hole).

6. Torque will be checked by a loosening action or breakaway for the selected combination andadjusting the torque tool for 50% of the value shown in the above table.

2.4 TORQUE ON FUSE HOLDERS

The torque required to tighten connections on fuse holders is described in the table below:

Fuse Holder P/N Bolt Size Grade 5 Torque 3140357 7/8" 55 FOOT-lbs (dry) 3140155 3/4" 55 FOOT-lbs (dry)

NOTE: When torquing any threads on studs mounted to fuse holders, always hold the second nut. Do not apply torque to the stud-plastic housing interface.


Issue 7, May 2015

2.5 INSTALLATION - PLANT

The 151N-A1 Power Plant is designed to be connected by the use of Cable Termination Assemblies. The Cable Termination Assemblies and wireway should be complete before any connections are made. For detailed information of the Bus Bar Assembly, see Job Bus Run Layout drawings.

NOTE: Installation of the Power Plant should be in areas accessible only to qualified personnel. All units should be secured to the building structure before operating.

NOTE: Before any connections are made to the 151N-A1 Power Plant, be sure that all Rectifier Output Circuit Breakers are in the "OFF" positions, and remove all Distribution Fuses in the Power Distribution Bays.

A. RECTIFIER CONNECTIONS

Listed below is a brief summary of the Rectifier connections to be made:

1. Connect AC Input leads (L1, L2, L3, GRD) of Rectifier to the AC Power source.

2. Output - Refer to Section 2.6, A1 & A2 for Rectifier output connections.

3. Load Sharing - Connect all Load sharing terminals together. Example: PEC 3875B Rectifier -Connect terminal TB201-3 (LS Out) of all Rectifiers together.

4. Refer to Section 2.6, B5 for sense and alarm connections.

NOTE: For more detailed information about Rectifier connections, refer to the Rectifier Manual.

B. BATTERY CONNECTIONS

Listed below is a brief summary of Battery connections to be made:

1. Connect first cell (+) terminals of equipped battery strings to the Grd Bus Termination Assembly.

2. Connect 23rd or 24th cell (-) terminals of equipped Battery Strings to the Bat Bus TerminationAssembly.

3. Refer to Section 2.6, B5 for "RB" (Reference Battery) and "RG" (Reference Ground) connections.

2.6 INSTALLATION - BAY

A. CABLE TERMINATION ASSEMBLY CONNECTIONS

1. Connect the Rectifier and Battery Ground (+) cables to the Distribution Ground Bus, mounted nearthe top of the Main Bay.

2. Connect the Rectifier and Battery -48V (-) cables to the Discharge Battery Bus, mounted near thetop of the Main Bay.

B. DISCHARGE BAY CONNECTIONS

All Discharge Bay connections are made in accordance with SD, T & J drawings. Listed below is a brief summary of the connections to be made:

1. EQUIPMENT GROUND (All Bays)

Connect Equipment Grd Lug to the Grd Bus.


Issue 7, May 2015

2. FRAME GROUND (All Bays)

Connect Frame Grd Lug to FR GRD wire running across top of Bays. (Consult Job Information)

3. METER & ALARM PANEL

See 4380031PD for connections of Meter & Alarm Panel (Digital).

4. RECTIFIER SENSE FUSE MODULE

See 4380404PD for connections of Rectifier Sense Fuse Module.

5. BRANCH SWITCH MODULE

See 4380029PD for connections of Branch Switch Module.

6. ALARM EXTENSION MODULE

See 4380031PD for connections of Alarm Extension Module.

7. HI/LO PLANT VOLTAGE CALIBRATION MODULE

See 4380027PD for connections of HI/LO Plant Voltage Calibration Module.

8. LOW VOLTAGE DISCONNECT CONTROL MODULE

See 4380028PD for connections of Low Voltage Disconnect Control Module.

9. -48V AUTOMATIC EQUALIZE TIMER PANEL

See 6420105P for connections of the -48V Automatic Equalize Timer Panel.

10. AUTOMATIC RECTIFIER RESTART MODULE

See 4380033PD for connections of Automatic Rectifier Restart Module after a high voltageshutdown.

