Installation Guide
Infinity C™ DC to DC Power System
Models 663 / 664
dc to dc Power Shelf
24v or 48V dc Output
Service and Assistance - +1 877 546 3243 or +1 972 244 9288 PE.TechSupport@ge.com
© 2012 General Electric Company. All rights reserved. http://www.ge.com/powerelectronics
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Table of Contents
Table of Contents ............................................................................................................................................................................ 2
Introduction ....................................................................................................................................................................................... 3
Reference Documents ..................................................................................................................................................................................................... 3
Customer Service Contacts .......................................................................................................................................................................................... 3
On-Line Power Systems Product Manuals and Software ........................................................................................................................ 3
Product Description ....................................................................................................................................................................... 4
Overview ................................................................................................................................................................................................................................... 4
Configurations ....................................................................................................................................................................................................................... 5
Converters................................................................................................................................................................................................................................ 5
Installation ......................................................................................................................................................................................... 6
Preparation .............................................................................................................................................................................................................................. 6
Safety ................................................................................................................................................................................................................................. 6
Installation ................................................................................................................................................................................................................................ 6
Safety................................................................................................................................................................................................. 11
Revision History ............................................................................................................................................................................ 14
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Calling from
Phone Number
• United States, Canada, Puerto Rico, and the US Virgin
+1 877 546 3243
• All other countries
+1 972 244 9288
Or contact your local field support center or your sales representative to discuss your specific needs.
Introduction
This manual is intended as a guide in assisting equipment understanding, installation, testing, and troubleshooting.
For additional assistance contact Customer Service or access additional information on-line.
Reference Documents
Document Title
CC848921024 Quick Start Guide
CC848836981 Pulsar Edge Controller Family Product Manual
Infinity C™ Product Line Brochure – Specifications and Ordering Guide
Customer Service Contacts
Customer Service, Customer Training, Technical Support,
Product Repair and Return, and Warranty Service
Services provided include initiating the spare parts procurement process, ordering documents, product warranty
administration, and providing other product and service information.
GE Energy phones are staffed from 7:00 am to 5:00 pm USA Central Time Zone (GMT -6), Monday through Friday, on
normal business days. At other times, this number is still available, but for emergencies only.
Islands
Or
USADCC
1
+ 877 546 3243
On-Line Power Systems Product Manuals and Software
Product manuals, product line brochures, and software are available on-line. Software includes Easy View and SNMP
MIB.
http://www.ge.com/powerelectronics
1
the USA direct country code for the country where the call is originating
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663
+24V
-48V
NE030DC48A4
30A
664
-48V
+24V
NE075DC24A5
75A
Product Description
Overview
Infinity C™ dc to dc power shelves convert and distribute available battery voltage to another dc voltage. This allows a
single bank of batteries to provide battery reserve for equipment operating at a different dc voltage.
Features
• Positive or Negative output
664 – Positive output
663 – Negative output
• DC to DC Converters
• 48V 30A output
• 24V 75A output
• Distribution
• Plug in circuit breakers
Up to 6
5A to 100A
• GMT fuses
Up to 10
0.18A to 15A
• Controller - Galaxy Pulsar Edge
• Ethernet and RS232 or USB
• Windows GUI compatible via GE EasyView software
• Mounting - 19” or 23” rack mount
• NEBS Level 3
2
Models
Model Input3 Output3 Converter Output per Converter
2
Available at http://www.ge.com/powerelectronics
3
Nominal voltage
4
CC109112471 or SM48N30L
5
CC109142881
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6 CB, 10 GMT, 3 Converters
4 CB, 10 GMT, 4 Converters
6 CB, 4 Converters
Converter retaining latch open
Converter Front View
Configurations
Converters
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Installation
Preparation
Safety
Read and follow all safety statements, warnings, and precautions in the Safety section of this manual and manuals of
all other equipment before installing, maintaining or repairing the equipment. Product manuals contain additional
safety statements, warnings, and precautions specific to the products.
Installation Tools
Even though most initial installations are performed while the system is turned off, the use of properly insulated tools
are recommended.
• Wire Cutters and Strippers
• SAE Socket Sets
• Digital Meter, +/- 0.02% accuracy
• Screw Drivers (flat-blade and Phillips)
• Torque Wrench (0-240 in-lb / 28 Nm)
• ESD Wrist or Heel Strap
Installation
Step 1 Mount Shelf
Shelf Mounting
• The 663/664 shelf power system
mounts in a 19 inch relay rack.