11. PEC 1015 RECTIFIER SYSTEM

Listed below is a brief summary of the Rectifier System connections to be made:

A. Connect AC Input leads (L2, GRD, L1) of the Rectifier System to the AC Power source.

NOTE: For a more detailed information about Rectifier connections, refer to the Rectifier System Manual, 6421015P.


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12. BTCM PANEL (If equipped)

If the Power Plant is equipped with a BTCM, refer to BTCM Manual for instructions on connecting the BTCM electrical interface.

C. DISTRIBUTION CABLING

The Distribution cabling for the 151N-A1 Power Plant is provided in the Discharge Bay by the following:

1. Distribution Fuse Panels (-48 VDC).

2. Overhead Ground Bus (GRD).

Connect output leads from these Distribution Panels and Overhead Bus Bar to the -48V loads (on an "as required" basis). The Output lead size is shown on job Power Plant Wiring Diagram.

NOTE: All fuse panels do not necessarily have to be equipped. See J-438151NP-A1 for a brief summary of fuse panels, and circuit breaker panels that can be mounted in the Discharge Bay.


Issue 7, May 2015

SECTION 3: TEST & ACCEPTANCE PROCEDURES

3.1 GENERAL

The Test & Acceptance Procedures are to be performed after the unit or system is in operation. The purpose of these procedures is to further determine if the unit or system is operating properly.

NOTE: Voltage settings are recommendations only. Consult local Engineering for any different requirements.

NOTE: If the Power Plant is equipped with a BTCM, disable the BTCM by moving the BTCM COMPENSATE/DISABLE switch to DISABLE prior to performing this procedure. When the switch is moved from COMPENSATE to DISABLE, the plant minor alarm will come "ON", but the BTCM PMN lamp on the BTCM will not illuminate.

After the Power Plant has been turned "ON" and the plant test and acceptance has been accomplished, refer to BTCM Manual for instructions on the test and acceptance of the BTCM.

3.2 VISUAL OBSERVATION

A. Normal operation of Power Plant should have the following visual observations on the Rectifiers:

1. Test/Normal switch should be in the "NORMAL" position.2. AC Input Switch should be "ON".3. Voltmeter Reading: 52.08 Volts.4. Ammeter Reading: 5-100% of rated capacity.5. AC ON LED (Green) should be "ON".6. CFA/RFA LED (Red) should be "OFF" if the load current is above 1% of rated output current of

Rectifier.7. Test LED (Amber) should be "OFF".8. Capacitor Charge Lamp should be "OFF".9. Float/Equalize Switch should be in "FLOAT" position.

B. PEC 1015 RECTIFIER SYSTEM

Normal operation of Power Plant should have the following visual observations on the PEC 1015 Rectifiers.

1. Voltmeter Reading: 52.08 Volts (Switch I/V should be in the "V" position).

2. Ammeter Reading: 5-100% of rated capacity (Switch I/V should be in the "I" position).

3. AC ON LED (Green) should be "ON".

4. CFA/RFA LED (Red) should be "OFF" if the load current is above 1% of rated output current ofRectifier.

5. AC Input Switch should be "ON" (Customer provided AC Circuit Breaker or other AC Inputdevise).

6. Float/Equalize Switch should be in "FLOAT" position.


Issue 7, May 2015

3.3 RECTIFIER ALARM TEST

In order to test the Rectifier Alarm (RFA), operate the first Rectifier to the "OFF" position. For this test to be passed, the following should happen:

A. Audible Alarm is sounding (When equipped).

B. RFA LED (Red), located on Meter & Alarm Panel, is "ON".

C. Power Minor Alarm (PMN) is sent to the Alarm System.

D. RFA/CFA lamp (Red), located on one "Failed" Rectifier front panel, is "ON".

E. Press the ACO switch, located on the Meter & Alarm Panel, to silence the Audible Alarm and light the ACO LED (Amber).

F. Operate the Rectifier to the "ON" position. All alarms should extinguish.

G. Repeat above Steps A-F on remaining Rectifiers.

3.4 DISTRIBUTION FUSE ALARM TEST

On Fuse Holder (61-800 Amp) with Indicator Fuse, replace the GMT Alarm Indicator Fuse on each Fuse Holder with one that is blown and observe the following:

A. FA LED (Red), located on Meter & Alarm Panel, is "ON".

B. Audible Alarm will sound (When equipped).

C. FA LED (Red), located on individual fuse or Circuit Breaker Panel, is "ON".

D. Power Major Alarm (PMJ) is sent to Alarm System.

E. Press the "ACO" switch, located on the Meter & Alarm Panel, to silence the Audible Alarm.

F. ACO LED (Amber), located on Meter & Alarm Panel, is "ON".

NOTE: Remove blown GMT-type fuse and replace with a good GMT- type fuse. All alarms should extinguish. Repeat above steps on all Distribution Fuse and Circuit Breaker Panels.

3.5 ALARM BATTERY SUPPLY FUSE ALARM TEST

In order to test the Alarm Battery Supply Fuse Alarm (ABSFA) replace one (1) of the F2-F10 Alarm Battery fuses, located on the Meter and Alarm Panel, with a blown GMT-type fuse and observe the following:

A. FA LED (Red), on Meter and Alarm Panel, should light.

B. Power Major Alarm (PMJ) is sent to the Alarm System.

C. Audible Alarm should sound (when equipped).

NOTE: Remove blown GMT-type fuse and replace with good GMT- type fuse. All alarms should extinguish.


Issue 7, May 2015

3.6 HIGH, LOW, & LOW LOW VOLTAGE ALARM TEST CAUTION: Operating the Calibrate switch (S2) to the "ON" position may cause alarms on the Meter & Alarm Panel to light and be extended to the alarm system until the Test Calibration Module has been adjusted to approximately the nominal plant voltage set point.

The Hi-Low Voltage Calibration Module is plugged into Jack 102, located on the CP1 card. Connect leads of Digital Voltmeter (DVM) to Test Points TP1 (-) and TP2 (+), located on the CP1 card. Operate the Calibrate (S2) switch to the "ON" position.

A. HIGH VOLTAGE ALARM

Press the ON/OFF switch (S1) and the Power ON LED (Green) should light. While monitoring at the Test Points (TP1 & TP2), adjust the Simulated Voltage Control, located on the Calibration Module, clockwise (CW) to raise the voltage until the High Voltage Alarm set point is reached. The following should happen:

1. HVA LED (Red), on Meter & Alarm Panel, should light.

2. Power Major Alarm (PMJ) is sent to the Alarm System.

3. Audible Alarm should sound (When equipped).

4. Adjust Simulated Voltage Control counterclockwise (CCW) one (1) turn. All alarms shouldextinguish.

B. LOW VOLTAGE ALARM

While monitoring voltage at Test Points, TP1 and TP2, adjust Simulated Voltage Control counterclockwise (CCW) to lower the voltage until the Low Voltage Alarm set point is reached. The following should happen:

1. LVA LED (Red) should light.

2. Power Minor Alarm (PMN) is sent to Alarm System.

3. Audible Alarm should sound (when equipped).

4. Adjust Simulated Voltage Control clockwise (CW), one (1) turn. All alarms should extinguish.

C. LOW LOW VOLTAGE ALARM

While monitoring voltage at Test Points, TP1 and TP2, adjust Simulated Voltage Control pot, counterclockwise (CCW) to lower voltage until Low Low Voltage Alarm set point is reached. The following should happen:

1. LVA and LLVA LED (Red) should light.

2. Power Major Alarm (PMJ) is sent to the Alarm System.


4. Adjust Simulated Voltage Control pot clockwise (CW) and all alarms should extinguish.

5. Press the ON/OFF switch (S1) and the Power ON LED (Green) will go "OUT".

6. Operate the Calibrate switch (S2) to the "OFF" position.

7. Remove the Digital Voltmeter (DVM) from the Test Points (TP1 & TP2) on the Meter & AlarmPanel.


Issue 7, May 2015

3.7 RECTIFIER SENSE FUSE ALARM TEST (Optional)

In order to test the Rectifier Sense Fuse Alarm, replace the GMT type Sense Fuse with one that is blown and observe the following:

A. FA LED (Red), on Meter and Alarm Panel, should be "ON".

B. RFA LED (Red), located on Meter And Alarm Panel, should be "ON".

C. Power Major Alarm (PMJ) signal is sent to Alarm Systems.

D. Rectifier output should reduce to zero (0) Amps.

E. Audible Alarm should sound (When equipped).

F. Remove blown GMT type sense fuse and replace with a good sense fuse. All alarms should extinguish. Rectifier output should return to "NORMAL". Repeat Steps above on all Sense Fuses.