Additional brackets are required for 23
inch mounting
19 inch mounting
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Chassis Ground
Loosen captive screws
Rear Cover
Supply and return connections
Step 2 Ground Chassis
Chassis Ground
• Vertical or horizontal chassis ground cable
landings are threaded holes 1/4-20 on 5/8 inch
centers
Torque to 240 in-lb
• Chassis ground connections are available if
customer standards require the power system to
have an independent grounding connection. The
manufacturer does not require this connection
when the relay rack or cabinet housing power
system is properly grounded to maintain product
operation or product warranty
NOTE: Failure to properly ground the power system is
hazardous to site personnel and can damage
the power system circuit cards and converter
modules. It may void the power plant warranty.
Connections
Step 3 Run and Terminate dc Input Connections
• Loosen captive hardware
• Remove cover by sliding to the left and back.
• Input supply and return lug landings are 1/4-20
on 5/8 inch centers
Torque to 240 in-lb
• Flex cable is recommended for sizes larger than
No. 2 AWG
• Narrow tough lugs are required for lug sizes
larger than No.2 AWG
• Supply and return tabs are staggered for ease of
cabling
• Cabling exists to the left when facing the rear of
the system
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Connectorized
Circuit breaker
GMT
Step 4 Run and Terminate Alarm Cabling
• Run and terminate alarm cabling
• Jumper settings are available for both
Close on Alarm and Open on Alarm
extensions
• Verify alarm extensions with the Alarm
Center
• See Pulsar Edge Controller Family
Product Manual for additional information
Alarm Cable
connection
Step 5 Run & Term. Supply and Return Cables
Output cabling
• With GMT fuses and circuit breakers
removed, land all supply and return cabling
at the rear of the system
• Circuit breaker lug landings -
1/4” on 5/8 inch centers
Torque to 240 in-lb
• GMT wire landings –
Strip wire 3/8”
Torque to 13 in-lb
landing positions
landing positions
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Green during
Step 6 Energize Power Plant
Start up
• Remove all converter modules from the power plant if
previously installed
• Insert a single converter and turn on the input breaker
to this converter. This will apply input voltage to the
controller and system load bus.
• The controllers’ self-diagnostic will start within 30
seconds after power has been applied to the load bus
• Normal operation is indicated by the Green illuminated
front display
Step 7 Install Converter Modules
Module Installation
Insert converter modules
• Converters can be added or removed with the
power plant energized
Status LEDs:
Pulsar Edge Controller
Normal Operation
normal
operation
• Normal = Green
• Input Fail = Amber
• Fail = Red
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Step 8
Using the Controller
• Verify that the display screen is illuminated Green
• Verify that no alarms are reported
• Verify status of all converter modules are
communicating properly
• Verify all extended alarms with the Alarm Center.
(see Pulsar Edge Controller Family Product
Manual for alarm extension test)
• Verify that the plant voltage displayed is within ±
0.05V of voltage measured between the charge
bus and DC Return using a calibrated DVM
• A Yellow display indicates the plant is in a Minor
Alarm condition
• A Red Display indicates the plant is in a Major
Alarm condition
NOTE: Alarms will be extended to the Network Alarm
Center during alarm controller based alarm
testing.
System Verification and Alarm Extension
Verification
Pulsar Edge Controller
Normal Operation
Pulsar Edge Controller
Minor Alarm Condition
Pulsar Edge Controller
Major Alarm Condition
Step 9 Verify Power Plant Set Points
• Using the controller, verify all Power Plant
set points are per customer standards
• See Pulsar Edge Controller Family Product
Manual for additional controller details
Pulsar Edge Controller
Normal Operation
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Safety
Safety Statements
Read and follow these statements and those in equipment manuals.
• Do not install this equipment over combustible surfaces.
• Follow all national and local rules and regulations when making field connections.
• Compression Connectors
• For installations in the U. S. or Canada, use Listed/Certified compression connectors to terminate
Listed/Certified field-wire conductors where required.
• For all installations, apply the appropriate connector to the correct size conductor as specified by the
connector manufacturer, using only the connector manufacturer’s recommended or approved tooling for that
connector.
• If the proper connector for the country of installation is not provided, obtain appropriate connectors and follow
manufacturer’s requirements and all local requirements for proper connections.
• Torque electrical connections to the values specified on labels or in the product documentation.
• Dress cables to avoid damage to the conductors (caused by routing around sharp edges or routing in areas
where wires could get pinched) and undue stress on the connectors.
• Size protectors (fuses or circuit breakers) as required by the National Electric Code (NEC) and/or local codes. Refer
to the equipment ratings to assure current does not exceed:
Continuous Load (List 1) - 64% of protector rating
Maximum Load (List 2 - typically end of discharge) - 80% of protector rating.