3.8 LOW VOLTAGE DISCONNECT TEST (Optional)

NOTE: Low Voltage Disconnect Module is an optional feature on some types of Distribution Panels or Low Voltage Disconnect of Battery Strings.

While monitoring the voltage at Test Points (TP1 & TP2), located on the Low Voltage Disconnect Module, proceed as follows:

A. Turn Test Switch (S1) to the "ON" position, and Test LED (Amber) should come "ON".

B. Lower the voltage by adjusting the Simulated Voltage pot (R26) counterclockwise (CCW) until the Low Voltage Drop-Out point is reached. The Low Voltage Disconnect LED (Red) should come "ON".

C. Raise the voltage by adjusting the Simulated Voltage pot (R26) clockwise (CW) until the Pick-Up Set Point is reached. The Low Voltage Disconnect LED (Red) should go "OFF".

D. Adjust the Simulated Voltage pot (R26) counterclockwise (CCW) and clockwise (CW) to confirm the set points of the Low Voltage Drop-Out and Pick-Up.

E. Turn Test switch (S1) "OFF" and Test LED should go "OFF".

3.9 EQUALIZE OPERATION & ALARM TEST

While monitoring the plant voltage at TB1-8 (-) and TB1-5 (+), press and hold the "Press for Manual/Equalize Switch" (S3), located on Manual Equalize Panel, for approximately one (1) minute and observe the following:

A. Output voltage will read approximately 2.00 volts less than "normal" plant voltage.

B. Discharge Timer LED (Red) will light.

C. Release the "Press for Manual/Equalize Switch" (S3).

D. After the "Press for Manual/Equalize Switch" (S3) has been released, the Discharge Timer LED will go "OUT" and the Equalize Timer LED (Green) will come "ON".

E. After approximately 4 to 6 minutes, the Equalize Timer LED will go "OUT", and the Output Voltage will return back to the "normal" plant voltage.

Issue 7, May 2015

GE Critical Power 151N-A1

Manual F. Push the "Press for Manual/Equalize Switch" (S3), and the following should happen:

1. After a short delay, the Discharge Timer LED (Red) will go "OUT", and the Equalize Timer LED(Green) will come "ON".

G. Push the "Press to Clear" switch (S2), and the following should happen:

1. Equalize Timer LED (Green) will go "OUT".

H. Plant Voltage should be 56.00 volts or voltage per Plant Specification. If not, adjust R7 until desired voltage is obtained.

I. Operate "S2" switch back to "FLOAT" (clear). All Alarms should extinguish and Plant Voltage should be 54.00 volts or per Plant specifications.

CAUTION: Removal of Fuse "RB 2A" in "J" paragraph will cause all Rectifiers (Chargers) to go to a "low" current condition and plant load will be supplied from the Battery source until "RB 2A" fuse is again replaced with a good fuse. This problem may be alleviated by placing GE chargers in a test mode via test switch prior to removing "RB 2A" fuse in Manual Equalize Panel

J. Replace the "RB 2A" fuse on the Manual Equalize Panel with a blown GMT-type fuse and observe the following:

1. Fuse Fail Lamp (Red) on Bay Alarm Panel should light.

2. FA LED (Red) on Meter & Alarm Panel should light.

3. Power Major Alarm (PMJ) is sent to Alarm System.


5. Remove blown GMT-type fuse and replace with good GMT- type fuse. All Alarms shouldextinguish.

3.10 RECTIFIER REMOTE HIGH VOLTAGE SHUTDOWN (HV) REMOTE RESTART (RRS) TEST

To test the High Voltage Shutdown feature proceed as follows:

A. Operate the AC INPUT Circuit Breaker (CB1) to the "OFF" position.

B. Operate the TEST NORMAL switch (S301) to the "TEST" position.

C. Operate the DC OUTPUT Circuit Breaker (CB2) to the "OFF" position.

D. Operate CAP CHARGE switch (S1) until the CAP CHARGE lamp (Red) goes "OUT". Next, operate the AC INPUT Circuit Breaker (CB1) to the "ON" position.

E. On CP4 card, connect a jumper between TP401 and TP402. This activates the "simulated load" circuit.

F. Turn the SIM CUR ADJ pot (R526) clockwise (CW) until the output current is approximately 100 Amps. CFA/RFA LED (Red) should be "OFF".


Issue 7, May 2015

G. Momentarily apply an External Ground to TB201-17 (HV). For this test to pass, the following must happen:

1. Rectifier shuts "down".

2. CFA/RFA LED (Green) comes "ON".

3. AC ON LED (Green) goes "OUT".

4. RFA, LCA, PMN, and PMNV alarms are sent to Plant Control Circuits.

H. When the Automatic Rectifier Restart Module (Optional) is equipped, it should receive a Rectifier Fail Alarm (RFA) signal from the Rectifier that is under the above test. It supplies a "closed loop" circuit to TB201-15 and 16 (Remote Restart Circuit). For this Test to pass, the following should happen:

1. Rectifier returns to "normal" operation.

2. AC ON LED (Green) comes "ON".

I. Operate AC INPUT Circuit Breaker (CB1) to the "OFF" position.

J. Remove the jumper from the CP4 card (test points TP401and TP402).

K. Turn the SIM CUR ADJ pot (R526) counterclockwise (CCW).

L. Operate the TEST/NORMAL switch (S301) to the "normal" position.

M. Operate the CAP CHARGE switch (S1) until the CAP CHARGE lamp (Red) goes "OUT", and then close Circuit Breaker (CB2).

METER & ALARM PANEL

(Digital) –48V 6180014P 23” Mounting 6180173P 30” Mounting

Product Manual Part Number: 438 0031PD Issue 7, June 2005 Engineer: H. D. Approved: H. D.

GE Critical Power Meter & Alarm Panel Manual

Page 2 Issue 7, June 2005



Issue 7, June 2005 Page 3

Product Information Spaces are provided below for recording product information. This data will allow faster service when calling GE to order accessories, spare parts, or request field service.

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.

Fill in the date code located on the label in the space below.

Fill in the serial number on the label in the space below

Fill in the ECN Level located on the label in the space below

PART NUMBER:

DATE CODE:

SERIAL NUMBER:

ECN Level: 860 _ _ _ _ P



Table of Contents PRODUCT INFORMATION.....................................................................................................................................3

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

FOREWORD ...............................................................................................................................................................7

SECTION 1: SPECIFICATIONS ..............................................................................................................................9 1.1 GENERAL.................................................................................................................................................9 1.2 ALARMS...................................................................................................................................................9 1.3 INDICATORS .........................................................................................................................................10 1.4 ALARM BATTERY SUPPLY (ABS) ....................................................................................................10

SECTION 2: DIMENSIONS ...................................................................................................................................11

SECTION 3: INSTALLERS CONNECTIONS .....................................................................................................13 3.1 CONNECTIONS .....................................................................................................................................13 3.2 ALARM EXTENSION MODULE CONNECTIONS (OPTIONAL) .....................................................14

SECTION 4: INSTALLERS NOTES .....................................................................................................................15 4.1 INSTALLERS INFORMATION NOTES...............................................................................................15

SECTION 5: CIRCUIT OPERATION...................................................................................................................17 5.1 METER CIRCUIT...................................................................................................................................17 5.2 VOLTAGE DETECTOR CIRCUITS......................................................................................................17

ATTACHMENTS......................................................................................................................................................19

Schematic 4390103P Att



Foreword This manual is intended to help the user of the Meter & Alarm Panel to install, test, troubleshoot, and understand the system. If you should have any questions or problems, please contact one of the following sources:

SERVICE - If for any reason further assistance is needed on any power equipment, complete engineering and field service groups are available in Galion, Ohio, to assist you in any way possible.

CALL: 419/468-7700 Field Service or

419/468-7600 and ask for Field Service.