• Field-wired Conductors - Follow all National Electric Code (NEC) and local rules and regulations when making field
connections.
• Size field-wired conductors based on listed recommendations, National Electric Code (NEC) and/or local codes
based on 70°C ampacity.
• Insulation rating: 90°C minimum; 105°C (minimum) if internal to enclosed equipment cabinets.
• Provide an accessible AC disconnect/protection device to remove AC power from the equipment in the event of an
emergency. This device must open all poles and be connected together.
• Equipment and subassembly ports are suitable for connection to intra-building or unexposed wiring or
cabling. The equipment and subassembly ports can be connected to shielded intra-building cabling
grounded at both ends.
• Alarm contacts are not fused within the equipment. Current limiting protection for these contacts must
be provided by external circuits. Exceeding these maximum ratings could result in fire or damage to the
unit. Alarm contacts are rated at 60V and 0.5A unless otherwise noted in the product Specifications
section.
• In enclosed equipment cabinets, the equipment chassis must be connected directly to the cabinet ac
service ground bus. For applications in huts, vaults, and central offices, the equipment chassis must be
connected to the system bonding network.
• Use only fuses and circuit breakers specified in the equipment documentation. Use of other parts may
result in injury to personnel or equipment damage.
• Use only GMT fuses provided with safety caps.
• This equipment operates equally well if installed as part of the Isolated Ground Plane (Isolated Bonding Network) or
the Integrated Ground Plane (Mesh-Bonding Network, aka, Common Bonding Network). Different grounding
techniques are equally successful. Adhere to a commonly accepted and consistent grounding approach to ensure
personnel safety, network protection, and proper equipment operation. Multiple low impedance paths to Earth
ground are essential.
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One of these two symbols (or equivalent) may be used to identify the presence of
precautions.”
Warning 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.” Signal words as described below may also be used to
indicate the level of hazard
DANGER
WARNING
CAUTION
Indicates the presence of a hazard that will cause death or severe personal injury if the
hazard is not avoided.
Indicates the presence of a hazard that can cause death or severe personal injury if the
hazard is not avoided.
Indicates the presence of a hazard that will or can cause minor personal injury or
property damage if the hazard is not avoided.
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.
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
One of these two symbols may be 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 protective safety earth ground for the equipment.
This symbol is used to identify other bonding points within the equipment.
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.”
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Precautions
Read and follow these precautions and those in equipment manuals.
• The equipment must be installed, serviced, and operated only by professional, 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.
• The equipment may be powered by multiple AC inputs. Ensure that the appropriate circuit protection device for
each AC input being serviced is disconnected before servicing the equipment.
• Do not disconnect permanent bonding provisions unless all ac inputs are disconnected.
• Batteries may be connected in parallel with the output of the rectifiers. Turning off the rectifiers will not
necessarily remove power from the bus. Make sure the battery power is also disconnected and/or follow safety
procedures while working on any equipment that contains hazardous energy/voltage.
• High leakage currents may be possible on this type of equipment. Make sure the equipment is properly
safety earth grounded before connecting power.
• Exercise care and follow all safety warnings and practices when servicing this equipment. Hazardous energy
and voltages are present in the unit and on the interface cables that can shock or cause serious injury.
When equipped with ringer modules, hazardous voltages will be present on the ringer output connectors.
• Use the following precautions in addition to proper job training and safety procedures:
• Use only properly insulated tools.
• Remove all metallic objects (key chains, glasses, rings, watches, or other jewelry).
• Wear safety glasses. Fuses can produce sparks. High energy levels on buses and distribution components
can produce severe arcing.
• Test circuits before touching.
• Lock out and tag circuit breakers/fuses when possible to prevent accidental turn on.
• Be aware of potential hazards before servicing equipment.
• Identify exposed hazardous electrical potentials on connectors, wiring, etc. (note the condition of these
circuits, especially wiring).
• Use care when removing or replacing covers; avoid contacting circuits.
• Use a personal ESD strap when accessing or removing electronic components.
• Electricity produces magnetic fields that can affect implanted medical electronic devices, such as pacemakers.
The strength of the magnetic field depends on the amount of current in the circuit, as well as other conditions
(such as number of conductors, placement, and distance from the conductor). DC power and distribution
systems, including batteries, which are typically used in telecommunications utility rooms, can operate at high
current levels. Personnel with electronic medical devices need to be aware of their restrictions when working
around electricity.
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Revision History
Issue 2 Removed reference to rectifiers, rebrand, reformat
Issue 1 Initial Release
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