PARTS ORDERING - Replacement parts for power equipment may be obtained by forwarding a Purchase Order to:

GE, Inc P. O. Box 910 Galion, Ohio 44833 or Fax to: (419) 462-8180

Include the following information: A. GE part number and engineering level of equipment B. If part is electrical, give circuit reference numbers and GE part numbers. C. If part is mechanical in nature, give description as to where it is used.

RETURN & REPAIR - Equipment may be returned to the Factory for repair. In order to do this, the procedure must be as follows:

A. Call: 419/468-7700 Field Service Or

419/468-7600 and ask for Field Service.

B. Request a Returned Material Authorization (RMA) number for the defective equipment.

C. Return material prepaid to:

GE, Inc 1376 State Route 598 Galion, Ohio 44833

Attn: Field Service Dept



WARNINGS 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.

2. The use of this equipment by unauthorized or untrainedpersonnel should not be attempted. Personnel that workon this equipment without the proper training maysubject themselves or others to electrical shock that maycause serious injury or death.

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 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.

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

5. Do not operate this equipment if it has been dropped orotherwise damaged. Trying to operate this equipment ifit has been damaged subjects yourself or others toelectrical shock that may cause serious injury or death.

6. Before you proceed, ensure the input source is not liveand the input circuit breaker(s)/fuse(s) has been trippedor removed. If these procedures have not been followedand the input/output power is live, serious personnelinjury or death may occur.

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 exposed connectorsor wires and, with permission, remove power to the othersystems. Failure to take the necessary safety precautionssubjects the installer or maintenance personnel to severeelectrical shock that may cause serious injury or death.

8. This equipment may connect to lead-acid batteries.Battery posts, terminals, and related accessories containlead and lead compounds, chemicals known to the stateof California to cause cancer and birth defects or otherreproductive harm. Wash hands after touchingbatteries.

CAUTIONS 1. Follow proper grounding instructions.

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

3. To remove the circuit breakers or fuses, the DC and/orAC input to the system will need to be disconnected,thereby disabling the system output to the load(s).Take the necessary precautions and inform the plantengineer that the system output power to the loads willbe disabled.

4. Before performing any maintenance, ensure AC or DCpower is not applied to the system.

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



SECTION 1: SPECIFICATIONS 1.1 GENERAL

The 6180014P & 6180173P Meter & Alarm (Digital) Panels are designed to provide Alarm Battery Supply (ABS) fusing, metering and alarm functions for the -48 VDC Power System. It is equipped with a digital meter to read Charge/Discharge Current and Voltage.

Optional modules may be added to the Meter & Alarm Panel as required. They are as follows:

A. Manual Equalize Module.

B. Branch Switch Module.

C. HI/LO Plant Voltage Calibration Module.

D. Rectifier Sense Lead Fuse Module

E. Low Voltage Disconnect Control Module.

F. Rectifier Fail Summation Module.

G. Current Monitor & Alarm Module.

H. Automatic Rectifier Restart Module.

Other optional equipment may be added to the Meter & Alarm Panel are as follows:

A. Alarm Extension PWB.

B. Audible Alarm & Bracket.

1.2 ALARMS

The Meter and Alarm Panel will accept various alarm input signals. These signals are categorized as either; a Major or Minor Alarm. They are as follows:

ALARM TYPE

ABS FA Major (PMJ)

FA, FA1 Major (PMJ)

HVA Major (PMJ)

LLVA Major (PMJ)

RFA1-6 Minor (PMN)

LVA Minor (PMN)

AUDIBLE ALARM: Whenever a Major or Minor Alarm occurs an Audible Alarm will sound (If equipped), and a dry set of "Form C" contacts will be available for the Central Office Alarm Circuits.

Audible Alarm Release switch (ACO) is pressed to silence the Audible Alarm.



1.3 INDICATORS

Individual Alarm Indicators are identified by LED's, located on the front of the Meter and Alarm Panel. They are as follows:

INDICATORS DESIGNATION

Fuse Alarm LED (Red) FA

Low Voltage Alarm LED (Red) LVA

Low Low Voltage Alarm LED (Red) LLVA

High Voltage Alarm LED (Red) HVA

Rectifier Fail Alarm LED (Red) RFA

Audible Cut-Off LED (Amber) ACO

1.4 ALARM BATTERY SUPPLY (ABS)

The Alarm Battery Supply (ABS) provides ten (10) ABS fuses. The first (1st) fuse is used for Internal Alarm Circuits. The remaining ABS fuses are available for miscellaneous requirements. Fuse ratings are available from 0.18 to 10 Amps. The following is a suggested fuse value rating for:

A. Audible Alarm Fuse should be 1-1/3 Amp.

B. Digital Voltmeter Fuse should be 3 Amps.

NOTE: Maximum output of all ABS fuses should not exceed a total of 30 Amps.



SECTION 2: DIMENSIONS



SECTION 3: INSTALLERS CONNECTIONS CAUTION: Before any connections are made to the Meter & Alarm Panel, be sure that power is not connected.

3.1 CONNECTIONS

To cable the Meter & Alarm Panel, proceed as follows:

A. TB1 Terminal Block

TERMINAL LEAD DESCRIPTION

TB1-1 TB1-2 TB1-3

PMNV PMNV PMNVR

(NO) (NC) (COM)

TB1-4 TB1-5 TB1-6∗

PMN PMN PMNR

(NO) (NC) (COM)

TB1-7 TB1-8 TB1-9

PMNVR PMJV PMJV

(COM) (NC) (NO)

TB1-10∗TB1-11 TB1-12

PMJR PMJ PMJ

(COM) (NC) (NO)

Office Alarm Circuit

(Dry “Form C” Contacts)

B. TB2 Terminal Block


TB2-1 TB2-2 TB2-3

NC COM NO

LLVA Alarm (Dry “Form C” Contacts)

TB2-4 ABS FA ABS Alarm (Factory Equipped)

TB2-5 TB2-6

FA FA1

From Fuse Alarms As required

TB2-7 TB2-8 TB2-9 TB2-10 TB2-11 TB2-12

RFA From Rectifier Fail Alarms

∗ Terminal TB1-6 and TB1-10 are tied to GRD when Audible Alarm Assembly is used.



C. TB3 Terminal Block


TB3-1 TB3-2

+S -S

To Gnd Bus or + Bat To Discharge Bus or - Bat

TB3-3 TB3-4

DS – DS + Total Discharge Shunt

TB3-5 TB3-6

CS – CS +

Total Charge Shunt (See Section 4.1E)

TB3-7 TB3-8

Cell – Cell + Cell Battery

TB3-9 Not UsedTB3-10 (F1) BAT Alarm Battery, Factory

Equipped TB3-11 Not UsedTB3-12 GND Equipment Ground

3.2 ALARM EXTENSION MODULE CONNECTIONS (Optional)

Alarm Extension Module (CP4) provides Dry "Form C" Contacts, which are used as scan points by computerized surveillance equipment (See Fig 3.1).

ALARM EXTENSION MODULES CONNECTIONS (CP4)

ALARM CONTACT TERMINAL ALARM CONTACT TERMINAL N/O COM N/C

TB4-1 TB4-2 TB4-3

N/O COM N/C

TB5-1 TB5-2 TB5-3 LVA N/O

COM N/C

TB4-4 TB4-5 TB4-6

RFA N/O COM N/C

TB5-4 TB5-5 TB5-6

N/O COM N/C

TB4-7 TB4-8 TB4-9

N/O COM N/C

TB5-7 TB5-8 TB5-9 HVA N/O

COM N/C

TB4-10 TB4-11 TB4-12

FA N/O COM N/C

TB5-10 TB5-11 TB5-12

NOTE: Alarm extensions RFA MJ and RFA MN only function when the RFA Summation Module (6310102P) is equipped.

N/O COM N/C

TB6-1 TB6-2 TB6-3

N/O COM N/C

TB6-7 TB6-8 TB6-9 RFA MJ N/O

COM N/C

TB6-4 TB6-5 TB6-6

RFA MN N/O COM N/C

TB6-10 TB6-11 TB6-12

FIG 3-1 INSTALLERS CONNECTIONS



SECTION 4: INSTALLERS NOTES CAUTION: It is essential to read and understand all Warnings, Cautions, and Notes before any connections are made to the Unit or System. If further assistance is needed call 419.468.7600 and ask for Field Service.

4.1 INSTALLERS INFORMATION NOTES

A. Battery is supplied directly to the Alarm Battery Fuses (F1-F10) via a 12 Ga wire.

B. TB1, TB2, and TB3 are pressure-type terminals, 18 Ga maximum.

C. If external alarm (Grd Signal) inputs are required, use tie points E1 (Minor) and E2 (Major), located on CP1 card.

D. If external alarm (Grd Signal) outputs are required, the following terminals, located on CP1 card, have been provided (See Fig 3-1).

E4 - ACO

E5 - RFA

E6 - FA

E7 - LVA

E8 - LLVA

E9 - HVA

E. If the Meter & Alarm Panel is equipped with two (2) momentary push button Switches (S201 and S202) to perform current and voltage monitoring, then both the Total Discharge and Charge Shunts in a system must be installed in the same polarity lead to prevent damage to Ammeter Circuit.



SECTION 5: CIRCUIT OPERATION 5.1 METER CIRCUIT

The digital meter normally monitors the Plant Discharge Voltage. To check the Battery Voltage, turn switch S201 to the "BATTERY/CHARGE" position. Meter Switch should be set in the "VOLTS" position.

The digital meter normally monitors the Total Discharge Shunt. To check the current of the Total Charge Shunt, turn switch S201 to the "BATTERY/CHARGE" position. Meter Switch should be set in the "AMPS" position.

5.2 VOLTAGE DETECTOR CIRCUITS

The Meter & Alarm Panel has High, Low, and Low Low Voltage Detector circuits. The voltage Detector settings are as follows:

High (HVA) 55.00 VDC, ±0.1 Low (LVA) 47.00 VDC, ±0.1 Low Low (LLVA) 44.00 VDC, ±0.1 LLVA is released at 46.00 VDC, ±0.1

NOTE: Voltage settings are factory settings only. These settings may be changed by using the HI/LO Voltage Detector Calibration Module.

To adjust the HI/LO Voltage Alarm set points proceed as follows:

NOTE: If the Meter & Alarm Panel is equipped with the Audible Alarm Module, either a "major" or "minor" alarm will activate the Audible Alarm. This can be extinguished by pressing the Alarm Cut-Off (ACO) switch (S203), located on the front panel.

A. Remove Plug 102, located on CP1 card. Plug the test cable of the Calibration Module into Jack 102.

B. Insert test probes of DMM into test points (-) TP1 and (+) TP2, located on CP1 card. These points are used to monitor the voltage during calibration.

C. Adjust Simulated Voltage pot, located on the Calibration Module, set voltage to read 50.0V ±1.0 Volt, there should be "no" alarms present.

D. Adjust LVA pot (R130) and LLVA pot (R131), located on CP1 card, fully counterclockwise (CCW). Adjust HVA pot (R129) and LLVA/REL pot (R132) fully clockwise (CW).

E. Adjust Simulated Voltage pot, located on the Calibration Module to the Low voltage set point. Adjust LVA pot (R130), located on CP1 card, clockwise (CW) until the LVA LED comes "ON".

F. Adjust Simulated Voltage pot, located on the Calibration Module to the Low Low Voltage Adjust set point. Turn LLVA pot (R131), located on CP1 card, clockwise (CW) until the LLVA LED comes "ON".

G. Raise the Simulated Voltage above the LLVA Adjust set point until the Low Low Voltage release set point is reached. Turn LLVA/REL pot (R132), located on the CP1 card, counterclockwise (CCW) until LLVA LED extinguishes.

NOTE: The LVA LED will extinguish when the simulated voltage is raised 0.2-0.5V above the Low Voltage set point.

H. Increase the Simulated Voltage to the high voltage set point, adjust HVA pot (R129), located on the CP1 card, counterclockwise (CCW) until the HVA LED comes "ON".



I. Lower the Simulated Voltage below the HVA set point and the HVA LED will extinguish.

J. Recheck both set points by adjusting the Simulated Voltage to the Low, Low Low, and High Voltage set points and check that the proper indicator LED turns "ON" with ±0.1V of the set point.

K. Remove DMM Test Probes, Test Cable of HI/LO Calibration Module, and re-insert jumper plug 102 into jack 102.



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